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M4500 User`s Manual

1. S4516 Faceplate S4516 Board Outline M4500 User s Manual SYSTEMS Electronics Group 5 APPENDIX A S4516 SERIAL COMMUNICATIONS BOARD This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group APPENDIX A S4563 DIGITAL DC INPUT BOARD S4563 DIGITAL DC INPUT BOARD 16 POINT 10 30VDC SOURCING FEATURES o 16 Digital Input Points o 16 Individual Status LED s 1 Led Per Input Point o Removable Field Wiring Connector o Optical Isolation o Standard M4500 I O Form Factor GENERAL DESCRIPTION The 4563 10 30VDC Input Board for use with the M4500 series of modules contains 16 identical solid state input circuits which accept the on off status of user devices such as push buttons limit switches and proximity sensors The inputs sense the voltage levels of digital DC input signals with the devices driving the inputs being defined as sourcing positive current into the input When the voltage at the input is high above the input on threshold the input is read as a 1 When the input is low approximately zero the input is read as a O The on off status of each input is indicated with individual LED s located on the front of the board The LED s provide the status of the actual input points field side rather than the internal logic status Input and user power wiring is implemented with a removable 18 pin field wiring connector which allows ea
2. USER S M4500 DEVICE ANALOG OUTPUT Q AINO 0 5 VOLT 0 5 VOLT ANALOG INPUT S USER S M4500 DEVICE ANN Q 1 0 5 VOLT 0 10 VOLT 1 ANALOG 1 40 INPUT Y USER S M4500 DEVICE ANALOG OUTPUT O Q ANo 0 5 VOLT 250 ohm 0 20 mA 1 ANALOG 1 2 INPUT S Q Figure 8 6 Typical Analog I O Wiring 63 SYSTEMS Electronics Group SECTION 8 INSTALLATION 8 7 WIRING THE FAULT INTERLOCK The fault interlock is a 24VDC sinking true low output which can be interfaced to an external relay or PLC input to indicate a fault condition with the M4500 module The output is capable of sinking 500 milliamps The fault output is on true low sinking current when the module is executing the user program properly If a fault condition is detected the fault output is turned off high Figure 8 7 shows the fault output wired to a 24VDC relay This relay could be interlocked with the digital outputs power to remove power from the outputs if the module was to fault out M4500 OUTPUT MODULE POWER L INPUT POWER S INTERNAL FAULT LOGIC MODULE POWER Figure 8 7 T ical Fault Interlock Wirin M4500 User s Manual 64 24VDC me _ _ CLOSED WITH A CR F No FAULT LI L o L FLT 24VDC Q RELAY S C INPUT POWER ise RETURN SYSTEMS Electronics Group SECTION 8 INSTALLATI
3. 0 5v ANALOG INPUT 0 A SYSTEMS SEDE Cr ANALOG INPUT 1 Jj m b 0 10V moe OUTPUT OL com 4 ower S 05001 000 04591 KEYPAD DISPLAY M4500 User s Manual SYSTEMS Electronics Group 1 APPENDIX FIELD WIRING PINOUTS This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group 2
4. 5 3 3 NUMBER OF PLS CHANNELS This is the number of PLS timing channels that will be used The M4500 PLS supports either 8 16 32 or 64 timing channels Enter one of these four numbers as desired for the number of PLS channels 5 3 4 SPEED COMPENSATION Independent Speed Compensation is available for timing channels 00 through 07 Each of these channels can be programmed to have from 0 to 255 milliseconds of timing signal lead see section 3 1 5 The values entered for the speed compensation are in milliseconds This is the amount of time that the timing signal will lead the programmed timing set point as the speed of the machine is varied The speed compensation for each channel is independently set If speed compensation for a particular channel is not to be used enter 0 for the compensation amount for that channel 5 4 CHANNEL SET POINT PROGRAMMING COMMANDS Three channel set point programming commands are available through SYSdev These are single set point programming set point fine tune and the pulse train programming command The single set point command allows the user to simply type in the complete set point both on and off parameters at the currently selected set point The fine tune command allows the user to either increment or decrement by one the on or off set point parameter of the currently selected set point The pulse train programming command allows the user to program the entire channel with a pul
