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EMBEDDED PLC BL2500 User`s Manual

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1. 18 Double click on Slot 0 or press Set board equipment button ES on the toolbar Select bl25di board 19 20 21 22 BL2500 Digital Inputs and press OK button The bl25di I O board is placed in Slot 0 Double click on Channel 1 On the Connect I O channel window press Connect button several times until all the free variables are connected Press Close button ow ISaGRAF B25TEST1 I O connection m iol x File Edit Tools Options Help amp BBA tl FR e E bi25di ss le SWI a CG le swe 2 jj EB ES ER 5 B2 Ls EZ Le L7 4 8 7i 5 B7 ER 10 4 Iu 4 Double click on Slot 1 and select bl25led BL2500 on board LEDs board Double click on Channel 1 and connect the free variable LED1 Press Close button Double click on Slot 2 and select bl25ai BL2500 Analog Input board Double click on Channel 1 and connect the ADO variable Press Close button Double click on Slot 3 and select bl25ao BL2500 Analog Output board Double click on Channel 1 and connect the DA1 variable Press Close button Select File menu Save or press Save button on the toolbar to save the I O connection Close the I O connection window Before downloading the PLC application to the Target PLC the application needs to be compiled On the B25TEST1 Programs window select Make menu Compiler Options to check that RABBIT TIC code for Rabbit ba
2. Double click on the action symbol placed on the No flow link to display the editing box Rename it LED1 ON and type in the code LED1L TRUE OEM Technology Solutions Page 33 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 11 Select the Insert a Repeat Until button a and place it in between the Begin symbol and the SW1 SW2 test symbol Press Delete to just leave the flow line connector behind 12 Select the flow link between the Begin symbol and the End symbol and delete it to allow for the program to run continuously without ending 13 Click on the flow line connector that both the LED OFF and the LED ON action symbols connect to Select the Insert a flow button Y and connect both the LED OFF and the LED ON action symbols to the flow line connector remaining from Step 11 This allows the SW1 SW 2 test to repeat continuously so if either of SW1 or SW2 change it can test again and change the LED1 output 14 The FCtest1 Flow Chart should now appear as follows ISaGRAF b25test fctest1 Flow Chart File Edit Tools Options Help we AS E RS E fd Qd e l EL o 4 OBDEFAFBEB Exclusive OR logic for switching an LED I2 SAM SW O4 LED1 OFF O3 LED1 ON pos 587 52 NEIN 15 Save the program by selecting File menu Save Press OK button on the Update diary window Close the FCtest1 Flow Chart window 16 Follow Steps 17 to 25 in 3 4 1
3. EMBEDDED PLC ISaGRAF Workbench becomes an alternative to Dynamic C to program Rabbit based controllers The EMBEDDED PLC system consists of two parts e he Target PLC A SBC BL2500 powered with the RabbitCore amp module RCM3200 Rabbit 3000 microprocessor 44 2 MHz clock speed 512K Flash 256K Battery backed SRAM 512K Fast SRAM and 10 100BaseT and loaded with the EMBEDDED PLC Firmware Kernel or refer to as the Kernel The Firmware Kernel is distributed as a bin Bg GRAF Workbench file which is loaded to the Target through the EMBEDDED PLC Utility The Kernel runs the PLC application in a loop reading inputs gt evaluate the logic updating outputs and also provides the communication interface between the Target and the Workbench e The ISaGRAF Workbench The Workbench provides a complete PLC programming environment including an editor for each of the PLC programming languages downloading PLC application to the target simulation program debugging tools and on line monitoring of the PLC application BL2500 Target PLC 1 2 BL2500 OVERVIEW The BL2500 is an advanced Single Board Computer that incorporates flash memory SRAM digital I O ports A D converter input D A converter outputs RS232 RS485 ports and Ethernet interface 10 100 Mbps The BL2500 SBC gives PLC designers extremely low cost embedded control for high volume applications such as product control factory equipment control acces
4. 6 2 1 Menu Commands 6 2 1 1 File Load Flash Image Allows a EMBEDDED PLC Kernel bin file to be chosen as the file to be loaded Clicking the ellipses button brings up an Open File dialog box to browse for a file s location 6 2 1 2 Setup Communications This version of the EMBEDDED PLC Utility only supports Serial Connection The default com port is COM1 The default baud rate is 115200 bps If the host PC is using a different com port change the default to match the port being used by the PC If the BIOS is using a different baud rate change the default to match the baud rate being used by the BIOS 6 2 1 3 Setup File Locations The first time EMBEDDED PLC Utility runs it assumes that coldload bin pilot bin and flash ini are located in the EMBEDDED PLC Utility subdirectory Those files are installed by the EMBEDDED PLC installation process The Rabbit Field Utility can be run from a different location if the location of coldload bin and pilot bin are specified using Setup File Locations OEM Technology Solutions Page 51 EMBEDDED PLC BL2500 User s Manual Loading or Upgrading the Firmware Kernel 6 2 1 4 Setup Target Configuration The configuration parameters can be changed at any time once the EMBEDDED PLC kernel is running but requires the Target to be reset or powered cycle Select Setup Target Configuration Follow the instructions that appear in the message dialog box and press OK
5. x i Connect DIAG cable press OK and reset target i Cancel The EMBEDDED PLC Utility will establish connection with the target to get the configuration parameters If connection is established the following window will appear EMBEDDED PLC Target Configuration x Copyright c 2005 OEM Technology Solutions Module Version 1 06 Kemel Version 1 03 Kernel Description EMBEDDED PLE for BL 2200 Madbus Slave Number f 1 255 Modbus TE Ce Use Modbus TCP IP address D 92 168 1 100 Subnet mask 255 0 0 0 Default gateway f 932 168 1 1 Modbus ATU over AS2s2 AS485 Use AS232 Use A5485 Baud Rate EE ERE Enter the desired configuration and press OK Configuration parameters e Modbus Slave Number This is slave number used to communicate with the ISaGRAF Workbench and a Modbus Master e IP Address IP address of the target must be static DHCP is not supported e Netmask Netmasks are used to identify which part of the address is the Network ID and which part is the Host ID For example 255 255 255 0 e Default Gateway IP address of the default gateway e Use Modbus TCP If this option is selected the Modbus RTU over RS232 RS485 box is disabled Select this option if Modbus TCP is required e Use RS232 If this option is selected the Modbus TCP configuration box is disabled Select this option if Modbus RTU over RS232 is required e Use RS485 If this option is selected
6. The following abbreviations are terms used throughout the document Analog to Digital Board Support Package Heating Ventilation and Air Conditioning This is sometimes referred to as climate control Input Output Instruction List Sequential Function Chart OEM Technology Solutions Page 4 OLE Object Linking and Embedding for Process Control EMBEDDED PLC BL2500 User s Manual Introduction SRAM Static Random Access Memory TCP IP Transport Control Protocol Internet Protocol Universal Serial Bus OEM Technology Solutions Page 5 EMBEDDED PLC BL2500 User s Manual Introduction This page is intentionally left blank OEM Technology Solutions Page 6 EMBEDDED PLC BL2500 User s Manual Getting Started 2 GETTING STARTED 2 1 INTRODUCTION The EMBEDDED PLC Application Kit provides all the necessary tools to program the Z World SBC BL2500 Coyote via the ISaGRAF Soft Logic package This chapter will help you to quickly install the necessary software to run a PLC sample application on the BL2500 target using the ISaGRAF Workbench This chapter contains also important information about licensing your product To run the EMBEDDED PLC software products it is required to have a Personal Computer PC with at least a 133 MHz processor 550 MHz or faster processor is recommended This PC will be referred as the Host The PC must have the following hardware and software configuration e Windows 2000 or XP operat
7. gt IF SWL SW2 THEN LED1 FALSE ELSE LED1 TRUE END_IF FALSE OR RETURN THEN ELSIF CASE 14 Save the program by selecting File menu Save Press OK button on the Update diary window Close the STtest1 ST Program window 15 Follow Steps 17 to 25 in 3 4 1 to compile the application and download it to the Target PLC 16 Double click on STtest1 program The STTEST1 ST Programs window is displayed Press the SW1 short circuit digital input INOO and the LED1 will be turned ON as well as the state of LED1 in the Programs window will change The PLC program implements a Boolean XOR operation on SW1 and SW2 with the result set on the LED1 17 To stop the monitoring of the PLC application close the Debugger window The programs and dictionary windows in debug mode will be closed OEM Technology Solutions Page 28 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 3 4 4 Using Instruction List 1 11 12 13 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs gt ISaGRAF 3 5 Projects On the Projects Management window select File menu New On the Create new project window enter the name of the project for example b25test4 and jns press OK button The name of project should not E a Cancel exceed 8 characters The b25test4 project is then none listed in
8. s ISaGRAF BL25TEST Global integers reals S oO x File Edit Tools Options Help Booleans IntegersvReals Timers Messages FB instances Defined words Mame Attrib Adar Value Comment D 1 Analog Output DAT OU output real Unit 28 To stop the monitoring of the PLC application close the Debugger window The programs and dictionary windows in debug mode will be closed 3 4 2 Using Quick Ladder Diagrams 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs gt ISaGRAF 3 5 Projects On the Projects Management window select File menu New On the Create new project window enter the name of the project for example b25test2 and Name press OK button The name of project should not 10 configuration Cancel exceed 8 characters The b25test2 project is then none E listed in the Projects Management window Select Edit menu Set comment text Enter a brief description of this project and press OK button This description will be displayed next to the project name in the Projects Management window Double click on b25test2 project An empty B25TEST2 Programs window is displayed ISaGRAF B25TEST2 Programs a x File Make Project Tools Debug Options Help amp mex nS xxi m ABs Begin LDtest1 Ladder Diagram 5 Select File menu New On the New program window
9. E ad ser BO E i t SW Z WORLD SINGLE BOARD COMPUTER BL2500 EMBEDDED PLC USER S MANUAL TURNING YOUR PRODUCT VISION www TECHNOLOGY SOLUTIONS SYSTEM ENGINEERS SOFTWARE ENGINEERS ELECTRONICS ENGINEERS Research Specify Design Develop Validate Support Custom Product Manufacture Configuration Warranty COPYRIGHT EMBEDDED PLC BL2500 User s Manual Part Number TD 0002 4 2006 OEM Technology Solutions Pty Ltd All rights reserved worldwide This document is the property of OEM Technology Solutions Pty Ltd and may not be copied used or disclosed in whole or in part except with the prior written permission of OEM Technology Solutions Pty Ltd or if it has been furnished under contract with another party as specified in that contract The copyright and the foregoing restriction on copying use and disclosure extend to all media in which this information may be embodied No liability is accepted for errors or omissions in this document The information contained within this document is subject to change without notice TRADEMARKS EMBEDDED PLC is a registered trademark of OEM Technology Solutions Pty Ltd Microsoft Windows Windows XP Windows 2000 and Windows NT are registered trademarks of Microsoft Corporation in the United States and or other countries ISaGRAF is a registered trademark of ICS Triplex ISaGRAF Inc Rabbit and Rabbit 3000 are registered trademarks of Rabbit Semico
10. for example STtest1 a brief comment select the Language to ST select Begin Style and press OK button The STtest1 program is displayed in the B25TEST3 Programs window Page 27 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 6 Follow Steps 6 to 11 in 3 4 1 to create and populate the application s Dictionary with SW1 and SW2 Boolean input variables and LED1 Boolean output variable On the B25TEST3 Programs window double click on STtest1 program Type in a comment in comment parentheses such as Exclusive OR logic for switching on LED When entered correctly comments are highlighted green 9 Press Enter to move to the next command line in the ST program editor 10 To enter Keyword commands either click the desired button in the Keywords tool box or type it such as for an if statement either click IF in the Keyword tool box or type IF on the command line When correctly entered Keyword commands are highlighted pink 11 To enter inputs outputs or variables for example input switch SW1 either select Edit Insert variable SW1 or type SW1 on the command line 12 Type the following command lines under the entered comment IF SW1 SW2 THEN LED1 FALSE ELSE LED1 TRUE END IF 13 The LDtest1 program should now appear as follows ISaGRAF B25TEST3 STTEST1 ST program File Edit Tools Options Help Aa zez m xh d E e Exclusive OR logic for switching on LED
11. serial port D serial ports are supported in EMBEDDED PLC at this present time OEM Technology Solutions Page 61 EMBEDDED PLC BL2500 User s Manual About Indusoft 9 ABOUT INDUSOFT Indusoft Web Studio IWS is a powerful integrated collection of automation tools that include all the building blocks needed to develop modern HMI SCADA instrumentation and embedded applications running on native Microsoft Windows XP 2000 NT CE and CE NET or in Internet and intranet environments Indusoft Web Studio provides a simple drag and drop point and click development environment which mimics the most complex behaviours of you live processes Indusoft Web Studio is ideal e automation solution for industry InduSoft Web Studio Demo Application Wi are 12 39 56 vg 8 Chemical Petrochemical Y About InduSoft CNS Gs ius rt z Main Features al i Process Control SE Process Started www indusoft com info indusoft com IWS applications consist of animated operator interface screens communication drivers for PLCs and UO protocols such as Modbus DFS Profibus etc tags database and additional modules such as alarm monitors logic trend charts recipes schedulers and security system IWS applications interface with industrial UO systems and other Windows applications in the run time environment using ODBC DDE NetDDE OPC or TCP IP protocols For more information about IWS contact OEM Technology Solutions http
12. the Modbus TCP configuration box is disabled Select this option if Modbus RTU over RS485 is required e Baud Rate Select between 600 to 19200 bits per second This operation can be repeated at any time but does require resetting or power cycle the Target OEM Technology Solutions Page 52 EMBEDDED PLC BL2500 User s Manual Loading or Upgrading the Firmware Kernel 6 2 1 5 Setup Kernel License This option can be used to establish connection with the target to check the current license status If license is required the following window will appear EMBEDDED PLC Firmware Kernel License Ka Copyright c 2005 OEM Technology Solutions Pty Ltd This iz a new or upgrade application program ou will need to enter the license key before the EMBEDDED PLC Firmware Kernel runs Please contact DEM Technology Solutions Pty Ltd or your local EMBEDDED PLC representative to obtain your license key rou will need to provide the reference number detailed below OEM Technology Solutions Pty Ltd can be contacted on Ph 67 2 9966 9424 Fas 61 2 9966 9429 Email zupportte aem net au User Reference Code Eg e SERIE EE See M License Key oed The User Reference Code can be copied into the Clipboard by double clicking on the box this will select the whole text and pressing Ctrl C The text can be pasted in any document Enter the valid license key in the entry box and press Send If license is valid a message confirming the val