5. START POS 1 CH xx SETPT 001 4 9 CLEAR CHANNEL COMMAND The clear channel command is used to clear all the set points in the currently selected channel To clear the channel perform the following 1 Press the CLEAR CHAN key to clear the channel 2 The display will display CH xx SETPT indicating that the channel has been cleared 4 10 SEARCHING RECALLING A CHANNEL To view the position and status of set points in the current channel perform the following 1 Press the SEARCH key The starting or ending position transition of the next set point is displayed If the position is the off to on transition of the set point the channel state indicator will be on If the position is the on to off transition the channel state indicator will be off 2 Press the SEARCH key again to view the next set point transition Continuing to depress the SEARCH key displays all set point transitions within the channel Example This example searches a channel programmed with two set points one on at 20 and off at 40 and another on at 60 and off at 80 Key Depressed SEARCH SEARCH SEARCH SEARCH SEARCH M4500 User s Manual Display CH xx SETPT 020 CH xx SETPT 040 CH xx SETPT 060 CH xx SETPT 080 CH xx SETPT 020 SYSTEMS Electronics Group 26 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY This Page Intentionally Left Blank M4500 User s Manual SYST
6. 10 0 volts 30 0 volts 5 0 volts 15 milliamps at Vin 30volts 0 50 milliseconds 0 35 milliseconds 0 80 milliseconds 8 10 30VDC VCC 2 00 volts VCC 0 25 volts 1 5 volts 0 5 amps DC 3 0 amps DC for 100msec 100 microamps 50 microseconds 75 microseconds 1500 Vrms 50 milliamps 0 to 85 degrees C 0 to 60 degrees C 5 to 95 non condensing SYSTEMS Electronics Group FUSE oo o7 o FUSE LOAD gt FUSE LOAD 10 30VDC ER SUPPLY Typical User Wiring M4500 User s Manual 0 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 SLOT 00 ON mm 12 54568 DC 1 0 10 30VDC SOURCING INPUT 0 THRU INPUT 7 OUTPUT 10 THRU OUTPUT 17 COM APPENDIX A 4568 DIGITAL DC I O BOARD INPUT STATUS LED S OUTPUT STATUS LED S 1 0 FIELD WIRING CONNECTOR SLOT ADDRESS DIP SWITCH ON N n gt a NO Board Outline SYSTEMS Electronics Group A 15 APPENDIX A 4568 DIGITAL DC I O BOARD 2 INPUT INPUT lt 1 STATUS N x oU AN 10 30VDC E X C SUPPLY 47K BUS YA INTERFACE CIRCUITRY TO OTHER INPUTS Typical
7. 11 4573 16 Point 10 30VDC Output sourcing 17 RS 232 Pinouts Cables Appendix B Appendix C Field Wiring Connector Pinouts M4500 User s Manual SYSTEMS Electronics Group iv SECTION 1 GENERAL DESCRIPTION The M4500 Product Line generically referred to as the M4500 is a modular design consisting of a series of high performance PLC Programmable Logic Controller chassis with a fully integrated PLS Programmable Limit Switch digital I O boards serial communication board display keypads and power supply Eight versions are available M4500 4 SLOT PLC PLS M4501 4 1 0 SLOT PLC ONLY M4502 3 SLOT PLC ONLY WITH DISPLAY KEYPAD M4503 SLOT PLC PLS WITH DISPLAY KEYPAD M4508 8 I O SLOT PLC PLS M4509 8 SLOT PLC ONLY M4512 12 SLOT PLC PLS M4513 12 SLOT PLC ONLY The M450X part numbers consist of the chassis with processor resolver interface M4500 M4503 M4512 and M4508 and either 3 I O slots M4502 and M4503 4 I O slots M4500 and M4501 8 VO slots M4508 and M4509 or 12 I O slots M4512 and M4513 I O boards 16 and 32 point Input and 16 point Output are installed by the user in the I O slots based on the requirements of the application The optional D4590 2 Line X 20 character or D4591 2 Line X 40 character displays with 24 key 3 Row X 8 Column keypads are available for use as a general operator interface or for PLS timing channel programming the D4591 Display Keypad is built in
8. Clear Chan commands Thus the cursor is not used to select set points since the commands that operate on individual set points are not valid If no set point is programmed at a given set point number the field is displayed as ___ Otherwise as an example the set point will be displayed as 020 040 where 020 is the location the channel turns on and 040 is where the channel turns off for the given set point SCALE FACTOR This is the scale factor as entered in the PLS configuration Note The scale factor cannot be changed from the channel edit menu but is displayed only for reference M4500 User s Manual SYSTEMS Electronics Group 34 MESSAGE OFFSET PULSE TRAIN ON OFF START SECTION 5 PLS PROGRAMMING USING SYSdev This is field which displays various status messages informing the user of invalid commands i e invalid set point operations in process i e loading file etc The current resolver offset of the selected program This is entered using the F10 Set Offset command Defines whether the channel is programmed as a pulse train YES or not NO The channel defaults to NO until the F5 Pulse Train command is executed Once programmed as a pulse train the channel must be cleared using the F8 Clear Chan command to reset PULSE TRAIN to NO See section 5 4 for details of the pulse train command On duration in degrees of the pulse train Off duration in degrees of
9. DIGITAL DC OUTPUT BOARD SLOT 00 ON m OUTPUT STATUS 12 LED S 7 54573 DC OUTPUT 10 30VDC SOURCING FUSE P FUSE 19 LOAD o OUTPUT 0 oO 1 ES 2 219 3 THRU 310 4 2 4 O 5 s FUSE 6 6 LOAD 7 OUTPUT 7 OUTPUT FIELD FUSE WIRING 7 SLOT ADDRESS CONNECTOR 10 10 OUTPUT 10 LOAD o f ro o TIS DIP SWITCH y 11 io 2 9 13 THRU ES 14 14 ON 15 15 FUSE 16 16 O 12 LOAD o fo 17 OUTPUT 17 1718 Y 10 30VDC SUPPLY COM Typical User Wiring Board Outline V pg d i BUS INTERFACE OUTPUT Y o CIRCUITRY I ae ES o y 10 30w0 J OUTPUT A T SUPPLY 4 4 Typical Output Circuit M4500 User s Manual SYSTEMS Electronics Group A 21 APPENDIX A S4573 DIGITAL DC OUTPUT BOARD This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group APPENDIX B RS 232 PINOUTS CABLES NOT USED RXD RECEIVE DATA IN TXD TRANSMIT DATA OUT NOT USED 56 SIGNAL GROUND NOT USED NOT USED NOT USED NOT USED PROG Port Pin Out OON ON DB9 FEMALE DB9 FEMALE COMPUTER INTERFACE PRO
10. 1 is connected to the resolver and tied to the reference inputs RI of both modules while the reference output of module 2 15 not used Up to 8 modules can be slaved off one resolver this way In all cases a shielded twisted pair cable should be used to wire the resolver to the M4500 making sure the cable is routed free of other high voltage wiring M4500 User s Manual SYSTEMS Electronics Group 68 SECTION 8 INSTALLATION M4500 RESOLVER Figure 8 10 M4500 Resolver Interface Stand Alone RESOLVER Figure 8 11 Two M4500 Slaved To One Resolver M4500 User s Manual SYSTEMS Electronics Group 69 SECTION 8 INSTALLATION 8 10 POWER UP SEQUENCE OF M4500 MODULES Once all connectors are wired and re installed in their respective sockets apply 115 230VAC power to the P4500 power supply The power sequence occurs as follows 1 At initial power up the module is reset for approximately half a second During this time the fault interlock will be off and the FLT RUN and PWR LED s will all be on The outputs will also all be off 2 Once the reset cycle is complete the module will begin to execute the program previously loaded The fault interlock will turn on sink true low and the FLT LED will extinguish The outputs will then be activated in the states as controlled by the user program 3 Ifa user program has not been loaded new module or module
11. 8 2 Mounting the M4500 Chassis 55 8 2 1 Installing the Optional Circulation Fan 55 8 2 2 Back Panel Mounting the M4500 Chassis 55 8 2 3 Door Mounting the M4500 Chassis 55 8 3 Mounting the P4500 Power Supply 57 8 4 Installing I O Boards in the M4500 Chassis 57 8 5 Wiring the Interrupt Inputs 58 8 6 Wiring the Analog I O 59 8 7 Wiring the Fault Interlock 60 8 8 Serial Network Installation 61 8 8 1 Wiring the Serial Network 61 8 8 2 Setting the Network Address 63 8 9 Resolver Interface 63 8 9 1 Resolver Wiring 64 8 10 Power Up Sequence of M4500 Modules 66 LIST OF FIGURES Figure 4 1 PLS Keypad Assignments 20 Figure 8 1 D4590 D4591 Keypad Display Bezel Removal 53 Figure 8 2 D4590 Keypad Display Recommended Panel Cut out 54 Figure 8 3 D4591 Keypad Display Recommended Panel Cut out 54 Figure 8 4 M4500 With Keypad Display Door Mount Detail 56 Figure 8 5 Typical Interrupt Wiring 58 Figure 8 6 Typical Analog I O Wiring 59 Figure 8 7 Typical Fault Interlock Wiring 60 Figure 8 8 Typical Network Wiring 62 Figure 8 9 Alternative Serial Connector Wiring 62 Figure 8 10 M4500 Resolver Interface stand alone 65 Figure 8 11 Two M4500 s Slaved to One Resolver 65 M4500 User s Manual SYSTEMS Electronics Group 1 CONTENTS APPENDICES Board Data Sheets Appendix A 4516 Serial Communications Board Al 4563 16 Point 10 30VDC Input sourcing AT 4568 8 Input 8 Output 10 30VDC I O sourcing
12. Input Circuit FUSE OH n 0 d E US FUSE INTERFACE 1 RM IS CIRCUITRY ds 5 10 30w0c A lt SUPPLY XX STATUS D LED d 4 Typical Output Circuit M4500 User s Manual SYSTEMS Electronics Group APPENDIX A S4573 DIGITAL DC OUTPUT BOARD S4573 DIGITAL DC OUTPUT BOARD 16 POINT 10 30VDC SOURCING FEATURES o 16 Digital Output Points o 16 Individual Status LED s 1 Led Per Output Point o 0 5 Amp Drive Capability Per Output Point o Output Transient Protection o Removable Field Wiring Connector o Optical Isolation o Standard M4500 I O Form Factor GENERAL DESCRIPTION The 4573 10 30VDC Output Board for use with the M4500 series of modules contains 16 identical solid state circuits which convert the logic status of 2 bytes written from the M4500 processor to the appropriate voltage in order to drive user devices such as solenoids relays and lamps On any given output point writing a 1 to the point turns the output on writing a 0 turns the output off When the output is on the voltage at the output is high approximately equal to the user s supply voltage When the output is off the voltage at the output is low approximately zero An output will source current to the load when on thus the outputs are defined as sourcing Each output is rated at 0 5 amp DC continuous with an inrush pulsed current drive ca