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14. IEC issued the IEC 61131 3 standard a specification of five PLC programming languages that can be freely mixed to define automation and control procedures In August 1996 ISaGRAF version 3 2 received the certificate of PLC open compliance class of IEC 61131 3 base level IL 5 1 5 1 Sequential Function Chart Editor SFC divides the process cycle into a number of well defined steps separated by transitions SFC is the core language of the IEC 61131 3 standard The other languages are used to describe the actions performed within the steps and the logical conditions for the transitions Parallel processing can easily be described using SFC 5 1 5 2 Function Block Diagram Editor The FBD is a graphical language that allows the user to build complex procedures by taking existing function blocks from the ISaGRAF library and wiring them together on the screen ISaGRAF includes a library with more than 60 blocks ready to use Users can enlarge this library by writing functions and function blocks in LD FBD ST IL or C 5 1 5 3 Ladder Diagram Editor The ladder diagram is one of the most familiar methods of representing logical equations and simple actions The ISaGRAF ladder diagram editor offers the best compromises between high level graphic capabilities and easy to use keyboard driven programming 5 1 5 4 Structured Text Editor Structured text is a high level structured language with a syntax similar to Pascal but more intuitive to the au
15. This description will be displayed next to the project name in the Projects Management window Double click on b25test6 project An empty B25TEST6 Programs window is displayed ISaGRAF B25TEST6 Programs Blx File Make Project Tools Debug Options Help B mex 5m sie E Name o Select File menu New On the New program window E enter the name of the program for example FCtest1 a Lemmer brief comment select the Language to FC select Begin SC Style and press OK button The FCtest1 program is displayed in the B25TEST6 Programs window Follow Steps 6 to 11 in 3 4 1 to create and populate the application s Dictionary with SW1 and SW2 Boolean input variables and LED1 Boolean output variable On the B25TEST6 Programs window double click on FCtest1 program Select the Insert a comment button E and place the comment box in the FCtest1 Flow Chart editor Double click on the box to type in a comment such as Exclusive OR logic for switching on LED Select the Insert a test button e and place it between the Begin symbol and the End symbol Double click on it to display the editing box for that symbol Rename it SW1 SW2 and type in the code SW1 SW2 Select the Insert an action button and place one on each of the two flow links from the test Double click on the action symbol placed on the Yes flow link to display the editing box Rename it LED1 OFF and type in the code LEDI FALSE
16. com port assigned is between COM and COM4 If not change the serial port settings on your Windows Operating System see Section 7 2 Many USB to serial converters are assigned to COM5 port or higher after its installation Select Debug menu Debug to open the Debugger window If Debugger window displays application name active message stop the current application that is running by pressing the Stop button im on the toolbar or select File menu Stop application A No application message is displayed Download the bottlef application by selecting File menu Download Select RABBIT TIC code for Rabbit based controllers on the Download window and press Download button A progress bar on the Debugger window will show the progress of the downloading process Once the downloading is completed the application runs immediately and the SpotLight window is displayed In the SpotLight double click on the START button and press TRUE button The bottle production will start E ISaGRAF BOTTLEF GRAF1 SpotLight ioj xi Fie Edit Insert Options Help DO Balis tapenen x ders JL START STOP OEM Technology Solutions Page 17 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 5 Onthe Debugger window select Options menu X Parameters Change the Cyclic refresh Communication time out duration value to 200 This value corresponds to Cochicirctresh duratiare ee 200 Cancel the refresh rate of the Sp
17. connected to the Target all the time No The programming DIAG cable is used only for entering license key or Target configuration parameters values After that it can be disconnected OEM Technology Solutions Page 55 EMBEDDED PLC BL2500 User s Manual FAQ and Troubleshooting Q8 already have a version of ISaGRAF Workbench V3 50 installed and licensed What should I do or install to make it EMBEDDED PLC compatible If you already have an ISaGRAF Workbench V3 50 running on you Host PC use the following instructions to make your ISaGRAF Workbench compatible with EMBEDDED PLC a Download the ISaGRAF V3 50 zip file from OEM Technology Solutions website http www oem net au b Extract all files to a local directory lt SaGRAF Install Dir gt c Copy lt SaGRAF Install Dir gt EXE RABBIT RSC and lt SaGRAF Install Dir gt EXE ISATXT ERR to where your ISaGRAF main directory resides lt SaGRAF Main Dir gt EXE for example C ISAWIN EXE Confirm yes at overwriting ISATXT ERR file d Edit lt ISaGRAF Main Dir gt EXE RSCDEF RSC and add the following line Resource RABBIT rsc This line will add the RABBIT TIC code for Rabbit based controllers in the Targets list in the Compiler Options window of the ISaGRAF Programs Manager You will have to recompile all your programs against this TIC code type in order to work with the EMBEDDED PLC BL2500 Q9 I have a BL2500 with 256K Flash Can use EMBEDDED PLC BL2500 The E
18. fully protected over a range of 36 V to 36 V and can handle short spikes of 40 V IN14 is protected over a range of 36 V to 5 V 4 2 DIGITAL OUTPUTS The BL2500 has eight digital outputs OUTO OUT 7 each of which can sink up to 200 mA Figure 6 shows a wiring diagram for using the digital outputs in a sinking configuration SINKING OUTPUTS Figure 6 BL2500 Digital Outputs K is an externally supplied voltage of 3 3 40 V DC and should be capable of delivering all the load currents Although a connection to a K supply is not absolutely required with sinking outputs it is highly recommended to protect against current spikes when driving inductive loads such as relays and solenoids Connect the positive K supply to pin 1 of friction lock connector terminal J10 and the negative side of the supply to pin 2 of friction lock connector terminal J10 A friction lock connector is recommended to connect this supply because the K inputs are not protected against reverse polarity and serious damage to the BL2500 may result if you connect this supply backwards 4 3 ANALOG INPUT The A D converter shown in Figure 7 compares the DAO voltage to ADO the voltage presented to the A D converter DAO therefore cannot be used for the D A converter when the A D converter is being used Note Only DA is available for EMBEDDED PLC as DAO is used by the A D converter OEM Technology Solutions Page 36 EMBEDDED PLC BL2500 User s Manu
19. main control time control Lea Drive inactive select process Lead inactive turn on 8 leds Flash inactive odd Seven led flip flop Random inactive random led lightning Sequential Gmain Sequential Function Chart 4 The I O simulation window shows the I O boards used by the application Boards 0 to 4 Board 0 column 0 has 8 digital inputs Board 1 column 1 has 8 analog inputs Board 2 column 2 has 8 message strings outputs Board 3 column 3 has 8 digital outputs and Board 4 column 4 has 8 analog outputs On Board 0 column 0 click on Input 1 and Input 4 a message start and Lead are displayed in message outputs 4 and 5 respectively and Board 3 will show the LED outputs being turned ON in sequence On the Debug programs window the Drive and Lead programs change to active state Unset the digital input 4 and set any of the digital inputs 5 Flash or 6 Random To close the simulation of the application close the Debugger window Close the Programs window Try with other sample applications such as the one listed in the introduction of this chapter All the sample applications can run in simulation mode OEM Technology Solutions Page 16 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 3 2 RUNNING APPLICATIONS THAT USE INTERNAL VARIABLES ONLY The Target PLC and your PC must be connected through Ethernet RS232 or RS485 Use the following procedure to run any sample application that uses only inter
20. name of project should no i al exceed 8 characters The b25test1 project is E E Cancel then listed in the Projects Management nonc El window 3 Select Edit menu Set comment text Enter a brief description of this project and press OK button This description will be displayed next to the project name in the Projects Management window 4 Double click on b25test1 project An empty B25TEST1 Programs window is displayed ISaGRAF B25TEST1 Programs JDL xl File Make Project Tools Debug Options Help HLA D cum ZS Ais ON Gu x New Program Name 9 Select File menu New On the New program pec window enter the name of the program for example canna FBtest1 a brief comment select the Language to l i FBD select Begin Style and press OK button The Style Begin Main program H FBtest1 program is displayed in the B25TEST1 Programs window 6 On the B25TEST1 Programs window select File menu Dictionary to open the Dictionary window OEM Technology Solutions Page 20 EMBEDDED PLC BL2500 User s Manual Running Sample Applications SS SaGRAF B25TEST1 Global booleans B x File Edit Tools Options Help 7 Select Tools menu Quick declaration Enter Numbering from 1 to 2 Symbol name SW and Attributes Input as shown in figure below Press OK button Quick declaration X pido Hom 1 Too Cancel Symbol Attributes Digits C Intern
21. the Projects Management window Select Edit menu Set comment text Enter a brief description of this project and press OK button This description will be displayed next to the project name in the Projects Management window Double click on b25test4 project An empty B25TEST4 Programs window is displayed ISaGRAF B25TEST4 Programs a x File Make Project Tools Debug Options Help 5 Select File menu New On the New program window SEI enter the name of the program for example ILtest1 a Toc brief comment select the Language to Quick IL select SE Begin Style and press OK button The ILtest1 program is Style displayed in the B25TEST4 Programs window Follow Steps 6 to 11 in 3 4 1 to create and populate the application s Dictionary with SW1 and SW2 Boolean input variables and LED1 Boolean output variable On the B25TEST4 Programs window double click on ILtest1 program Type in a comment in comment parentheses such as Exclusive OR logic for switching on LED When entered correctly comments are highlighted green Press Enter to move to the next command line in the IL program editor To enter Keyword commands either click the desired button in the Keywords tool box or type it such as for an AND statement either click AND in the Keyword tool box or type AND on the command line When correctly entered Keyword commands are highlighted pink To enter inputs outputs or variabl
22. vU EU LEE EN 36 AA ANA OG OCU TR EE 37 4 5 COMMUNICATION INTERFACES esses n mmm mmm nre retetertRtetetetttmet ttti rrr rtt e nnns 38 4 5 1 SC Mla POLIS ENEE 38 4 5 2 Elhermet PO ee 39 AG BEDINDIGATORJIO vetteitedodidE ite edemudaiuudidtdud eE 40 5 SOFTWARE REFERENGE 1 elit ereb ore eeh ech ee 41 TABLE OF CONTENTS OEM Technology Solutions Pagei EMBEDDED PLC BL2500 User s Manual Sd MORE ABOU TTISAGIRA EE 41 5 1 1 reiege EE 41 5 1 2 Program Manager EE 41 5 1 3 Vanale Denno EE 41 5 1 4 Functional Module Programming c ccccccseecceeeeeeeeeeseeeeeseueeeeeueesseeeeaeeeeeaneessaees 41 5 1 5 IEC 61131 3 Language Editors EH 42 5 1 6 FOWO EE dO EE 42 5 1 7 Document Ewe EE 42 5 1 8 ENEN ELE EE 42 5 2 ISAGRAF SOFTWARE REFERENC E 43 5 2 1 LOM sore EE 43 0 2 2 ISd E leie EE 45 9 2 9 ISa GI AF C Function Ree 46 6 LOADING OR UPGRADING THE FIRMWARE KERNEL eere neeee nnne nnn 48 ou INTRODUCTION E 48 6 1 1 Installing EMBEDDED PLC Utility 0 0 cccceeeeeeeeeeeeeeesaeeeeeesaeeeeesaeneeneneeees 48 6 1 2 Connecting to the BE2500 ninami e ree Pede oa aed oua tod reddet 48 6 1 3 Loading and licensing the Firmware Kernel cccceecccseeeeeseeeeeeeeeeseeeeeeeeeesaeees 49 6 1 4 Configuring the Fmmwarekemel enne 50 62 EMBEDDED PLC UTILITY SOFTWARE REFERENCE esee 51 6 2 1 Menu Command Sonye dto eege eege ege 51 6 2 2 LGACING e R o HL
23. 5 2 2 2 RD TIME rd time Sel Q Arguments Sel INT format of the time and date in the output message Q Q MSG time date and day of the week depending of Sel value If Sel 0 Q format is YYYY MM DD If Sel 1 Q output format is HH MM SS OEM Technology Solutions Page 45 EMBEDDED PLC BL2500 User s Manual Software Reference If Sel 2 Q output format is the day of the week Description Gives the time date and the day of the week depending on the value of argument sel ST Equivalence Gesu 42 dg came sel Remarks Not available for simulation 5 2 3 ISaGRAF C Function Blocks 5 2 3 1 SET TIME set time Trigger yy mm dd hh minute SS dOfWeek result Arguments Trigger BOO ifRising edge sets the time and date of the BL2500 VY INT Year 1900 2050 mm INT Month 1 12 dd INT Day of month 1 31 hh INT Hour 0 23 minute INT Minute 0 59 ss INT Second 0 59 DOFWEEK INT Day of the week 0 6 0 means Sunday result BOO 1ifoperation was successful 0 otherwise Description Set the time and date of the BL2500 Real Time Clock ST Equivalence result Set LIme LrEigo yy Im dd hh minute ss 00tWeek Remarks Not available for simulation OEM Technology Solutions Page 46 EMBEDDED PLC BL2500 User s Manual Software Reference OEM Technology Solutions Page 47 EMBEDDED PLC BL2500 User s Manual Loading or Upgrading the Firmware Kernel 6 LOADING OR UPG
24. BEE 12 gioi s LZ BN PINOUT EE 35 Figure 5 BL2500 Digital Inputs Pull up factory deiault cc cecccccseceeeseeeeeeeeeeeeeeaeeeeesseseeeseeeeesseeeeeeas 36 Figure 6 BE2500 Be DECKT Ki e EE 36 Figure 7 Schematic Diagram of the A D Converter 37 Figure 8 Schematic Diagram of D A Converters ANE 37 Figure 9 BLEZ2500 Mulidrop INGIWOIK E 39 Figure 10 RS485 Termination and Bias Resistors ccceceeeceeceeeeeecaeeeeeeeeeeeesaeeeeesaeeeeeeseseeeaeeeeesaaeeeeeeas 39 Figure T4 RJ45 Ethernet Port PINOUT EEN 39 Figure 12 Programming Cable Connection E 49 FIgure T3 BEZ500 DIMENSIONS 35 99 sui ad cuba odd onc ida vo Dani Kore pe via aUe Pl gea ud eua Da Maura dr SIRVE Dui avuto RC Ge Duda 60 OEM Technology Solutions Page iii EMBEDDED PLC BL2500 User s Manual This page is intentionally left blank OEM Technology Solutions Page iv EMBEDDED PLC BL2500 User s Manual Introduction 1 INTRODUCTION 1 1 WHAT IS EMBEDDED PLC The EMBEDDED PLC system turns a Rabbit based controller such as the Coyote BL2500 Single Board Computer SBC into a high performance and yet inexpensive Programmable Logic Controller PLC The Target PLC can be programmed using the EMBEDDED PLC ISaGRAF Workbench in any of the standardized automation control programming languages IEC 61131 3 e Sequential Function Chart SFC e Function Block Diagram FBD e Ladder Diagram LD e Structured Text ST e Instruction List IL
25. C Board Support Package BSP for BL2500 Use the following procedure to install EMBEDDED PLC BSP for BL2500 from the CD ROM 1 Goto BL2500C BSP V1 04 9 0003 006 folder located in the root directory of the CD ROM 2 Open the ISaGRAF folder and double click on INSTALL EXE to launch the ISaGRAF installation wizard Enter the location where the ISaGRAF Workbench was installed default C ISAWIN and press Install The installation wizard will update the ISaGRAF main directory with the I O boards C functions C function blocks and sample applications for the EMBEDDED PLC BL2500 target 2 3 LICENSING THE ISAGRAF WORKBENCH The ISaGRAF V3 50 Workbench you just installed runs for a trial period of 30 days before requiring licensing When not licensed you can not create modify or export IEC programs to a library or export variables to ASCII text file You can license ISaGRAF using either hardware or software license When using a hardware license a dongle which you place on the parallel or USB port of your PC is delivered pre programmed with the selected feature set When using software license you need to obtain a set of registration keys The software license is specific to a PC hardware configuration and Operating System Therefore if you re install the Operating System and then re install ISaGRAF Workbench a new software license will be required However it is possible to transfer a software license from one PC to another Section A 1 2 2 of