13. M4500 for use by the PLC section or can be written to output boards for use in general PLS applications The timing channels can be programmed on and off at user defined position set points Each timing channel can be programmed with up to 50 unique on off set points or with a pulse train of fixed on and off divisions throughout the entire channel The number of timing channels used 8 16 32 or 64 is predicated by the application On applications requiring a large number of channels up to 64 are available On applications requiring only a small number of channels as few as 8 are available The more channels used the higher the over head scan time will be to implement the timing channels Therefore it is advantageous to configure the M4500 for no more than the number of channels that are required 3 1 2 SCALE FACTOR The scale factor of the PLS is programmable from 2 to 4096 divisions per revolution If 360 degrees are to be used set the scale factor to 360 3 1 3 OFFSET ELECTRONIC ZERO The offset is used to electronically zero the resolver shaft The M4500 contains an auto zero algorithm which will automatically calculate the offset required to make the current position of the resolver shaft zero This is implemented by simply entering 0 for the offset This indicates to the M4500 to auto zero the offset In addition the user can actual enter the desired position that is to be zero This allows the offset to be set in a
14. To select a specific mode set the corresponding pole on or closed Not that only one mode can be selected therefore the pole for the mode not used must be set off or open M4500 User s Manual SYSTEMS Electronics Group A 2 APPENDIX A S4516 SERIAL COMMUNICATIONS BOARD To install the S4516 in the M4500 chassis turn power to the M4500 off and remove the cover plate of the M4500 by loosening the captive screws that retain it Install the S4516 in the respective slot of the M4500 making sure the DIN connector on the 4516 fully mates with the DIN connector in the M4500 motherboard and that the top of the S4516 is seated correctly in the card guides at the top of the M4500 Install the M4500 cover back onto the M4500 making sure the LED s and Field connector protrude through the respective openings in the cover The M4500 cover will retain the 54516 both from the top and the front holding the 4516 in place during normal operation Tighten the captive screws that retain the cover on the M4500 Install the S4516 overlay on the M4500 cover at the slot the S4516 is installed in Install the female field wiring connectors to the corresponding male connectors on the S4516 The S4516 is now installed and ready to run To remove the S4516 simply perform the previous steps in reverse M4500 User s Manual SYSTEMS Electronics Group A 3 APPENDIX A S4516 SERIAL COMMUNICATIONS BOARD SPECIFICATIONS Board Size Length Height
15. address set it in The M4500 modules network address is set via sfunc19 in the user s PLC application program Refer to the application program for details on setting the M4500 network address 8 9 RESOLVER INTERFACE The M4500 PLS is generally interfaced to the RSV34 MSI resolver but can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals Separate resolver reference input and output connections are provided on the resolver interface connector This allows The M4500 modules to be slaved to other M4500 modules or to other manufactures programmable limit switches off one resolver M4500 User s Manual SYSTEMS Electronics Group 67 SECTION 8 INSTALLATION 8 9 1 RESOLVER WIRING Figure 8 10 shows the typical wiring to a generic resolver for stand alone operation M4500 PLS provides reference voltage for resolver Note The reference output RO is tied to the reference input RI The reference output excites the resolver while the reference input and two stator inputs are used to determine the absolute position of the resolver The direction of rotation is determined by the connection S1 and S3 Swapping 51 and S3 will reverse the direction of rotation for the M4500 module Figure 8 11 shows two M4500 modules wired to one resolver with module 2 slaved to module 1 reference for resolver supplied by module 1 In this case the reference output RO of module
16. features The M4500 can be used as a stand alone PLS PLC section not used by downloading the program BASICPLS to the M4500 This is a PLC program which simply enables all the PLS features and maps the timing channels to the following outputs CH00 07 OUTPUT SLOTO 0 BYTEO CH10 17 OUTPUT SLOTO 0 BYTE1 CH20 27 OUTPUT SLOTO 1 BYTEO CH30 37 OUTPUT SLOTO 1 BYTE1 CH40 47 OUTPUT SLOTO 2 BYTEO CH50 57 OUTPUT SLOTO 2 BYTE1 CH60 67 OUTPUT SLOTO 3 BYTEO CH70 77 OUTPUT SLOTO 3 BYTE1 The BASICPLS program is included with the SYSdev software package and is loaded into the EXAMPLES sub directory of the PLS51 sub directory To download BASICPLS into the M4500 perform the following 1 Power up the M4500 and the IBM PC or compatible loaded with SYSdev 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4500 3 From the root directory of the hard drive that SYSdev is loaded on type SYSDEV PLS51 EXAMPLES BASICPLS lt ENTER gt 4 From the main development menu of SYSdev select 6 Target Board Interface 5 Download the BASICPLS application program to the M4500 by selecting 1 Download Program to Target Board from the target board interface menu A prompt will be displayed verifying the download press the lt ENTER gt key to start the download Once the download is complete press any key to return to the target board interface menu 6 Return to the SYSdev main menu and then exit SYSdev Whe
17. key to initiate the configuration command The display will now read PLS PROGRAM x where x is the currently selected PLS program To select a new PLS program enter a number between 0 and 7 and press ENTER The timing set points for the selected PLS program will be recalled from memory and used as the active set points for the timing signals Ifthe PLS program is not to be changed simply press ENTER Now the display will read OFFSET xxxx where xxxx is current offset This offset is used primarily to electronically zero the resolver shaft at machine zero The offset can be programmed from 0 to one minus the scale factor To set the offset perform the following Locate the machine at machine zero Read the resolver shaft position on the keypad display Enter the value read and press ENTER The M4500 will calculate the value required to make the position entered machine zero and enter this as the offset this value may not equal the value entered Alternatively the resolver can be zeroed simply enter the number 0 and pressing ENTER The M4500 PLS contains an auto zero algorithm which will calculate the offset required to make the current position zero To continue without changing the offset simply press ENTER Next the display will read SCALE FACTOR xxxx where xxxx is the current scale factor The scale factor of the M4500 PLS is programmable from 2 to 4096 divisions per revolution For 360 degrees per revolution the scale facto
18. level or Assembly Blocks of the different languages can be intermixed as necessary within the file Since the M4500 incorporates memory mapped I O I O update is performed by the user s application program In most applications this is done at the beginning of the main program and or the beginning of the timed interrupt See the M4500 Program Development Manual for complete details on programming the PLC section of the M4500 M4500 User s Manual SYSTEMS Electronics Group SECTION 2 PLC FEATURES 2 2 SPECIAL FUNCTION VARIABLES SFV s Directly addressed Many of the features of the M4500 are accessed via certain variables in the M4500 These are referred to as Special Function Variables The following is the list of SFV s of the M4500 and is provided as a reference only For a complete description of each SFV refer to the M4500 Program Development Manual Address Description B160 PLS Command Flags B160 0 Execute PLS command from PLC B160 1 Reserved Do not access thru B160 5 Reserved Do not access B160 6 Bypass Recall Ack B160 7 Reserved Do not access B161 System Enable Flags B161 0 PLS Mode Enable B161 1 PLS 7 Speed Compensation Enable B161 2 PLS Keypad Commands Enable B161 3 Analog I O Update Enable B161 4 PLS Update in TIMED 1 PLS Update in MAIN O B161 5 PLS Program Commands Enable B161 6 sfunc13 slave mode enable in 84516 B161 7 sfunc18 interleaved 0 executed complete 1 W162 AINO Analog Input
19. of the channel edit menu and set point programming commands Note Any changes to the channel set points made are updated immediately to the M4500 module This allows set point editing during machine operation if desired When editing is complete press ESC to return to the main development menu The modified channel set points will also be saved in the channel data file on disk for the selected program when existing the on line mode 2 Offline Channel Setpoint Programming This selection is used to edit the channel set points off line while not connected to an M4500 module All changes made to the channel set points are saved in the channel data file for the selected program The channel set points can then be downloaded to an M4500 module using the Download Channels to PLS selection To initiate the off line programming mode select 2 Offline Channel Setpoint Programming This invokes the channel edit menu and loads the existing channel set points from the channel data file on disk See section 5 2 2 for a description of the channel edit menu and set point programming commands When editing is complete press ESC to return to the main development menu The modified channel set points will then be saved in the channel data file on disk for the selected program 3 Edit PLS Configuration This activates the PLS configuration menu See section 5 3 When SYSdev is initially invoked and the program name entered does not exist the PLS co