26. C Kernel Dir gt BL2500C_V1 04 3 0231H bin and press Flash Image File Location EAn A e Open Press OK on the Choose Flash Image DK SES Help window 3 A Progress window is displayed with the status of the loading process The process consists of four stages sending Coldloader Sending Pilot BIOS Erasing Flash Sending Program 4 After loading is completed a message dialog box is displayed Follow the instructions in the same order Connect DIAG cable Reset Target Press OK There are two ways to reset the BL2500 gj Unplugging the power supply and then plugging it again also known as a d Load bin File successful Connect DIAG cable reset target and press OK power cycle and the other is shorting out the reset pads on the back of the BL2500 board For more information about the location of the hardware reset see Section 2 2 1 in 1 OEM Technology Solutions Page 49 EMBEDDED PLC BL2500 User s Manual 5 On the Kernel License window write down the User Reference Code you can select the code in the User Reference Code and copy it to the clipboard using Ctrl C Contact OEM Technology Solutions or your local distributor to obtain a valid license key Remember to quote the User Reference Code Press Cancel An error message dialog is displayed press OK and close the EMBEDDED PLC Utility 5 Note Loading or Upgrading the Firmware Kernel EMBEDDED PLC Firmware Kernel License
27. File menu Save Press OK button on the Update diary window Close the SFCtest1 Program window 13 Follow Steps 17 to 25 in 3 4 1 to compile the application and download it to the Target PLC 14 Double click on SFCtest1 program The SFCTEST1 SFC Program window is displayed The step currently active is shown with a black box Short circuit digital input INOO to change the activity to Step 2 which set the LED1 DS3 LED output to TRUE ES ISaGRAF B25TESTS SFCTEST1 SFC program inl x File Edit Options Help Sei pos 0 0 15 To stop the monitoring of the PLC application close the Debugger window The programs and dictionary windows in debug mode will be closed OEM Technology Solutions Page 32 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 3 4 6 Using Flow Chart 1 10 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs gt ISaGRAF 3 5 Projects On the Projects Management window select File menu New p e On the Create new project window enter the name of the project for example b25test6 and press OK button The name of project should not 2 Semisuretion Cancel exceed 8 characters The b25test6 project is then one E listed in the Projects Management window Select Edit menu Set comment text Enter a brief description of this project and press OK button
28. GRAF WORKBENCH mmm rettet 8 2 3 1 Adding the software EE 9 2 3 2 Adding a hardware license optional 9 24 BL2500 CONNECTION 10 2 4 1 Connect a Power Supply nennen nennen nna nene annes nns 10 2 4 2 Connect an Ethernet Cable Immer eterne reir er inris 10 2 4 3 Connect an RS232 Cable optional 12 2 5 RUNNING A SAMPLE APPLICATION aaa cece cc ccccccecccccccccececececececececececeneauauauauaenenes 12 2 0 WHERE DO IGOGO FROM HERE EE 14 3 RUNNING SAMPLE APPLICATIONYS 3 n nean de ree ooo on og eDegoz EA ee 15 3 1 RUNNING APPLICATIONS IN SIMULATION MODE 15 3 2 RUNNING APPLICATIONS THAT USE INTERNAL VARIABLES ONLY 17 3 3 RUNNING APPLICATIONS THAT USE BL2500 INPUTS AND OUTPUTS 18 3 3 1 Greatng V O CONNEC EE 18 3 3 2 Downloading and running the ISaGRAF application ccccccseeeeeeeseeeeeeaeeeeeeaees 19 3 4 CREATING A NEW PLC APDRDUICATION IH RIHRHRIRHIHRHRHRRRtI 20 3 4 1 Using Function Blocks Diagrams nne 20 3 4 2 Using Quick Ladder Diagrams ccccceecccccseeeeecaeeeeeeaeeeeeeseueeesaaeeeesaaeeeseaeneeeesaess 25 3 4 3 LISING Structured RK EE 2f 3 4 4 Using Instuclion BCEE 29 3 4 5 Using Sequential Function Chart 30 3 4 6 RE ne geed d P EMEN 33 4 HARDWARE REFERENCE nannan ceres oce EE 35 Ge DIGITAL INPUTS estecct rcs siceles coc 35 AZ JDIGILAL OW Me RE 36 4 3 ANALOG INPUT een ne MES EN E
29. I TRUE XOR SW2 TRUE ST LEDI FALSE 17 To stop the monitoring of the PLC application close the Debugger window The programs and dictionary windows in debug mode will be closed 3 4 5 Using Sequential Function Chart 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs ISaGRAF 3 5 Projects On the Projects Management window select File menu New On the Create new project window enter the i ame name of the project for example b25test5 and S c press OK button The name of project should not SE Cancel exceed 8 characters The b25test5 project is then Meel El listed in the Projects Management window Select Edit menu Set comment text Enter a brief description of this project and press OK button This description will be displayed next to the project name in the Projects Management window Double click on b25test5 project An empty B25TEST5 Programs window is displayed OEM Technology Solutions Page 30 EMBEDDED PLC BL2500 User s Manual Running Sample Applications ISaGRAF B25TESTS5 Programs Oo x File Make Project Tools Debug Options Help New Program Name 5 Select File menu New On the New program window CORDE enter the name of the program for example SFCtest1 a Tee brief comment select the Language to SFC select Begin o aT ETE Style and press OK butto
30. Ka Copyright c 2005 OEM Technology Solutions Pty Ltd This is a new or upgrade application program ou will need to enter the license key before the EMBEDDED PLC Firmware Kernel runs Please contact DEM Technology Solutions Pty Ltd or your local EMBEDDED PLC representative to obtain your license key ou will need to provide the reference number detailed below OEM Technology Solutions Pty Ltd can be contacted on Ph 61 2 9966 9424 Fax 61 2 3366 9429 Email support 2ioem net au User Reference Code ERIPAXAIERSE UU IEEE ARES License Key es Even if your Target is not active without valid license key you can run several samples in the ISaGRAF Workbench in simulation mode To run those sample files go to Section O 6 Once you have a valid license key open the EMBEDDED PLC Utility Select Setup Kernel License Follow the instructions on the message dialog box in the same order Press OK Reset Target After a few seconds the License Window will be displayed and the DS2 led red will be turned on 7 Enter the valid license key in the License Key entry box and press Send A confirmation message is displayed Save the User Reference Code and License Key for future reference and technical support Press OK The DS2 led red will be turned off and DS1 led yellow will start flashing every second as an indication that the Kernel is licensed and active For more information about the BL2500 LED status see Sec
31. LC BL2500 User s Manual Z amp ISaGRAF B25TEST2 LDTEST1 Quick LD Program File Edit Options Help A ms Qai Exclusive OR XOR logic for switching on LED d Swit Gw LED ee gt mi VUN VR KM Ge pos 5 1 19 To stop the monitoring of the PLC application close the Debugger window The programs and dictionary windows in debug mode will be closed 3 4 3 Using Structured Text Running Sample Applications 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs gt ISaGRAF 3 5 Projects On the Projects Management window select File menu New Create new project x Cancel On the Create new project window enter the name of the project for example b25test3 and press OK button The name of project should not exceed 8 characters The b25test3 project is then none Ei listed in the Projects Management window Name b25test3 10 configuration Select Edit menu Set comment text Enter a brief description of this project and press OK button This description will be displayed next to the project name in the Projects Management window Double click on b25test3 project An empty B25TEST3 Programs window is displayed File Make Project Tools Debug Options Help New Program x o Select File menu New On the New program window OEM Technology Solutions enter the name of the program
32. MBEDDED PLC Firmware Kernel for BL2500 Version 1 04 was built specifically for the BL2500 with Rabbit core module RCM3200 10 100BaseT 512K Flash 256K 512K SRAM 44 2 MHz clock speed Z World P N 101 0602 If you have any special requirements regarding targets that EMBEDDED PLC supports visit OEM Technology website or contact sales directly via phone 61 2 99669424 or email sales oem net au Q10 What does the letter C after the BL2500 in the BSP filename stand for The C letter in the filename BL2500C BSP V1 04 9 0003 006 zip corresponds to the type of the BL2500 board supported by EMBEDDED PLC Thus the letter C corresponds to the BL2500 with Rabbit core module RCM3200 10 100BaseT 512K Flash 256K 512K SRAM 44 2 MHz clock speed At this moment only the BL2500 mentioned above is supported by EMBEDDED PLC Q11 Can l use the EMBEDDED PLC Utility to download binary files compiled with Dynamic C No The EMBEDDED PLC Utility works only with EMBEDDED PLC firmware kernels Use Rabbit Field Utility instead Q12 Can I use the Rabbit Field Utility to download the EMBEDDED PLC Firmware Kernel to the Target No If you do so when you tried to enter the run time license using the EMBEDDED PLC Utility the following message is displayed UMEN E e Ilegal reference code Possibly the kernel was downloaded using another application Please use this utility to download the EMBEDDED PLC Firmware Kernel OEM Technology Solutions P
33. Manual FAQ and Troubleshooting 7 3 2 Before Contacting Technical Support some things you should try before you contact Technical Support are e Check out the documentation e Consider recent changes on your system If something used to work think about what may have changed New software installation or general system changes can affect performance and general functionality of other software on your system e Verify that the entire system has good low impedance separate grounds for analog and digital signals The BL2500 is often connected between the host PC and another device Any differences in ground potential can cause serious problems that are hard to diagnose e Do not connect analog ground to digital ground anywhere e Verify that the power supply has enough capacity and filtering to support the BL2500 If you cannot find an answer to your technical question in the product documentation or help system send your request to OEM Technology Solutions technical support via email Support oem net au Please try to define the problem before you contact Technical Support so that you can repeat the steps that led to the problem and specifically identify when and how the problem occurred The Technical Support representative will need to know exactly what the problem is in order to provide help These steps will help us pinpoint and solve your problem more quickly Please have the following information available e Hardware environment Targ
34. OTO EE 53 7 FAQ AND TROUBLESHOOTING iiec a vacuckvatsosescswasteaveeanaacecnenasacetsanencsbaxvaddeavsneskaetsenecedven ees 54 LI CN SUES E o4 7 1 1 BL2500 with Rabbit 3000 Microprocessor Revision 0 OCI o4 7 1 2 BL2500 with Large Sector Flash AAA o4 7 1 3 ISaGRAF Floating Point Arithmetic cccccccceeeeeeeeeeeeeseeeeeeseeeeeeseeseeesaaeeeesaaeeees 54 7 1 4 Reading writing 32 bit integer real analog variables via Modbus 01nnn00010000n o4 T2 Vo er CC M 55 1 3 TROUBLESHOOTING erian O A a a EL RIS 57 7 3 1 e ul elo EE 57 7 3 2 Before Contacting Technical Support 58 8 SP EGIPIGA wget 60 8 1 ELECTRICAL AND MECHANICAL SPECIFICATIONS eeeeeeeeernrennm enn 60 9 ABOUT INDUSOET Eeer 62 9 1 USING INDUSOFT WEB STUDIO WITH EMBEDDED DI 62 OEM Technology Solutions Page ii EMBEDDED PLC BL2500 User s Manual LIST OF TABLES Table 1 Main Features of the EMBEDDED PLC Firmware Kernel V1 04 on the BL2500 2 Table 2 EMBEDDED PLC BL2500 Serial Port Configuration cccccceccccceeceeceeeeeseeeeeaeeesaeeeeseeeeseaeess 38 Table 3 BL2500 Electrical Mechanical and Environmental Specifications sssesss 61 LIST OF FIGURES Figure 1 Power SUPDIY GOMMECTON DEE 10 FIgure Z Get E connections EE 11 Figure 3 PC lt gt BL2500 RS232 connection
35. RADING THE FIRMWARE KERNEL 6 1 INTRODUCTION The EMBEDDED PLC Utility is used to load the EMBEDDED PLC Firmware Kernel to the Rabbit based Target such as the SBC BL2500 The Firmware Kernel once loaded into the Target requires a license key to run The EMBEDDED PLC Utility does not check for an existing license key before loading the Kernel Thus a new license key is required after a Kernel is loaded to a Target Upgrading the EMBEDDED PLC Firmware Kernel means also loading the newer version of the Firmware kernel file into the Target Therefore after loading a newer version of the Firmware Kernel file into a licensed Target PLC a new license key will also be required v Caution Loading of the Firmware Kernel file is NOT needed if you purchased the EMBEDDED PLC Application Kit as the BL2500 comes with a pre loaded and licensed Firmware Kernel If you re load the Firmware Kernel to a pre loaded Target the license information will be lost and a new license key will be required To verify if your BL2500 have the EMBEDDED PLC Kernel running power up the BL2500 and if after 10 seconds the DS2 red LED turns off and DS1 starts flashing then the Kernel is loaded and licensed This chapter describes how to install the EMBEDDED PLC Utility load and license the EMBEDDED PLC Firmware Kernel Also includes a complete reference of the Utility software 6 1 1 Installing EMBEDDED PLC Utility Use the following procedure to install EMBEDDED PLC Uti
36. SE enter the name of the program for example LDtest1 a Komment brief comment select the Language to Quick LD select Language Begin Style and press OK button The LDtest1 program Stie is displayed in the B25TEST2 Programs window OEM Technology Solutions Page 25 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 6 Follow Steps 6 to 11 in Section 3 4 1 to create and populate the application s Dictionary with SW1 and SW2 Boolean input variables connected to Channel 1 and 2 of the bl25di I O board respectively and LED1 Boolean output variable connected to Channel 1 of the bl25led I O board 7 Onthe B25TEST2 Programs window double click on LDtest1 program The Quick Ladder Diagram Editor contains an editing grid a logical matrix where each cell of the matrix may contain F2 JEJE up to one LD symbol Press F2 Contact on the left button on the toolbar to insert a new rung A new rung with one contact and one coil is created 8 Double click the rung comment cell to insert a comment such as Exclusive OR logic for switching on LED 9 Double click the contact on the rung and select SW1 for an input 10 With the SW1 contact selected press F3 Contact on the right button on the toolbar 11 Double click the new contact and select SW2 variable Click once on the Coil contact type button 12 to negate this contact 12 Select the Select button l on the toolbar Select both contacts on th
37. TCP and 2 x cycle duration for Modbus RTU over RS232 RS485 Cycle duration corresponds to the time that kernel executes one cycle read inputs execute logic update outputs Digital Input scan time is approx 200 ps Analog Input scan time is approx 83 ms Digital Output update time is approx 30 us per output Analog Output update time is approx 120 us Boolean instruction execution time is approx 30 us Program execution overhead is approx 100 us per program Maximum size of ISaGRAF application database is 50000 bytes Size of ISaGRAF real time database holds variables SFC engine data C function and function blocks data is 10000 bytes Free root memory on the BL2500 is approx 9000 bytes EMBEDDED PLC firmware kernel total code size is approx 260000 bytes On line modifications This feature enables the user to modify the application while the process is running Uploading application stored in the target 1 3 ABOUT THIS MANUAL This manual provides instructions for installing testing configuring and interconnecting the Z World SBC BL2500 running the EMBEDDED PLC Firmware Kernel Instructions are also provided for using the ISaGRAF Workbench This User s Manual is divided into the following chapters OEM Technology Solutions This chapter provides and overview of the EMBEDDED PLC and information about this publication such as conventions used and reference documents Chapter 2 Getting St