20. points should then be tied to earth ground 5 The two extreme ends of the network should be terminated with 150 ohm resistors as shown in figure 8 8 6 The network wiring should be isolated from other high voltage wiring by routing the network in a separate conduit dedicated to the network 7 The network should be wired directly to the network comm port connectors No intermediate terminations or splices should be used The network should be wired in a direct connect topology as shown not in multi drop or cluster topologies Note The network comm interface connectors contain two sets of and terminals The two sets of terminals are tied together internally on the module to to and are provided as tie points to ease wiring Communications across the network will continue even if one of the nodes has failed provided all the connectors are installed in their respective module However if a connector is pulled from it s module communications to the modules downstream will be lost the internal tie point will be broken If it is desired this situation can be avoided by wiring the connector as shown in figure 8 9 M4500 User s Manual SYSTEMS Electronics Group 65 SECTION 8 INSTALLATION M4000 BELDEN CABLE 9182 MODULE OR EQUIVALENT M4500 MODULE NOTE SHIELD TIED TO EARTH GROUND AT ONE BOARD ONLY 53012 53014 1 W SPB3012 1 TO OTHER S
21. the position will read and the channel state indicator will be set on or off as appropriate 4 5 SETTING THE PLS CONFIGURATION The following PLS configuration parameters can be set via the keypad display CONFIG command PLS program scale factor offset and through CH07 speed compensation Note Once the CONFIG command is initiated each parameter will be prompted for and displayed sequentially by the keypad display To simply view the existing configuration parameters without changing them press ENTER when the corresponding parameter is displayed The CONFIG command can be exited at any time simply by pressing the ESC key The following configuration parameters are prompted for sequentially PLS Program 0 7 Offset 0 to Scale Factor 1 Scale Factor 2 4096 Number of Timing Channels 8 16 32 or 64 Speed Compensation 0 to 255msec CHO1 Speed Compensation 0 to 255msec 2 Speed Compensation 0 to 255msec Speed Compensation 0 to 255msec 4 Speed Compensation 0 to 255msec 0 5 Speed Compensation 0 to 255msec 1 CH06 Speed Compensation 0 to 255msec 2 1 2 3 4 5 6 7 8 9 1 1 12 CHO7 Speed Compensation 0 to 255msec M4500 User s Manual SYSTEMS Electronics Group 2 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY To view or set the configuration parameters perform the following 1 2 Press the CONFIG
22. to connect these inputs as described will result in a fault detected when test 2 is performed All tests are automatic and require no interaction once the test is initiated Each test performs a complete check of the respective hardware area of the module If a fault is detected the test is stopped and a test fault code is displayed to indicate the nature of the hardware failure Note The actual input and output points hardware is not checked with these tests This can be done using the on line monitoring mode of SYSdev to view the states of the inputs and set the states of the outputs M4500 User s Manual SYSTEMS Electronics Group 51 SECTION 7 HARDWARE CONFIDENCE TEST 7 2 PERFORMING THE HARDWARE CONFIDENCE TEST WARNING The hardware confidence test should not be performed in an M4500 module installed in a user s control system Unpredictable output states may result while the test is being performed 7 2 1 EQUIPMENT REQUIRED In order to perform the hardware confidence test the following is required 1 IBMPC or compatible with SYSdev installed 2 RS 232 interface cable to connect the COM port on the PC to PROG port on the M4500 module 3 24VDC power supply to power fault interlock 4 M4500 module to be tested 5 P4500 power supply to power M4500 module M4500 User s Manual SYSTEMS Electronics Group 52 SECTION 7 HARDWARE CONFIDENCE TEST 7 2 2 EXECUTING THE TEST To execute the test perfo