38. age 56 EMBEDDED PLC BL2500 User s Manual FAQ and Troubleshooting 7 3 TROUBLESHOOTING 7 3 1 Common Errors Listed below are some solutions of common errors that you may encounter with EMBEDDED PLC products 7 3 1 1 Communications If you experienced problems with the communication between the Target and either the ISaGRAF Workbench or a Modbus master check the items below Disconnect all the physical I Os connected to the Target and try again Check that the Modbus Slave Number value in the Target is the same as the Target Slave Number in the ISaGRAF Workbench If you are using Ethernet link check that IP address Netmask and Default Gateway values are correct in the Target Check also that the port in the ISaGRAF Workbench is set to 1100 If you are using RS232 or RS485 link remember that either the ISaGRAF Workbench or the Modbus master can be connected to the Target at a certain time Check that the serial port parameters on the ISaGRAF Workbench and or Modbus master are the following Baud rate 19200 to 600 depending on the Target configuration no parity 8 data bits 1 stop bits and no flow control If you are using a RS232 to USB converter cable check that the COM port assigned to it is within COM1 to COM4 range If not follow the instructions described in Q3 of the FAQ section The minimum value of the polling period from ISaGRAF Workbench or a Modbus master must be greater than the PLC cycle execution time In any case the a
39. al C Constant C Dutput Other Retain Format Integer t Rea Length Ree 8 On the Dictionary window the SW1 to SW2 variables are listed ISaGRAF B25TESTI Global booleans E B x Fille Edit Tools Options Help Mame Attrib A dar Comment PRM oood EMT M0000 input false true 9 On the B25TEST1 Dictionary double click on the empty row Enter the name LED1 and select it as output 10 On the Dictionary window select Integers Reals tab Press Insert objects button or select Edit menu New Enter the following information on the Integer Real Variable window Name ADO Comment Analog Input ADO Unit V Attributes Input and Format Real Press Store button Repeat this step to create the analog output variable Name DAT Comment Analog Output DAT Unit V Attributes Output and Format Real Press Cancel to close the Integer Real Variable window OEM Technology Solutions Page 21 EMBEDDED PLC BL2500 User s Manual Running Sample Applications x Comment Analog Input ADO Unit Conversion none Attributes Format inama C nteger standard C Output Next w o Previous Extended 11 Save the current dictionary by selecting File menu Save Close the Dictionary window 12 On the B25TEST1 Programs window double click on FBtest1 program Press Insert variable button on the toolbar and click on the working area On the Select va
40. al Hardware Reference DAO too low en lc m N a Rie M24 Add Pa i Pl 10 ki Le afs k Rm LM324 s AAA PBS SL 7 wn ii DAD too high Figure 7 Schematic Diagram of the A D Converter The A D converter programs DAO using a successive approximation binary search until DAO equals the A D converter input voltage That programmed DAO voltage is then reported as the A D converter value The A D converter transforms the voltage at DAO into a 13 2 mV window around DAO Because the A D converter circuit uses a 13 2 mV window the accuracy is 6 6 mV DAO can range from 0 1 V to 3 1 V which represents 227 steps of 13 2 mV This represents a resolution of approximately 8 bits Since the D A converter is able to change the DAO output in 3 22 mV steps there are 930 steps over the range from 0 1 V to 3 1 V This represents a resolution of approximately 10 bits The A D converter has no reference voltage There is a relative accuracy between measurements but no absolute accuracy without calibration This is because the 3 3 V supply can vary 5 the pulse width modulated outputs might not reach the full O V and 3 3 V rails out of the Rabbit 3000 microprocessor and the gain resistors used in the circuit have a 1 tolerance For these reasons each BL2500 needs to be calibrated individually with the constants held in software to be able to rely on an absolute accuracy The BL2500 has this calibration support An A D conversion takes a
41. anagement to resume ISaGRAF development 7 1 4 Reading writing 32 bit integer real analog variables via Modbus EMBEDDED PLC supports reading and or writing 32 bit integer real analog variable through Modbus Requests are handled by using two consecutive words multiple registers in little endian format i e the less significant word goes first The constraint is the Modbus address for analog variables must be odd number OEM Technology Solutions Page 54 EMBEDDED PLC BL2500 User s Manual FAQ and Troubleshooting 7 2 FAQ Q1 Q2 Q3 Q4 Q5 Q6 Q7 What happens if I try to load the EMBEDDED PLC Firmware Kernel to a Target already running a licensed EMBEDDED PLC Kernel The EMBEDDED PLC Utility does not check for an existing license before performing a loading and a new license is required after a Kernel is loaded to a Target This means that after loading a new Kernel to a Target a new User Reference Code is generated and you will need to contact OEM Technology Solutions or your local distributor to obtain a new license key to activate the EMBEDDED PLC Kernel Which are the Modbus function codes supported by EMBEDDED PLC The EMBEDDED PLC BL2500 supports the following Modbus function code read N bits write 1 bit s Leien These are the function codes supported by ISaGRAF see Section C 8 2 of 2 How can I change the assigned serial port number to the RS 232 to USB converter cable on Windows XP Open C
42. arallel port F Thus any operation on analog UO affects the normal operation of outputs serial RS485 transmitter enable signal SPI enable signal and LEDs DS3 and DS4 If you have an SBC BL2500 with the Rabbit 3000 microprocessor revision O IL1T or IZ1T and want to use the analog features bear in mind that outputs 0 to 3 RS485 and RabbitNet can not be used For more information about the Rabbit 3000 microprocessor revisions see Appendix B of 3 7 1 2 BL2500 with Large Sector Flash The EMBEDDED PLC kernel writes the ISaGRAF application on flash to preserve the application on power cycles This operation is done only with BL2500 with small sector flash EMBEDDED PLC kernel saves the ISaGRAF application on Battery Backed RAM if the BL2500 has large sector flash 7 1 3 ISaGRAF Floating Point Arithmetic The floating point arithmetic implemented by Dynamic C for the Rabbit 3000 microprocessor is not 10096 compliant with the IEEE Standard When doing arithmetic operations with numbers close to the upper limit 3 4E38 instead of causing an overflow the result goes beyond the limits set by the standard External applications such as ISaGRAF Debugger monitoring those values will fail because those values are invalid floating point NaN When this condition happens the ISaGRAF Debugger stops but leaves some processes running If you experience this problem close all ISaGRAF applications including the Project Management Re open the Project M
43. arted Explains how to install the different EMBEDDED PLC products and run a sample application Chapter 3 Running Sample Applications Provides instructions how to run the different types of sample applications and also how to create a PLC application using the ISaGRAF Workbench Chapter 4 Hardware Reference Provides a detailed description of the I Os and communication ports present in the SBC BL2500 and how to configure them in order to work with EMBEDDED PLC Page 2 EMBEDDED PLC BL2500 User s Manual Introduction e Chapter 5 Software Reference Provides an overview of the ISaGRAF Workbench functionalities and detailed description of the ISaGRAF library elements I O boards software configuration C functions and C function blocks available from the ISaGRAF Workbench e Chapter 6 Using EMBEDDED PLC Utility Detailed description of the EMBEDDED PLC Utility e Chapter 7 FAQ and Troubleshooting Describes the known issues with this release frequently asked questions and troubleshooting e Chapter 8 Specifications Describes the electrical mechanical and environmental specifications of the BL2500 e Chapter 9 About Indusoft A brief description of Indusoft Web Studio and how can be used in conjunction with EMBEDDED PLC 1 4 EMBEDDED PLC APPLICATION KIT The EMBEDDED PLC BL2500 Application Kit contains the hardware and software needed to use the SBC BL2500 with EMBEDDED PLC system It contains e BL2500 Single Board Compu
44. bsolute minimum values for the polling period must be greater than the following Modbus over TCP IP 50 ms Modbus over RS232 or RS485 200 ms 7 3 1 2 ISaGRAF Workbench for EMBEDDED PLC If you experienced problems downloading an application to the Target check the items below Check that you have communication with the Target check items above In order to work with EMBEDDED PLC make sure that the RABBIT TIC code for Rabbit based controllers is selected in the Compiler options list before making and downloading the application 7 3 1 3 EMBEDDED PLC Utility Check the items below if you have problems downloading the EMBEDDED PLC Firmware Kernel Check that the programming cable is connected through DIAG connection to the Target Check that no other application is using the selected COM port Check the location of the cold loader pilot BIOS xj and Flash initialization files Select Setup File Locations from the main menu bar Check that the Cold loader COLDLOAD bin Pilot Cold Loader BEDDED_PLC Wtility COLDLOAD BIN Ra BIOS pilot bin and Flash table Pilot BIOS ech EMBEDDED_PLC Utity pilot bin flash ini files locations are correct It should point to where the EMBEDDED PLC Utility is Flash table Tech EMBEDDED_PLCitility flash ini D installed default C OEMTech EMBEDDED PLC Utility Press OK OK Cancel Help File Locations OEM Technology Solutions Page 57 EMBEDDED PLC BL2500 User s
45. cts Management window double click on the b25qld project 2 Select Debug Link setup or press Link Setup and configure the Target PLC lt gt PC link Follow the guidelines on Step 2 of the previous section 3 Select Debug Debug or press Debug to open the Debugger window If an application is running stop it press Stop button on the toolbar On the Debugger window select File gt Download to download the b25qld application to the target A progress bar on the Debugger window shows the progress of the download process Once the downloading is completed the application starts running and the following SpotLight window is displayed K ISaGRAF B25QLD ROUM SpotLight B sl File Edit Insert Options Help 4 The Digital inputs INOO and INO1 of the BL2500 are wired as the Left and Right switches on the b25qld application The BL2500 on board LED DS3 is the output of the light The BL2500 digital inputs INO2 and INO3 move the window s screen to the left and right respectively 5 Tocheck the I O connections close the Debugger window and on the B25QLD Programs window select Project I O connection Check the wiring of the channels sir ISaGRAF B25QLD 1 0 connection B x File Edit Tools Options Help o skb n tl FA e w bl25di ne e 3E o SwLeft t Switch lett turns light ontott 2 m tf bl25led m e amp SwRight Switch right turns light on off o LiCmd Move Left user command e AtO
46. e rung by clicking on one contact and dragging the mouse over to the next contact before releasing the mouse button Press F4 Parallel contact button bi to create two new contacts in parallel with the selected contacts 13 Repeat steps 9 and 11 except negate the SW1 contact with the Coil contact type button this time instead of the SW2 contact 14 Double click on the coil on the rung and select LED1 for an output 15 The LDtest1 program should now appear as follows i ISaGRAF B25TEST2 LDTEST1 Quick LD Program File Edit Tools Options Help Aa zez Be sid Bt aua G pn FO Fr it FTH FE ze Exclusive OR XOR logic for switching on LED 1 S S2 LED1 HH mm S1 SwW2 X E 5 3 16 Save the program by selecting File menu Save Press OK button on the Update diary window Close the LDtest1 QuickLD Program window 17 Follow Steps 17 to 25 in Section 3 4 1 to compile the application and download it to the Target PLC 18 Double click on LDtest1 program The LDTEST1 Quick LD Programs window is displayed with the variables in BLUE or RED colour depending on its current state FALSE or TRUE respectively Press the SW1 short circuit digital input INOO and the LED1 will be turned ON as well as the state of LED1 in the Programs window will change The PLC program implements a Boolean XOR operation on SW1 and SW2 with the result set on the LED1 OEM Technology Solutions Page 26 EMBEDDED P
47. ect an Ethernet Cable The BL2500 that comes in the EMBEDDED PLC Application Kit has the Firmware Kernel loaded licensed and configured The default factory configuration is Modbus Slave Number 1 Use Modbus TCP IP Address 192 168 1 100 OEM Technology Solutions Page 10 EMBEDDED PLC BL2500 User s Manual Getting Started Netmask 255 0 0 0 Default gateway 192 168 1 1 If you want to change the default values go to section 6 1 4 for instructions how to change the configuration of the Target PLC The following instructions will guide you on how to connect the Target PLC to the Workbench using TCP IP There are two ways of connecting the Target PLC to your PC via Ethernet see Figure 2 e Using a crossover Ethernet cable provided in the EMBEDDED PLC Application Kit to connect directly the Target PLC to your PC or e f your PC is currently connected to an Ethernet hub use a straight through Ethernet cable not provided in the EMBEDDED PLC Application Kit to establish an Ethernet connection to the BL 2500 from the hub BL2500 BL2500 LJ n Ethernet cables crossover To additional cable network elements User s PC Direct Connection network of 2 computers Direct Connection Using a Hub Figure 2 Ethernet connections When your PC is connected directly to the BL2500 via an Ethernet connection you need to set or change the TCP IP parameters of your computer in order to establish a proper connection with
48. elected objects Engineering Runtime e NUM x 41 Y 6 You can quickly add the Modbus driver on the Workspace define its operational parameters and define the I O variables tags that will be exchanged between the EMBEDDED PLC and the IWS application OEM Technology Solutions Page 63 EMBEDDED PLC BL2500 User s Manual Index INDEX JSt 17 B software license cece ececcecececececeeaecececeeaees 8 le Re LE 13 17 BL2500 BID CLG Le iE eiie ie LO rer were 36 WOFKDGFPOCDI3 ee Eeer 1 D A Converter 37 M GIGHAMMINDUIS EE 35 digital outputs a a 36 Modbus Ethernet DOM uoa usted eate tavetahinatan 39 configuration cccceeeeeeeeeeeeeeeeeeeeesaeeeeeeneees 51 Main features c ccccccecececececececececececececes 1 DINOU MEE RE DT 35 N E network configuration sssuusss 11 EMBEDDED PLC R Application kit contents 3 Board Support Package BSP 7 Elei LEE 35 Definition 1 e Firmware Kernel enm 1 GE ue software Imstallaton 7 S Target PEG aii oe do bbb Cte OU MES Lans 1 Bo MR RR ERE 7 sample applications EEN 12 Workbench oana issus dldrh 1 DZIA erc P m 15 DZ OF DEE 15 F EE 15 DINK SOO EE 15 poss de Kernel 50 le EE a 15 ES A eead o a 50 Helio EE 15 mud E DEENEN 49 AETIA EE 15 GE EE Ee 15 DEE E 15 EM 15 IidlsofLz c eie eU ee uin 62 SGORTIING 12 ISaGRAF Serial Ports hardware Icense eene 8