23. verify the COM port for proper operation see manual from PC manufacture 6 3 3 INVALID PROGRAM FAULTS 5CH and 5DH The Program invalid 5CH fault occurs when the module does not contain a valid user program This typically occurs when a new module is installed which has never had a user program downloaded to it or after the hardware confidence test is performed which erases the program memory The Program dump timeout 5DH fault occurs when program download to the M4500 module is interrupted while program download is in progress Trouble Shooting 1 Dump the user program to the M4500 module These faults will clear once the module is loaded with a valid user program 2 Ifre loading the module with the user program does not clear the fault replace the M4500 module and try again M4500 User s Manual SYSTEMS Electronics Group 46 SECTION 6 FAULT DETECTION 6 3 4 USER PROGRAM sfunc09 SYSTEM FAULT CALL 45H This fault code is set when the user program performs an sfunc09 system function fault call See the user program for the purpose of the system fault call See the M4500 Program Development manual for details on sfunc09 6 3 5 INTERNAL M4500 FAULTS 44H 59H 5BH The remainder of the fault codes detected by the M4500 module represent an internal failure of the module These can range from the RAM battery low to invalid interrupt requests Trouble Shooting 1 Perform the hardware confidence test
24. which the confidence test has just been executed the FLT LED will stay on and the RUN LED will extinguish Download the user program and data files to the module The RUN LED will flash while the user program is downloading When the download is complete the FLT LED will extinguish and the RUN LED will turn on Ifthe FLT LED turns on after the download is complete read the fault code in the M4500 module see section 6 See the SYSdev program manual for details on downloading programs to the M4500 modules M4500 User s Manual SYSTEMS Electronics Group 70 APPENDIX A S4516 SERIAL COMMUNICATIONS BOARD S4516 SERIAL COMMUNICATIONS BOARD 3000 NETWORK PORT AND RS 232 RS422 USER PORT FEATURES o 53000 Serial Network Port and One RS 232 RS 422 User Port o 3000 Network Port Configurable For 106kbps 228kbps Or 344kbs o RS 232 RS 422 Port Configurable For 9600 Or 19 2k Baud RS 232 RS 422 Data Receive and Transmit LED s o Serial Network Comm Led o Removable Field Wiring Connectors o Standard M4500 I O Form Factor GENERAL DESCRIPTION The 4516 for use with the M4500 series of modules contains one 3000 Serial Network Interface port and one RS 232 RS 422 User Port The S4516 provides a means for an M4500 module to communicate to other S3000 M4000 or M4500 modules processors via the S3000 serial network The RS 232 RS 422 port allows communications to other PLC or host computers Multiple 54516 board
25. 0 0 1023 W164 AIN1 Analog Input 1 0 1023 B166 AOUTO Analog Output O 0 255 B167 AOUT1 Analog Output 1 0 255 B170 CHO PLS Channel byte 0 CH00 07 B171 CH1 PLS Channel byte 1 CH10 17 B172 CH2 PLS Channel byte 2 CH20 27 B173 CH3 PLS Channel byte 3 CH30 37 B174 CH4 PLS Channel byte 4 CH40 47 B175 CH5 PLS Channel byte 5 CH50 57 B176 CH6 PLS Channel byte 6 CH60 67 B177 CH7 PLS Channel byte 7 CH70 77 M4500 User s Manual SYSTEMS Electronics Group SECTION 2 PLC FEATURES Address Description W178 Resolver Position updated in TIMED Interrupt W180 Resolver Position updated in MAIN Program W182 Resolver RPM W184 Resolver Period msec per revolution W186 Resolver Scale Factor W188 Resolver Offset W192 Resolver Period speed compensation B191 Depressed Key on Keypad 0 no key 1 24 key 194 Display wait delay B194 28 for D4590 194 47 for D4591 B8158 Keypad Debounce time in main scans W8154 Slave Slot Address for S4516 sfunc13 slave mode W8156 4516 Slot Address for sfunc10 11 13 B8159 Current Firmware Revision PLS Programming from PLC SFV s B190 Selected PLS Channel Program 0 7 B212 PLS Command B212 09 Recall Channel B212 27 Single set point programming command B212 43 Pulse Train Programming command For Recall Channel command B213 Channel to read set by user prior to command B213 Recall State O off 1 on return value W214 Position of set point change of state return va
26. 00 is to be connected to a D4590 91 keypad display connect the ribbon cable for the display to the M4500 display interface connector prior to mounting the M4500 chassis The ribbon cable connector is polarized and should mate with the M4500 display interface connector only one way Once the M4500 chassis is installed a lugged earth ground wire should be installed on one of the mounting screws to insure that the chassis is grounded 8 2 3 DOOR MOUNTING THE M4500 CHASSIS If mounting to the D4590 91 the M4500 chassis is mounted to the mounting studs of the display 4 places with the M4500 chassis mounted to the inside of the door door sandwiched between D4590 91 and M4500 chassis see figure 8 4 Prior to mounting the M4500 chassis to the back of the D4590 91 keypad display connect the ribbon cable from the display to the M4500 module display interface connector located on the back of the M4500 module The ribbon cable connector is polarized and will only mate with the M4500 display interface connector one way Once the M4500 chassis is installed a lugged earth ground wire should be installed on one of the mounting screws to insure that the chassis is grounded M4500 User s Manual SYSTEMS Electronics Group 59 SECTION 8 INSTALLATION 8 32 NUT WITH DOOR 8 LOCK WASHER TYPICAL 4 PLACES GASKET D4590 KEYPAD DISPLAY KEYPAD DISPLAY RIBBON CABLE M4500 M4501 CHASSIS OUTSIDE OF DOOR INSIDE