49. elp 8 OBDA suerte aea xB dese oo Troubled If you experienced problems running this application such as an error message Cannot install communication or Cannot start download target not ready follow this checklist 1 3 Make sure that the TCP IP connection between the Target PLC and your PC is alive use ping command See Section 2 4 2 on how to configure TCP IP parameters If connection is alive repeat accurately the step by step instructions in this Section Remember to put correctly the Target Slave Number and the IP address of the Target PLC in the PC PLC link parameters window Step 2 If the Target PLC has already an application running stop it before downloading a new one If you still can not run this sample application go to Chapter 7 FAQ and Troubleshooting which contains more information about how to troubleshoot your particular problem OEM Technology Solutions Page 13 EMBEDDED PLC BL2500 User s Manual Getting Started 2 6 WHERE DO I GO FROM HERE The next chapter describes how to run the other sample applications and step by step instruction on how to create a simple PLC application The ISaGRAF User s Manual and the ISaGRAF Workbench on line help contain a complete description of the Workbench features and capability as well as a complete PLC programming languages reference The User s Manual can be found in the Documentation folder of the CD ROM ISaGRAF pdf OEM Technology So
50. er s Manual Software Reference 5 SOFTWARE REFERENCE 5 1 MORE ABOUT ISAGRAF 5 1 1 Project Manager The ISaGRAF methodology begins with the preparation of a detailed project specification This step is common to all PLC programming techniques and is usually the result of a thorough analysis of the project and consultation between the integrator and the user Distributed applications can be represented as several ISaGRAF projects grouped together in the project list Distributed applications can be edited simulated or debugged on the same Windows screen 5 1 2 Program Manager With the program manager the application specification is divided into smaller functional modules The exact operation that is to be performed within each module is defined at that stage ISaGRAF s program management facilities allow the user to define each of these modules their operations and their interaction to form the complete application 5 1 3 Variable Definition All variables are declared or imported in the ISaGRAF dictionary When this step is achieved during programming a mouse click will insert the variable in the program Any external database can be imported to build the ISaGRAF dictionary A quick declaration allows many variables to be declared with one command and an easy to use mapping tool is provided for Modbus based SCADA systems such as Indusoft For a brief description about Indusoft and how to use it in conjunction with EMBEDDED PLC
51. es for example input switch SW1 either select Edit Insert variable SW1 or type SW1 on the command line Type the following command lines under the entered comment LD SW1 XOR SW2 er LEDI The ILtest1 program should now appear as follows OEM Technology Solutions Page 29 EMBEDDED PLC BL2500 User s Manual Running Sample Applications SaGRAF B25TEST4 ILTEST1 IL program File Edit Tools Options Help B a VOR mg Ed amp e Keywords E j Ca Exclusive OR logic for switching on LED si TRUE FALSE LD ST OR MUL EQ CAL XOR Div NE JMP ST LED1 14 Save the program by selecting File menu Save Press OK button on the Update diary window Close the ILtest1 ST Program window 15 Follow Steps 17 to 25 in 3 4 1 to compile the application and download it to the Target PLC 16 Double click on ILtest1 program The ILTEST1 ST Programs window is displayed with the line numbers visible and the TRUE or FALSE current state for each variable displayed in the Value column Short circuit digital input INOO to set SW1 to FALSE the LED1 will be turned ON as well as the state of LED1 in the Programs window will change The PLC program implements a Boolean XOR operation on SW1 and SW2 with the result set on the LED1 ISaGRAF B25TEST4 ILTEST1 IL program of x File Edit Search Options Help HS A Line Label Inst Ope Comment Exclusive OR logic for switching on LED LD SW
52. et details BL2500 model Host PC details and a brief description of the physical I Os used e Software environment Windows Operating System e EMBEDDED PLC filenames used e EMBEDDED PLC Kernel version You can obtain this information from the Target Configuration Window Module Version Kernel Version Kernel Description e EMBEDDED PLC license information e Description of the problem or error including specific text or error messages e Steps to reproduce the problem if it is reproducible OEM Technology Solutions Page 58 EMBEDDED PLC BL2500 User s Manual FAQ and Troubleshooting This page is intentionally left blank OEM Technology Solutions Page 59 EMBEDDED PLC BL2500 User s Manual Specifications 8 SPECIFICATIONS 8 1 ELECTRICAL AND MECHANICAL SPECIFICATIONS RJ 45 jack extends Diameter of mounting 0 16 4 0 mm holes 0 12 3 mm past edge of board This mounting hole P SIE c7 gy m s O O at d o EK s MENN St s o UI O RS Q o kme EET ILIA d sl gFHEFPHRHWI SH g HSR dese 2 T e d Hl ir o f corn Wie TP Se CC CR e c asd Th SLU o EO mum lt g 5 f Mie gt L E TT uo Oo coco WO VD l s ue mo OLD w co D Ka a Ei E zT moms B gnniisnd c SEN E Ek RS 415 TERMINATION RESISTORS TOO OC We SE 2 i S am D 58 iun i E m S Li dei el Il um rrr Uu
53. g Debug or press Debug to open the Debugger window If an application is running stop it press Stop button on the toolbar On the Debugger window select File gt Download to download the b25test1 application to the Target PLC A progress bar on the Debugger window shows the progress of the download process Once the downloading is completed the B25TEST1 Debug programs window is displayed On the Debugger window the application state will be RUN Double click on FBtest1 program The FBTEST1 FBD LD Programs window is displayed with the variables in BLUE or RED colour depending on its current state FALSE or TRUE respectively If the digital input INOO of the BL2500 is short circuited SW1 is FALSE and LED DS3 will be turned ON as well as the state of LED1 in the Programs window will change The PLC program implements a Boolean XOR operation on SW1 and SW2 with the result set on the LED1 Si ISaGRAF B25TESTI FBTESTI FBD LD Program e ioj zl File Options Help Ee Co LED F ALSE c NZTRLIE D pos 24 11 OEM Technology Solutions Page 24 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 27 On the FBTEST1 FBD LD Programs window select File menu Dictionary On the dictionary window click on Integers Reals tab Double click on DAT variable and set its value to 1 5 V any value in the 0 3 3 V range Connect a multimeter between DAT and AGND of the BL2500 and check that the voltage is 1 5 V
54. hart Sorting of tokens depending on their size and colour e Sample applications pre configured to use BL2500 I O boards These applications can be simulated or downloaded to the BL2500 Target PLC and requires that the Target is connected to physical I Os gt b25qld Demo with Quick LD programming gt b25rota Rotation of 2 BL2500 on board LEDs DS3 and DS4 and 2 digital outputs gt b25scope Signal generation BL2500 Analog Out and SpotLight A description of each of the sample applications appears at the bottom of the ISaGRAF Project Manager 3 1 RUNNING APPLICATIONS IN SIMULATION MODE Use the following procedure to run any sample application in simulation mode 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs ISaGRAF 3 5 Projects A ISaGRAF Project Management oj x File Edit Project Tools Options Help Dem e t D B Samples 2 b25qld Demo with Quick LD programming b25rota Rotation of 2 on board leds and 2 digital outputs gp b25scope Signal generation BL2500 Analog Out and SpotLight mm blinkseq Same implementation with various languages mp bottlef Flow Chart Simulation of bottle production Complete SFC demo m rfsample Sample described in user s quide r sfc Demonstrates SFC actions in SFC rfstack Demonstrates STACKINT function block sorting Flow Chart Sorting of tokens depending on their size and col
55. he cable as the EMBEDDED PLC Utility will need to have this parameter configured Note that COM1 on the PC is the default COM port used by the EMBEDDED PLC Utility OEM Technology Solutions Page 48 EMBEDDED PLC BL2500 User s Manual Loading or Upgrading the Firmware Kernel Colored e PC COM port Ki Color PEG GABE Zeta aer D OOOOOOOHN Figure 12 Programming Cable Connection 2 Connect the power supply to the BL2500 following the instructions in Section 2 4 1 6 1 3 Loading and licensing the Firmware Kernel The EMBEDDED PLC BL2500 Firmware Kernel file BL2500C V1 04 3 0231H bin is located in the BL2500C BSP V1 04 9 0003 006 Kernels directory of the CD ROM or in the ZIP file if downloaded from the website It is recommended to copy this file from the CD ROM to a local PC folder referred in this procedure as EMBEDDED PLC Kernel Dir gt Use the following procedure to load the EMBEDDED PLC Firmware Kernel to the Target 1 Open the EMBEDDED PLC Utility and select Setup Communications from the main menu bar Select the serial COM port where the programming cable is connected Check the Use USB to Serial converter check box if you have the RS232 to USB converter cable Press OK 2 Select File Load Flash Image from the main Ei menu bar On Choose Flash Image window press button On the Open window select the EMBEDDED PLC Firmware Kernel file lt EMBEDDED PL
56. idation will appear and the EMBEDDED PLC will be active If license is already valid a message dialog box will show the current Reference Code and License Key Keep this numbers for your records and for customer support 6 2 1 6 Setup Utility Settings The Target Communication Timeout corresponds to the maximum amount of time waiting for a message coming from the EMBEDDED PLC target during licensing or configuring the kernel The value is expressed in seconds and has to be an integer Minimum value is 1 seconds 6 2 2 Loading Shortcuts 6 2 2 1 Right Mouse Click Clicking the right mouse button anywhere on the main window will bring up a list of the most recently loaded programs Selecting any of the programs in the list will automatically load that program to the attached controller 6 2 2 2 Drag and Drop Once the EMBEDDED PLC Utility is open if a file is dragged from Windows Explorer the Desktop etc and dropped into the main window the file will be automatically loaded to the controller OEM Technology Solutions Page 53 EMBEDDED PLC BL2500 User s Manual FAQ and Troubleshooting 7 FAQ AND TROUBLESHOOTING 7 1 KNOWN ISSUES 7 1 1 BL2500 with Rabbit 3000 Microprocessor Revision 0 IL1T The Rabbit microprocessor R3000 Revision O IL1T or IZ1T has a bug on the parallel port F see Z World s TN228 http www zworld com documentation docs refs TN228 TN228 pdf The analog inputs and analog outputs use the PWM which uses p
57. ignal is at 3 3 V is equal to the time the signal is O V the duty cycle will be 50 and the average signal will be 1 65 V If the time at 3 3 V is only 25 of the time then the average voltage will be 0 825 V Thus the software needs to only vary the time the signal is at 3 3 V with respect to the time the signal is at 0 V to achieve any desired voltage between 0 and 3 3 V It is very easy to do pulse width modulation with the Rabbit 3000 microprocessor because the chip s architecture includes an advanced PWM feature 4 5 COMMUNICATION INTERFACES 4 5 1 Serial Ports The BL2500 can be configured using EMBEDDED PLC Utility to use either one RS 232 serial port E or the RS485 serial port D The serial port chosen will be used as the communication channel with either the ISaGRAF Workbench or a Modbus master The serial port A is used by the programming cable Table 2 EMBEDDED PLC BL2500 Serial Port Configuration Programming Port J3 Rabbit core module RS 232 3 wires 4 5 1 1 RS 232 The BL2500 RS 232 serial communication is supported by an RS 232 transceiver This transceiver provides the voltage output slew rate and input voltage immunity required to meet the RS 232 serial communication protocol Basically the chip translates the Rabbit 3000 s CMOS TTL signals to RS 232 signal levels Note that the polarity is reversed in an RS 232 circuit so that a 3 3 V output becomes approximately 6 V and O V is output as 6 V The RS 232 t
58. ing system e 128 MB of RAM required 256 MB or more recommended e 1 25 to 2 GB of available hard disk space e CD ROM or DVD ROM drive e VGA or hardware that supports console redirection required Super VGA supporting 800 x 600 or higher resolution monitor recommended e 1 serial port COM1 COM4 e Ethernet card ZS Note The EMBEDDED PLC Application Kit comes with one Z World SBC BL2500 pre loaded with the EMBEDDED PLC Firmware Kernel If you require to load the Firmware Kernel to another BL2500 or to upgrade the current one go to Chapter 6 which describes in detail the installation of the additional software and how to load or upgrade the EMBEDDED PLC Firmware Kernel to the Target 2 2 SOFTWARE INSTALLATION The EMBEDDED PLC CD ROM contains the following software e ISaGRAF V3 50 EMBEDDED PLC ISaGRAF V3 50 Workbench installer This particular installation is intended to work in stand alone mode or only with EMBEDDED PLC Rabbit based targets After installation of the Workbench the software runs in a trial mode for 30 days After period expires license is required e BL2500C BSP V1 04 9 0003 006 EMBEDDED PLC Board Support Package BSP for the SBC BL2500 It contains the EMBEDDED PLC BL2500 Firmware Kernel and the ISaGRAF I O boards and sample files to be installed in the ISaGRAF directory e EmbeddedPLCUtility V1 03 3 0237G Microsoft Windows Installer of the EMBEDDED PLC Utility The EMBEDDED PLC Utility allows you
59. it to O V FALSE Digital output is open circuit 5 2 1 3 BL2500 On board LEDs Name bl25led Description Controls the BL2500 on board LEDs DS3 and DS4 Number of Channels 2 Connection Terminals None Channel Value Correspondence TRUE LED is ON FALSE LED is OFF 5 2 1 4 BL2500 Analog Input Board Name bl25ai Description Software Reference Monitors ADO Analog Input of the BL2500 10 bit resolution over 0 3 3V range Number of Channels 1 Connection Terminals ADO Connection for positive signal channel 1 AGND Connection for negative signal channel 1 Channel Value Correspondence Analog REAL type variable Voltage input in the range 0 3 3 V OEM Technology Solutions Page 44 EMBEDDED PLC BL2500 User s Manual Software Reference 5 2 1 5 BL2500 Analog Output Board Name bl25ao Description Controls DA1 Analog Output of the BL2500 10 bit resolution over 0 3 3V range Number of Channels 1 Connection Terminals DA1 Connection for positive signal channel 1 AGND Connection for negative signal channel 1 Channel Value Correspondence Analog REAL type variable Voltage output in the range 0 3 3 V 5 2 2 ISaGRAF C Functions 5 2 2 1 KERNVER kernver versi versi MSG EMBEDDED PLC kernel version number minimum message length 8 Arguments Description Returns the kernel version number ST Equivalence result kernver Remarks Not available for simulation
60. j T 3 gt Figure 13 BL2500 Dimensions OEM Technology Solutions is located under the RabbitCore module Page 60 EMBEDDED PLC BL2500 User s Manual Specifications Table 3 BL2500 Electrical Mechanical and Environmental Specifications Ethernet Port 10 100 Base T 512K program 256K data Digital I O 16 inputs 15 protected to 36 V DC 1 protected to 5 36 V threshold is 1 5 V nominal 8 outputs sink up to 200 mA each 36 V DC max standoff voltage Analog Inputs One 10 bit resolution 8 bit accuracy input range 0 1 3 1 V 10 samples s Analog Outputs Two 9 bit PWM 0 1 3 1 V DC 17 ms settling time Serial Ports 6 serial ports 1 RS 485 2 RS 232 or 1 RS 232 with CTS RTS 1 CMOS level asynchronous or clocked serial port 1 expansion serial port for multiplexed to two RS 422 clocked SPI ports 1 CMOS compatible serial port for programming debug 10 8 bit timers 6 cascadable from the first and one 10 bit timer with 2 match registers Power 8 40 V DC 1 W typical w no load Humidity 5 to 9596 noncondensing Connectors Friction lock connectors five polarized 9 position terminals with 0 1 pitch two 2 position power terminals with 0 156 pitch two 4 position terminals with 0 156 pitch Part Number 101 0602 Only 1 analog output is available for EMBEDDED PLC Not Supported in EMBEDDED PLC at this present time Only 1 RS232 serial port E and 1 RS485
61. l the driver After the installation is completed connect the dongle to a parallel or USB port and open the License Manager Start menu gt Programs ISaGRAF 3 5 Licensing On the Selected Components list the ISaGRAF 3 Hardware license will be shown active 2 4 BL2500 CONNECTIONS 2 4 1 Connect a Power Supply 1 Connect the AC adapter to header J2 on the BL2500 as shown in Figure 1 Match the friction lock tab on the friction lock connector to the back of header J2 on the BL2500 as shown The friction lock connector will only fit one way Plug in the AC adapter Application Kits sold outside North America or Australia include a friction lock connector that can be connected to header J2 on the BL2500 Connect the leads from your power supply to the friction lock connector to preserve the polarity indicated in the figure The power supply should deliver 8 40 VDC at 500 mA Figure 1 Power Supply Connection 2 Plug the AC Adapter DS1 yellow and DS2 red LEDs indicate the Firmware Kernel status after the board has been powered up If after 10 seconds DS2 red is turned off and DS1 yellow starts blinking the Firmware Kernel is licensed and active If DS2 red remains turned on during more than 10 seconds it indicates that Kernel requires licensing If DS1 and DS2 are off after powered up it indicates that the board has no EMBEDDED PLC Firmware Kernel loaded In both cases contact your local distributor 2 4 2 Conn
62. lity from the CD ROM 1 Insert the EMBEDDED PLC BL2500 CD ROM and open the root folder 2 Double click on the EmbeddedPLCUtility V1 03 3 0237G msi file to launch the EMBEDDED PLC Utility Setup Wizard Follow the on screen instructions to proceed with the installation 3 Once all the EMBEDDED PLC Utility files have been copied the EMBEDDED PLC Utility icon is added to your Desktop and the following group is added to your main Programs group fi EMBEDDED PLC Utility sl xi File Edit View Favorites Tools Help ay Back v gt K J Search gt Folders RRE Address m C Documents and Settings 4ll Users Start Menu Programs EMBEDDED PLC Utility EJ Go EMBEDDED PLC Utilit EMBEDDED PLC Utility Hel A Uninstall File and Folder Tasks B Shortcut ty Shortcut ek befrot 1 KB R O 2 KB g Make a new folder z DS Publish this Folder to the Web kJ Share this Folder xl 3 objects 3 19 KB A My Computer Z 6 1 2 Connecting to the BL2500 1 Connect the 10 pin PROG connector of the programming cable to header J3 on the BL2500 s RabbitCore module Ensure that the coloured edge lines up with pin 1 as shown in Figure 12 There is a small dot on the circuit board next to pin 1 of header J3 Do not use the DIAG connector which is used for licensing and configuring only Connect the other end of the programming cable to a COM port on your PC Make a note of the port to which you connect t
63. ll C functions and C function blocks are available for simulation Section 5 2 2 and 5 2 3 describes C functions and C function blocks that are specific to the BL2500 and are not available for simulation 5 2 ISAGRAF SOFTWARE REFERENCE This section presents information about the specific elements of the ISaGRAF Workbench Library for the EMBEDDED PLC BL2500 I O boards C functions and C function blocks 5 2 1 UO Boards ISaGRAF I O board library for the BL2500 is included as part of the BL2500 BSP to make it easy to communicate with the BL2500 supported inputs and outputs These I O boards are described in the following sub sections 5 2 1 1 BL2500 Digital Inputs Board Name bI25di Description Monitors INOO IN15 of the BL2500 Digital Inputs Parameters None Number of Channels 16 Connection Terminals INOO to IN15 Connection for positive signal channel 1 to 16 GND Connection for negative signal all channels Channel Value Correspondence TRUE When digital input pulled up to greater than 2 3 V Vinumin FALSE When digital input pulled down to less than 0 9 V Vi wa OEM Technology Solutions Page 43 EMBEDDED PLC BL2500 User s Manual 5 2 1 2 BL2500 Digital Outputs Board Name bl25do Description Controls OUTO OUT of the BL2500 digital sinking outputs Number of Channels 8 Connection Terminals OUTO to OUT7 Connection of channels 1 to 8 Channel Value Correspondence TRUE Digital output is short circu
64. lutions Page 14 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 3 RUNNING SAMPLE APPLICATIONS The ISaGRAF Workbench provides two modes of running PLC applications e Simulation mode The PLC application runs entirely on the PC without the need to have a Target PLC connected This mode is very useful to perform complete structural and functional tests prior to deploying the application to the target hardware e Real mode The PLC application is first downloaded to a Target PLC and then the Target PLC executes the application The Workbench monitors the program execution as well as the status of internal and I O variables The EMBEDDED PLC ISaGRAF V3 50 Workbench plus the EMBEDDED PLC BL2500 BSP includes several sample applications There are three types of sample applications e Sample applications that use Virtual Boards xai8 xao8 xbi8 xbo8 vm xmo8 These applications can run ONLY in simulation mode gt blinkseq Same implementation with various languages gt rfdemo Complete SFC demo rfsample Sample described in ISaGRAF User s Guide see 2 gt rfsfc Demonstrates SFC actions in SFC e Sample applications that use internal variables only These applications can be simulated or downloaded to the Target PLC The Target PLC does not need to be connected to physical I Os gt bottlef Flow Chart Simulation of bottle production gt rfstack Demonstrates STACKINT function block gt Sorting Flow C
65. md Move Right user command 4 6 Ji Ls I 4 8 I EE 4 SO E OEM Technology Solutions Page 19 EMBEDDED PLC BL2500 User s Manual Running Sample Applications Follow the same procedure to run the b25rota application This application will turn ON the BL2500 on board LEDs DS3 and DS4 in sequence 3 4 CREATING A NEW PLC APPLICATION The following Section describes how to use the ISaGRAF Workbench to create simple PLC applications using the 5 IEC 611131 3 PLC programming languages FBD LD ST IL and SFC and Flow Chart that later you will download to the BL2500 Target PLC The Target PLC must be connected to physical l Os It also assumes that the Target is connected to the PC either via Ethernet or serial port To create or modify PLC applications the ISaGRAF Workbench must be licensed The PLC application that is written using 6 different languages implements a simple Boolean operation XOR between digital input INOO and INO1 SW1 and SW2 Boolean variables respectively The DS3 LED LED1 Boolean output variable is used as the output 3 4 1 Using Function Blocks Diagrams 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs ISaGRAF 3 5 Projects On the Projects Management window select File menu New 2 Onthe Create new project window enter the x name of the project for example b25test1 and press OK button The
66. n The SFCtest1 program is displayed in the B25TEST5 Programs window 6 Follow Steps 6 to 11 in Section 3 4 1 to create and populate application s Dictionary with three Boolean variables SW1 SW2 and LED1 7 On the B25TEST5 Programs window double click on SFCtest1 program 8 Click on below Step 1 Click on OR divergence Fe H to add a single divergence Click on below single divergence and then on Transition F4 H to add a transition after the single divergence Click on below the transition and add Step 2 by pressing Step F3 a button Repeat the same procedure to add Transitions 3 4 and 5 Step 3 a single divergence and a Jump to Step 1 The final program screen should be as shown below E ISaGRAF B25TESTS SFCTEST1 SFC program Bl x File Edit Tools Options Help DA SOA Ml sc Qai a Fo Fx L F amp 4 ref eh FaH tep aH oe ES Fs Gl tre By 9 Double click on Transition 1 and write the expression SW1 XOR SW2 on the Transition GT1 ST LD editor that is displayed OEM Technology Solutions Page 31 EMBEDDED PLC BL2500 User s Manual Running Sample Applications iBl x File Edit Tools Options Help 10 Double click on Transition 2 and write the expression not SW1 XOR SW2 on the Transition GT2 ST LD editor that is displayed 11 Double click on Step 2 and write the action LED1 S on the Step GS2 that is displayed Add the action LED2 R on Step 3 12 Save the program by selecting
67. nal variables 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs gt ISaGRAF 3 5 Projects On the Projects Management window double click on the bottlef project On the BOTTLEF Programs window select Debug menu Link setup On the PC PLC link parameters window enter the Target Slave Number corresponds to the Modbus Slave number of the Target PLC and the Communication port ETHERNET for Modbus TCP or COM for Modbus RTU over RS232 RS485 a If ETHERNET is selected press Setup button and enter the IP address of the target default is 192 168 1 100 Press OK button Press OK button to close the PC PLC link parameters window D Caution Do not change the port number from 1100 otherwise the Ethernet communication with the ISaGRAF Workbench will not work This port is used exclusively by the communication between ISaGRAF Workbench and the EMBEDDED PLC target b If serial COM port is selected COM1 COMA press Setup button and select either 19200 9600 4800 2400 1200 or 600 baud rate depending on the current configuration of your EMBEDDED PLC target Note The EMBEDDED PLC Kernel supports baud rates from 19200 to 600 The other parameters are fixed no parity 8 data bits 1 stop bit and no flow control Note also that ISaGRAF supports serial ports COM1 to COM4 If you are using a USB to serial converter cable check that the
68. nductor RabbitNet is a trademark of Z World Inc Dynamic C is a registered trademark of Z World Inc Indusoft is a registered trademark of Indusoft Ltd All other brand or product names are trademarks or registered trademarks of their respective holders NOTICE TO USERS When a system failure may cause serious consequences protecting life and property against such consequences with a back up system or safety device is essential The buyer agrees that protection against consequences resulting in system failure is the buyer s responsibility This device is not approved for life support or medical systems OEM Technology Solutions Unit 13 82 Reserve Road Artarmon NSW 2064 AUSTRALIA Telephone 61 2 9966 9424 Fax 61 2 9966 9429 www oem net au EMBEDDED PLC BL2500 User s Manual 1 INTRRODUG THO IN rc EE 1 tI WVHA TS EMBEDDED BEE 1 1 2 BL2500 OVERVIEW iiisceceieiesece d ausa aUa Dac aU DECR a Ree URL ax dE 1 Ee ABOUT TA S MANUA WEEN 2 1 4 EMBEDDED PLC APPLICATION KIT 54 5 easy ve vean uo bench caidas Woe Oven Duces 3 E Oe NC A Ree E CC HH el LEE 3 Te WINDOWS CONVENTIONS tito eee sk ee ee eee 3 lee REFERENCE DOCUM N RE 4 1 8 ABBREVIATIONS AND TERMINOL OGN 4 2 GETTING SFARTED EE 7 2 1 INTRODUG TIN EEN 7 22 SOFTWARE INSTALLATION EE 7 2 2 1 Installing ISAGRAF Workbench V3 0 8 2 2 2 Installing EMBEDDED PLC Board Support Package BSP for BL2500 8 2 3 LICENSING THE ISA
69. ntered press OK The communication protocol and slave number are used to communicate the Target PLC with the ISaGRAF Workbench and Modbus master Note The Modbus Slave Number parameter corresponds to the Target Slave Number on ISaGRAF Workbench Default is 1 In order to communicate the ISaGRAF Workbench with a specific Target PLC both numbers must be the same This is also valid for communication between the Target PLC and a Modbus master using Modbus protocol 3 After pressing OK the following message dialog box is shown Press OK and your H Ge Ge e idis W De Configuration stored OK EMBEDDED PLC Firmware Kernel is ACTIVE active and ready to be used wi e ISaGRAF Workbench The DS2 red LED is turned OFF and the DS1 yellow LED starts flashing every second 6 2 EMBEDDED PLC UTILITY SOFTWARE REFERENCE To use the EMBEDDED PLC Utility you must have an EMBEDDED PLC Firmware Kernel bin file to load to your Rabbit based controller Click on File Load Flash Image enter the bin file s location in the dialog box and click OK This Utility works only with serial connection and it requires the programming cable for the Rabbit based controller 1 27mm programming cable for Rabbit 3000 microprocessor based controllers This Utility downloads ONLY EMBEDDED PLC Firmware Kernels If you want to download another binary file generated with Dynamic C use the Rabbit Field Utility RFU that comes in the Dynamic C installation
70. ogramming tm b25rota Rotation of 2 on board leds and 2 digital outputs b25scope Signal generation BL2500 Analog Out and SpotLight fm blinkseq Same implementation with various languages bottlef Flow Chart Simulation of bottle production r demo Complete SFC demo rfsample Sample described in user s guide rfsfc Demonstrates SFC actions in SFC rfstack Demonstrates STACKINT function block D sorting Flow Chart Sorting of tokens depending on their size and color Reference b25gld E Author OEM Technology Solutions al Date of creation 9 August 2005 Version number 3 0240G 1 04 Description House control lights and shutter This application displays the SpotLight showing a simple room of a house It uses some of the physical I O of the BL2500 board Digital Input INOO Switch on the left Digital Input INO1 Switch on the right Digital Input INO2 Moves the window s screen to the left Digital Input INO3 Moves the window s screen to the right On board LED DS3 Central light 2 Onthe SORTING Programs window select x Debug menu Link setup On the PC PLC link parameters window check the Target Slave Intenet address EEATERBIT Number is set to 1 and ETHERNET Port number Cancel communication port is selected Press Setup E E EEE E E QE button and check the IP address of the BL2500 Jang e lure target is set to 192 168 1 100 Press OK button esti a to close this window Press OK button to cl
71. ontrol Panel System Click on Device Manager On the Device Manager window expand the Ports COM amp LPT category and select the USB Serial Port COMx Select Action gt Properties on the menu bar On the USB Serial Port COMx Properties window click on Port Setting tab and click on Advanced On the Advanced window change the COM port number to within COM1 to COM4 range For more information about device settings contact your local system administrator Can use the other serial ports on the BL2500 from an ISaGRAF application The EMBEDDED PLC Firmware Kernel Version 1 04 uses one RS232 serial port E or one RS485 serial port D to communicate with the ISaGRAF Workbench or Modbus master Contact OEM Technology Solutions or your local EMBEDDED PLC distributor for information about custom solutions for the EMBEDDED PLC Kernel Can have 2 analog outputs instead of 1 analog input and 1 analog output The EMBEDDED PLC Firmware Kernel Version 1 04 has the analog I O configuration fixed For more information about custom IO configuration on the EMBEDDED PLC BL2500 contact OEM Technology Solutions of your local EMBEDDED PLC distributor Can I use RabbitNet with EMBEDDED PLC BL2500 In Version 1 04 of the EMBEDDED PLC BL2500 BSP RabbitNet is not supported Contact OEM Technology Solutions or your local EMBEDDED PLC distributor for information about features to be implemented in upcoming versions Do I need to keep the programming cable
72. or Reference RfDemo E Author OEM Technology Solutions amp Date of creation 9 August 2005 Version number 3 0239H 1 14 Description Workbench demo This application shows a complete example of SFC programming with a complex hierarchy of SFC programs It uses the virtual boards for SIMULATION only How to use this application with the debugger The first input button is the start stop command Other buttons are designed to select one between three animations lead is a single sequential display of the outputs zj OEM Technology Solutions Page 15 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 2 Double click on the sample application for example rfdemo to open the Programs Manager window I5aGR AF RFDEMO Programs oO x File Make Project Tools Debug Options Help SS DES xxi mm age Sequential FAA main control time control SCH Drive select process SCH Lead turn on leds SCH Flash odd even led flip flop SCH Random random led lightning Sequential Gmain Sequential Function Chart HEA 3 On the Programs Manager window select Debug Simulate or press Simulate button E on the toolbar The Debugger I O simulation and Debug program windows are displayed D ISaGRAF RFDEMO Debugger File Control Tools Options Help Phe GC Af i amp l xi iii rfdema File Tools Options Help File Project Tools Options Help ES umi TUE LUG EINUM B
73. ose the PC PLC link parameters window OEM Technology Solutions Page 12 3 5 EMBEDDED PLC BL2500 User s Manual Getting Started Ix If you are using RS232 on the PC PLC link parameters w window select COM port and press Setup button Select EN GM the baud rate 19200 to 600 depending on the current Serial link parameters Baudrate 9200 Parity Le Fao ee value of the Target PLC Flow control none D Select Debug menu Debug to open BEZ the Debugger window The Debugger Ee EE window is displayed with a No application message Qi tun AO No application ZS Note If the Debugger window shows that an application is currently running application name gt active on the Target PLC press Stop button cm on the toolbar to stop the application before downloading a new one You can also stop the application from the Debugger window menu File menu Stop application x RABBIT TIC code for Rabbit based controllers Den as 4 On Debugger window select File menu Download Select RABBIT TIC code for Rabbit based controllers on the Download window and press Download button A progress bar on the Debugger window will show the progress of the downloading process Once the downloading is completed the application runs immediately and the SpotLight window shown below is displayed ISaGRAF SORTING WAY GRAF SpotLight loj x File Edit Insert Options H
74. otLight Press OK button All times ares given in milliseconds x vandbcuspEED 6 Onthe SpotLight window double click on the t 1s box Enter new value Change the variable SPEED value to t 200ms and press Write button The bottle production will speed up 2 REECH by a factor of two 7 Repeat this procedure for the rfstack application 3 3 RUNNING APPLICATIONS THAT USE BL2500 INPUTS AND OUTPUTS 3 3 1 Creating I O connectors The EMBEDDED PLC Application Kit comes with a bag of cables connectors and crimp terminals in order to connect to the I Os of the BL2500 To create an I O connector you will need to assemble a wiring harness using the friction lock connectors and crimp terminals supplied with the EMBEDDED PLC Application Kit In addition you will need e Wire 22 to 30 AWG 0 33 mm to 0 049 mm for the 0 1 crimp terminals 22 to 26 AWG 0 33 mm to 0 13 mm for the 0 156 crimp terminals e Wire cutters and wire insulation stripper e Crimp tool pliers may be used but a crimp tool provides a better crimp with a stronger force Follow these steps to build your wire harness 1 Prepare a few lengths of wire about 30 cm 12 long The wires should have different colours of insulation to facilitate identifying the connections rimp wire Crimp Trim about 2 3 mm 0 1 of insulation from your wire ete insulation Position the wire in the crimp terminal as shown in the figure d Use acrimp tool or plier
75. ppears in the License Registration Form User Code 1 and 2 and Contact details and send it to support oem net au 5 Alternatively if you do not have an e mail address or access to the Internet copy the User Code 1 and User Code 2 into the ISaGRAF License Registration Form that comes in the Application Kit and send the completed form to OEM Technology Solutions by fax Fax Number 61 2 9966 9429 6 OEM Technology Solutions will send you the ISaGRAF software license within two business days of receiving the completed Form Press Close button to close the License Manager 2 3 1 Adding the software license The ISaGRAF software license consists of two sets of 4 Registration Keys Upon reception of the Registration Keys open License Manager and follow these instructions 1 Onthe Available Components select ISaGRAF 3 Software License and press Add button Select the purchased number of UO points to license 32 if you purchased the EMBEDDED PLC Application Kit and press OK button 2 Enterthe first set of Registration Keys and press Register button Setup Code will change to SET WDE15 Enter the second set of Registration Keys and press Register button again In the Selected Components ISaGAAF 3 Software License Active Wad Selected Components ISaGRAF 3 Software aoc License will be displayed as Active Press Close button to close the License Manager Remove Congratulations Your ISaGRAF Workbench is now licensed No
76. pproximately 83 ms 4 4 ANALOG OUTPUT Two D A converter outputs DAO and DAT are supplied on the BL2500 These are shown in Figure 8 ZS Note Only DA 1 is available for EMBEDDED PLC BL2500 as DAO is used by the A D converter Figure 8 Schematic Diagram of D A Converters The D A converters have no reference voltage Although they may be fairly accurate from one programmed voltage to the next they do not have absolute accuracy This is because the 3 3 V supply can change 5 the PWM outputs might not achieve the full O V and 3 3 V rail out of the processor and OEM Technology Solutions Page 37 EMBEDDED PLC BL2500 User s Manual Hardware Reference the gain resistors in the circuit have a 1 tolerance The D A converters therefore need individual calibration with the calibration constants held in software before absolute accuracy can be relied on The BL2500 has such calibration Pulse width modulation PWM is used for the D A conversion The digital signal which is either O V or 3 3 V will be a train of pulses This means that if the signal is taken to be usually at O V or ground the pulses will be some 3 3 V pulses of varying width The voltage will be O V for a given time then jump to 3 3 V for a given time then back to ground for a given time then back to 3 3 V and so on A hardware filter that consists of a resistor and capacitor averages the 3 3 V signal and the 0 V signal over time Therefore if the time that the s
77. ransceiver also provides the proper line loading for reliable communication RS 232 can be used effectively for distances of up to 15 m 4 5 1 2 RS 485 The BL2500 has one RS 485 serial channel which is connected to the Rabbit 3000 Serial Port D through an RS 485 transceiver The half duplex communication uses PA4 to control the transmit enable on the communication line Using this scheme a strict master slave relationship must exist between devices to insure that no two devices attempt to drive the bus simultaneously The BL2500 can be used in an RS 485 multidrop network spanning up to 1200 m 4000 ft and there can be as many as 32 attached devices Connect the 485 to 485 and 485 to 485 using single twisted pair wires as shown in Figure 9 Note that a common ground is recommended OEM Technology Solutions Page 38 EMBEDDED PLC BL2500 User s Manual Hardware Reference Figure 9 BL2500 Multidrop Network The BL2500 comes with a 220 W termination resistor and two 681 W bias resistors installed and enabled The load these bias and termination resistors present to the RS 485 transceiver limits the number of BL2500s in a multidrop network to one master and nine slaves unless the bias and termination resistors are removed When using more than 10 BL2500s in a multidrop network or when you need the full common mode immunity per the RS 485 specification leave the 681 W bias resistors in place on the master BL2500 and leave the 220 W te
78. riable window select SW1 and press OK button SW1 variable box is drawn on the working area Place SW2 and LED1 variables following the same procedure 13 Select on the Function blocks combo box the exclusive OR 71 function block and click on the working area The exclusive OR 271 function block is displayed 14 Select button Le on the toolbar and move SW1 and SW2 variables to the left of the function block also move the LED1 variable to the right of the function block 15 Click on Draw connection line button on the toolbar and press left mouse button on the SW1 variable and drag the line towards the function block A connection line will be drawn between SW 1 and IN1 of the function block Repeat the same procedure to connect SW2 with IN2 of the function block and LED1 with Q of the function block connection lines are dragged always from left to right Bi ISaGRAF B25TEST1 FBTEST1 FBD LD Program ni x File Edit Tools Options Help Da xul He xd aai e ES mm oz 48S oH o e l exclusive OR sl pos 26 a 16 Save the program by selecting File menu Save Press OK button on the Update diary window Close the FBtest1 FBD LD Program window 17 On the B25TEST1 Programs window click on I O connection button ET on the toolbar OEM Technology Solutions Page 22 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 10 x File Edit Tools Options Help PBem on EM e
79. rmination resistors in place on the BL2500 at each end of the network Goce dE ili TEE ER TI 1 E D I H LI L fe NW I E k d CRT sti E Figure 10 RS485 Termination and Bias Resistors 4 5 2 Ethernet Port Figure 11 shows the pinout for the RJ 45 Ethernet port J4 Note that some Ethernet connectors are numbered in reverse to the order used here ETHERNET RJ A5 Plug Figure 11 RJ 45 Ethernet Port Pinout Three LEDs are placed next to the RJ 45 Ethernet jack one to indicate an Ethernet link LNK one to indicate Ethernet activity ACT and one to indicate when the RCM3200 is connected to a functioning 100Base T network SPD The RJ 45 connector is shielded to minimize EMI effects to from the Ethernet signals OEM Technology Solutions Page 39 EMBEDDED PLC BL2500 User s Manual Hardware Reference 4 6 LED INDICATORS The EMBEDDED PLC Kernel running on the BL2500 uses three LEDs to indicate status e DS1 yellow When this LED is flashing every second it indicates that the Target PLC is licensed and active e DS2 red This LED is turned ON after reset the Target PLC If the Target PLC is not licensed the LED will remain ON indefinitely If the Target PLC is licensed the LED will be turned OFF after 8 seconds Also this LED is turned ON during configuration of the Target PLC DS3 and DS4 yellow LEDs are used via ISaGRAF Workbench I O boards OEM Technology Solutions Page 40 EMBEDDED PLC BL2500 Us
80. s control HVAC and vending machines The BL2500 s compact board size of 100 x 100 mm is easily mountable in standard 100 mm DIN rail trays External connections via polarized locking industry standard Molex type connectors enable rapid assembly with wire harnesses These connectors also provide dependable cable harness connectivity to UC Main features of the EMBEDDED PLC Firmware Kernel running on the BL2500 Target PLC are shown in Table 1 OEM Technology Solutions Page 1 EMBEDDED PLC BL2500 User s Manual Introduction Table 1 Main Features of the EMBEDDED PLC Firmware Kernel V1 04 on the BL2500 Kernel filename BL2500C V1 04 3 0231H bin SBC model supported I Os supported Communications Memory Space ISaGRAF V3 50 features not supported by EMBEDDED PLC BL2500 with Rabbit core module RCM3200 10 100BaseT 512K Flash 256K 512K SRAM 44 2 MHz clock speed Z World P N 101 0602 16 Digital Inputs 8 Digital Outputs 1 Analog Input connected through ADO 10 bits resolution 0 3 3 V 1 Analog Output connected through DA1 10 bits resolution 0 3 3 V Modbus RTU over TCP IP using static IP address Modbus RTU over RS232 using serial port E or RS485 using serial port D Baud rate 19200 9600 4800 2400 1200 or 600 configurable through EMBEDDED PLC Utility Parity None Data bits 8 Stop bits 1 Flow Control None Minimum polling period time is 1 cycle duration for Modbus
81. s to first crimp the bare wire then the insulation as shown in figure 5 Insert the crimp terminals with wires into the friction Es SEN lock connector with the tab on the crimp terminal facing Ee SU the opening on the side of the friction lock connector Insert the crimp terminal until the tab snaps into place Insert with tab facing in the side opening side opening Ai E Repeat these steps until all the wires and crimp s HUH terminals have been assembled opening Note On 10 pin friction lock connectors insert a plug into the hole indicated in last figure to polarize your connector to help prevent offsetting the connector by one pin when you attach it to your BL2500 Polarizing plugs are not included in EMBEDDED PLC Application Kit OEM Technology Solutions Page 18 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 3 3 2 Downloading and running the ISaGRAF application Use the following procedure to download a sample application b25q d to the BL2500 Target that uses physical l Os The Target PLC must be running a licensed EMBEDDED PLC Firmware Kernel and be connected to 4 digital inputs use the procedure above to create an O connector It also assumes that the Target is connected to the PC either via Ethernet or serial port 1 Open the ISaGRAF Project Management by double clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu Programs ISaGRAF 3 5 Projects On the Proje
82. sed controllers is selected Press OK button If RABBIT target is not selected click on RABBIT target and press Select button Alternatively you can double click on RABBIT target Compiler options x Targets gt SIMULATE Workbench Simulator Select gt RABBIT TIC code for Rabbit based controllers V Use embedded SFC engine Upload Optimizer Run two optimizer passes Evaluate constant expressions Default Suppress unused labels Optimize variable copying Optimize expressions Suppress unused code Optimize arithmetic operations OK Optimize boolean operations Build binary decision diagrams BDDs Cancel OEM Technology Solutions Page 23 EMBEDDED PLC BL2500 User s Manual Running Sample Applications 23 24 25 26 Select Make menu Make application to compile the PLC application The Code generator window is displayed Press Exit button File Options Edit Help Verifying variables declarations Verifying FBtestl No error detected Code Generator x No error detected Resetting temporary files Building configuration data Linking object files Do you want to exit the Code Generator now Relocating object files Post compiling code No error detected No error detected Select Debug Link setup or press Link Setup and configure the Target PLC lt gt PC link Follow the guidelines on Step 2 of Section 3 2 Select Debu
83. see Chapter 9 The EMBEDDED PLC Firmware Kernel implements three types of Modbus communication Modbus over TCP IP Modbus RTU over RS232 and Modbus RTU over RS485 The EMBEDDED PLC Kernel can run only one protocol at one time Note EMBEDDED PLC has the TCP IP port 502 reserved this port can not be modified to support Modbus over TCP IP communications Since ISaGRAF Workbench uses a different TCP IP port for communication with the Target PLC port 1100 the Workbench and a Modbus master HMI or SCADA can communicate with the Target at the same time i e when the Target is configured as Modbus over TCP IP the ISaGRAF Workbench and a Modbus master can share the same physical line Ethernet However when the Target is using either RS232 or RS485 only an ISaGRAF Workbench or a Modbus master can be connected to the target at any one time 5 1 4 Functional Module Programming The next step in the ISaGRAF methodology is the actual programming of the various functional modules This can be done using any one of the six supported languages e Sequential Functional Chart SFC e Function Block Diagram FBD e Ladder Diagram LD e Structured Text ST e Instruction List IL e Flow Chart FC OEM Technology Solutions Page 41 EMBEDDED PLC BL2500 User s Manual Software Reference 5 1 5 IEC 61131 3 Language Editors In February 1993 responding to the need for standards to reduce training costs and guaranteed portability the
84. te If you want to purchase a hardware license or upgrade your current software license please contact OEM Technology Solutions sales oem net au for pricing information and payment options When you purchase a software license it is very important to include the following information in your Purchase Order e Setup Code User Code 1 and User Code 2 To obtain these codes open the ISaGRAF License Manager Start menu Programs ISaGRAF 3 5 Licensing On the Available Components select ISaGRAF 3 Software License and press Add button Select the desired number of I O points to license 128 256 or Unlimited and press OK button The Setup and User codes appear on the License Manager window If you press Proceed button a new e mail message window is displayed if you have an e mail client running such as Microsoft Outlook You can fill out the required information and send that e mail to obtain license pricing and payment information Contact details Company Name Address Telephone Fax and e mail 2 3 2 Adding a hardware license optional When using a hardware license dongle on Windows 2000 XP systems you must install the Sentinel driver in order for the dongle to be seen OEM Technology Solutions Page 9 EMBEDDED PLC BL2500 User s Manual Getting Started Open the ISaGRAF V3 50NSentinel folder located in the root directory of the CD ROM and double click on Setup exe Follow the on screen instructions to instal
85. ter with Ethernet capability and pre loaded with the EMBEDDED PLC Firmware Kernel e 1 2 mm programming cable e Ethernet crossover cable e EMBEDDED PLC BL2500 CD ROM with complete product documentation on disk e EMBEDDED PLC ISaGRAF V3 50 Workbench License Registration form e Getting Started instructions 1 5 TEXT CONVENTIONS This manual uses special formatting to help you quickly identify certain items as follows e Titles labels and new terms are indicated using italic text e File names messages and screen text are indicated using bold courier text for example C NOEMTechNMInstall exe e Variables and information you must provide are indicated using bold italicized text enclosed in lt and gt brackets for example run the driver name gt exe file indicates you must provide a driver name e Buttons menu options and keyboard key are indicated in bold e Text requiring special emphasis is in bold italic e Some information is segregated into Note and Caution boxes as follows gt Notes provide supplemental information related to the surrounding text usually the text just preceding the note gt Caution provides information necessary to prevent damage or problems 1 6 WINDOWS CONVENTIONS This manual uses the following Windows conventions e Dialog boxes or dialogs are windows that allow you to enter information e Text boxes or fields are areas in dialogs where you can type in text e Radio but
86. the BL2500 If you require changing the TCP IP configuration of the BL2500 go to section 6 1 4 for instructions how to change the configuration of the Target PLC To configure your PC with an IP address and netmask suitable for establishing a TCP IP connection with a pre configured BL2500 Target PLC follow these instructions you might need Administrator privileges to perform these steps 1 Goto Control Panel Start button Settings Control Panel and start N etwork C onn ecti ons File Edit View Favorites Tools Ay Back r lt be E Search 2 Select Local Area Connection and choose Properties File menu gt S Pro perties LAN or High Speed Internet Select Internet Protocol TCP IP and press Properties button Bb Wizard 4 Click on Use the following IP Address and fill in the following fields Ce Use the following IP address IP address 192 766 1 101 Subnet mask 255 285 255 O Default gateway 192 168 1 1 5 Press OK button to close the Internet Protocol TCP IP Properties window Press OK button to close the Local Area Connection Properties and to update the new TCP IP values 6 To verify the communication between your PC and the BL2500 use the ping command Open a Command Prompt window Start button Programs Accessories Command Prompt and type C ping 192 168 1 100 The command output should display the replies from the Target PLC OEM Technology Sol
87. the ISaGRAF User s Manual See 2 and the License Manager on line help describe in detail how to transfer a software license The EMBEDDED PLC Application Kit entitles you to a 32 I O points software license To obtain the software license follow these instructions 3 Open the ISaGRAF License Manager Start menu Programs ISaGRAF 3 5 Licensing On Setup Code SET WDX32WDE15 the Available Components select ISaGRAF 3 ier ode d 286474670 Software License and press Add button Click meret ees Option 32 on Number of IO Variables box and press OK button The Setup Code SET WDX32 Proceed WDE15 will be displayed in the Setup Code box OEM Technology Solutions Page 8 EMBEDDED PLC BL2500 User s Manual Getting Started 4 If you have access to the Internet and have an e mail account a Press Proceed button A new mail message of your default e mail client such as Microsoft Outlook will be displayed Fill out the information on the message body Contact details and Workbench Serial Number located on the License Registration Form Once you have filled out all the information send the e mail to support oem net au The e mail client application must be running before pressing Proceed button b Alternatively if instead of e mail client such as Microsoft Outlook you use web based email or a command line e mail such as pine compose manually a new message indicating the Workbench Serial Number that a
88. the jack labelled Ethernet Two 4 pin 0 156 friction lock connector terminals at J7 and J8 are installed to supply power DCIN and 5 V to the RabbitNet peripheral boards Two 2 pin 0 156 friction lock connector terminals at J2 and J10 are for power supply and K connections Analog RabbitNet Analog DI An Ja 5 Powor Oulputs RE eA AEEHHIE o oocooocom I Ji 00 oe E J 15 232 Di gitaT Oufputs Digital Inputs Digital Inputs Ether rmt Figure 4 BL2500 Pinouts For detail about electrical and mechanical specifications of the BL2500 go to Section 8 1 4 1 DIGITAL INPUTS The BL2500 has 16 digital inputs INOO IN15 INOO IN13 and IN15 are each protected over a range of 36 V to 36 V and IN14 is protected over a range of 36 V to 5 V The inputs are factory configured to be pulled up to 3 3 V INOO INO 7 can also be pulled up to K or they can be pulled down to 0 V by changing a surface mounted 0 W resistor Figure 5 shows a sample digital input circuit INOO INO7 and IN15 are protected against noise spikes by a low pass filter composed of a 22 kQ series resistor and a 10 nF capacitor OEM Technology Solutions Page 35 EMBEDDED PLC BL2500 User s Manual Hardware Reference Figure 5 BL2500 Digital Inputs Pull up factory default The actual switching threshold between a zero and a one is between 0 9 V and 2 3 V for all 16 inputs i e ViNLMax 0 9 V and VINHMin 2 3 V INOO IN13 and IN15 are each
89. tion 4 6 6 1 4 Configuring the Firmware Kernel If you purchased an EMBEDDED PLC Application Kit the BL2500 comes pre configured for Use Modbus TCP and the following TCP IP values IP address 192 168 1 100 Netmask 255 0 0 0 Default gateway 192 168 1 1 If you want to check or change the Target PLC configuration follow these instructions 1 Open the EMBEDDED PLC Utility and select Setup Target Configuration Follow the instructions on the message dialog box in the same order Press OK Reset Target After a few seconds the Target Configuration Window is displayed EMBEDDED PLC Target Configuration X Copyright c 2005 OEM Technology Solutions Module Version 1 06 Kernel Version 1 03 Kernel Description EMBEDDED PLC for BL2500 Modbus Slave Number fi 1 255 Modbus TC f Use Modbus TCP IP address Subnet mask 192168 1 100 255 0 0 0 Default gateway 382 168 1 1 C Use A5232 Baud Rate S600 Cancel Help Modbus ATU aver H5232 H5485 C Use R5485 OEM Technology Solutions Page 50 EMBEDDED PLC BL2500 User s Manual Loading or Upgrading the Firmware Kernel 2 Enter the desired Modbus Slave Number Default is 1 Select Use Modbus TCP radio button and fill the Modbus TCP configuration parameters if you want to use Modbus TCP as communication protocol Otherwise select Use RS232 or Use RS485 radio buttons Once all the configuration parameters have been e
90. to compile and download it to the Target PLC 17 Double click on FCtest1 program The FCTEST1 Flow Chart window is displayed Short circuit the digital input INOO SW1 will be FALSE the LED1 will be turned ON as well as the state of LED1 in the Programs window will change The PLC program implements a Boolean XOR operation on SW1 and SW2 with the result set on the LED1 18 To stop the monitoring of the PLC application close the Debugger window The programs and dictionary windows in debug mode will be closed The ISaGRAF User s Manual See 2 and the on line help of the ISaGRAF Workbench describes in detail all the Workbench functionalities editor simulation debugger etc including also a reference manual of the PLC programming languages IEC 61131 3 OEM Technology Solutions Page 34 EMBEDDED PLC BL2500 User s Manual Hardware Reference 4 HARDWARE REFERENCE The Figure 4 shows the signal names and connectors of the BL2500 The BL2500 are equipped with five 1 x 10 friction lock connector terminals J1 J3 J9 J11 and J12 where pin 9 is removed to polarize the connector terminals a 2 x 5 RS 232 signal header a 2 x 5 programming header and an RJ 45 Ethernet jack on the Rabbit core module The RJ 45 jacks at J4 and J5 labelled RabbitNet are serial I O expansion ports for use with RabbitNet I O boards Wy Caution The RabbitNet jacks do not support Ethernet connections Be careful to connect your Ethernet cable to
91. to load or upgrade the EMBEDDED PLC Firmware Kernel to a Rabbit based Target The installation of this software is optional and is described in Chapter 6 These software products can also be downloaded in ZIP format from the OEM Technology Solutions website www oem net au OEM Technology Solutions Page 7 EMBEDDED PLC BL2500 User s Manual Getting Started 2 2 1 Installing ISaGRAF Workbench V3 50 Use the following procedure to install the EMBEDDED PLC ISaGRAF Workbench V3 50 from the CD ROM 1 Insert the CD ROM and open the ISaGRAF V3 50 folder 2 Double click on ISAGRAF EXE to launch the ISaGRAF installation wizard Follow the instructions provided by the wizard to proceed with the installation Note It is recommended that the ISaGRAF Workbench be installed on a new directory to avoid confusing files with files from other ISaGRAF versions 3 Once all the ISaGRAF files have been copied the following group is added to your Programs group o EA File Edit View Favorites Tools Help Pek 7 Search Folders Ign Address e C Documents and Settings All Users Start Menu Programs ISaGRAF 3 5 Book Diagnosis Libraries File and Folder Tasks Shortcut Bi Sh ce it hortcut n9 Ze u B Other Places Y y EL Licensin g Bel Projects Read Me Shortcu H Shortcut Shortcut Details a 1 KB E 1 KB amp 9 7 objects 4 08 KB P My Computer A 2 2 2 Installing EMBEDDED PL
92. tomation engineer This language is mainly used to implement complex procedure that cannot be easily expressed with graphical languages IF THEN ELSE FOR WHILE etc 5 1 5 5 Instruction List Editor Instruction list is a low level language similar to the simple textual PLC languages 5 1 6 Flow Chart Editor In addition to the five IEC 61131 3 languages ISaGRAF implements another graphical language Flow Chart Flow Chart is a decision diagram which can also be used to describe sequential operations 5 1 7 Document Generator ISaGRAF features a self documentation capability that can automatically generate the project s most current project description project architecture history of modifications I O wiring lists dictionaries and cross references 5 1 8 Simulation Without any target hardware platform the programmer can validate the complete application in the office With ISaGRAF s powerful simulator on the workbench the user can perform structural and functional tests of each module separately or on the global application The simulator makes it easy to trace the program execution and to see the status of any internal variable The I O hardware can be fully simulated and internal status and variables manual forced by the user OEM Technology Solutions Page 42 EMBEDDED PLC BL2500 User s Manual Software Reference During simulation editors can be opened in debug mode to see how programs are executed 5 Note Not a
93. tons are white circles in which a black dot appears or disappears when you click on the button Typically the black dot indicates that the option or function is enabled active The absence of a black dot indicates the option or function is disabled inactive OEM Technology Solutions Page 3 EMBEDDED PLC BL2500 User s Manual Introduction e Check boxes are white squares in which a check appears or disappears when you click on it with the cursor Typically the check indicates that the option or function is enabled active The absence of a check indicates the option or function is disabled inactive e Buttons are icons in boxes that appear pressed when you click on them e Lists are panes white boxes in windows or dialog boxes containing two or more selectable options e Combo boxes have arrows that when clicked show part or all of an otherwise concealed list Note The dialogs and procedures described in this manual are valid for Windows 2000 and XP Some terms may vary according to the operating system type language and version you are using 1 7 REFERENCE DOCUMENTS 1 019 0120 041215 H Coyote BL2500 C Programmable Single Board Computer with Ethernet User s Manual 2002 2004 Z World Inc 2 SaGRAF Version 3 5 User s Guide 1994 2004 ICS Triplex ISaGRAF Inc 3 019 0108 050610 P Rabbit amp 3000 Microprocessor Users Manual 2002 2005 Rabbit Semiconductor 1 8 ABBREVIATIONS AND TERMINOLOGY
94. utions Page 11 EMBEDDED PLC BL2500 User s Manual Getting Started 2 4 3 Connect an RS232 Cable optional If your Target PLC is configured to Use Modbus TCP you can go straight to Section 2 5 If your Target PLC is configured to Use RS232 connect a serial cable to a COM port of the PC and to the RS232 port E of the BL2500 The RS232 cable must follow the diagram shown in Figure 3 A serial cable is not provided in the EMBEDDED PLC Application Kit BL2500 PC 0 1 Fitch 2x 5 DB 9 Male RS2d2 Header J6 Connector Je 2 5 np J6 3 X TD J6 4 aM ne J6 5 ee c PRE J5 7 amp J6 8 J8 9 Sup ege 2 5 Figure 3 PC BL2500 RS232 connection 2 5 RUNNING A SAMPLE APPLICATION Once you have established connection between your PC and the Target PLC follow these instructions to run the sorting sample application This sample application displays a SpotLight which shows different tokens being sorted depending on size and colour see the Project Description at the bottom of the Projects Management window This PLC application was written in Flow Chart 1 Start ISaGRAF Workbench by double clicking on the ISaGRAF 3 5 shortcut on your desktop or Start button Programs ISaGRAF 3 5 gt Projects On the Projects Management window double click on the sorting project A ISaGRAF Project Management iol sl File Edit Project Tools Options Help Death Gre t D B Samples emt Demo with Quick LD pr
95. www oem net au 9 1 USING INDUSOFT WEB STUDIO WITH EMBEDDED PLC The EMBEDDED PLC implements Modbus over TCP IP or RTU over RS232 RS485 to communicate with Modbus masters such as Indusoft Web Studio Indusoft Web Studio IWS applications can be quickly developed to be used in conjunction with EMBEDDED PLC since it has built in communication drivers for Modbus OEM Technology Solutions Page 62 EMBEDDED PLC BL2500 User s Manual About Indusoft InduSoft Web Studio MOTCP MAIN DRI ER SHEET x File Edit view Insert Project Tools Window Help EI Q 2 m p E ap Ho Lex 2 6 ORAE apo pWwi meee HEH irs BO re es ORG ie m ES az MG O78 ND x firMOTCP MAINDRIVER SHEET Rausch ES le EL Rees E D Project CEDemo app CH Drivers Description x hy j E EN MOTCP MAIN DRIVER SHEET ux m i R MAIN DRIVE SE amp gg orc el gg TCP IP Do 0 0 0 0 0 0 0 0 0 ac Read Completed Read Status Z L4 Write Completed Write Status E i B a TagName Staion VO Address Aion 1 Cmi 10 20 5 84 502 1 Read Screen m 10 20 5 84 502 1 Read Screen tii 10 20 5 84 502 1 Read Screen B Ke 10 20 5 84 502 1 Read Screen SE e 10 20 5 84 502 1 Read Screen B 10 20 5 84 502 1 Read Write D Screen E vt 10 20 5 84 502 1 Read el Screen E b gt xi c All Mo kimi Bc x Name Value alit Continuous SwLeft No DEI D NLA ADB 2 ADB 3 ADB Se Log AXRet 7 IER Align vertical center of s

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