27. 3012 S amp 3014 S TOTAL OF 32 MAX BLK YEL 150 ohm TERMINATING RESISTOR USED AT EXTREME ENDS OF NETWORK Figure 8 8 Typical Network Wirin M4500 MODULE TO OTHER M4500 MODULES UPSTREAM TO OTHER M4500 MODULES DOWNSTREAM SHLD Ny Figure 8 9 Alternative Serial Connector Wirin M4500 User s Manual SYSTEMS Electronics Group 66 SECTION 8 INSTALLATION 8 8 2 SETTING THE NETWORK ADDRESSES Each S3000 board M4000 module on the network must be set with a unique network address between 1 and 32 This is how the modules can distinguish one node from another To set the network address for a particular module perform the following 1 Connect an IBM PC or compatible running SYSdev from the COM port on the PC to the PROG port on the module using the RS 232 interface cable see appendix B 2 From the SYSdev Main Development Menu select 6 Target Board Interface 3 From the Target board Interface Menu select 5 Target board Network Address 4 SYSdev will read the current network address of the S3000 board M4000 module and display it in the network display If the network address is to be changed follow the directions displayed and enter the new address The above steps must be done for all S3000 boards M4000 modules on the network This is true when the network is first installed and when a new module is added or replaced that module must have the network
28. C or BDC stops However as the brake wears the press will no longer stop at TDC but will instead overshoot The brake wear compensation algorithm automatically adjusts the TDC timing such that the press always stops at the desired stopping position regardless of brake wear Brake Wear Alarm In conjunction with the brake wear compensation brake response determination and a brake wear alarm can be implemented in the PLC section This determines the actual number of degrees the brake takes to stop the press from de clutch to stop The brake wear alarm can be activated if the brake response exceeds a preset number of degrees Speed Windows These signals can be activated at preset speed thresholds as desired or needed Since the RPM is directly available to the PLC section virtually an unlimited number of speed windows could be generated by the PLC section Automatic Zero Since the offset of the PLS can be accessed by the PLC section it can also be changed in response to any desired logic condition even as a function of speed which would in affect implement a speed compensation for all the timing channels The above advanced PLS features are not implemented in the firmware of the M4500 but would be instead implemented with user logic in the PLC section of the M4500 M4500 User s Manual SYSTEMS Electronics Group 15 SECTION 3 PLS FEATURES 3 3 PLS CHANNEL PROGRAMMING The PLS section of the M4500 is programmed either through S
29. EMS Electronics Group IT SECTION 5 PLS PROGRAMMING USING SYSdev SYSdev is a DOS based software package used for program development Ladder and High Level of the PLC section of the M4500 In addition SY Sdev can be used to configure and program the timing channels of the M4500 PLS An RS 232 cable connected to the COM port of an IBM PC or compatible running SYSdev is used to interface with the M4500 module for on line programming program upload download etc No other additional hardware is required 5 1 PLS FEATURES OF SYSdev SY Sdev incorporates the following PLS programming features 1 6 Online Channel Set point Programming using the same set point programming commands and menus used with the off line channel programming the user can alter channel set points in the M4500 module directly using an RS 232 cable which connects the M4500 module to the COM port of an IBM PC or compatible running SYSdev This allows machine timing to be altered while in operation Offline Channel Set point Programming set points for each channel can be entered with easy to use set point programming commands and saved on disk for download to the M4500 at a latter time This allows the channel programming to be implemented without having an M4500 present PLS Configuration the configuration of the M4500 is set using SYSdev This includes defining the PLS program scale factor the number of PLS timing channels and the speed compensation for c
30. ENDIX A S4563 DIGITAL DC INPUT BOARD SLOT 00 ON mm INPUT STATUS 12 LED S 54563 DC INPUT 10 30VDC SOURCING 0 O 0 01 1 1Q 2 2 3 THRU 5 4 5 s 6 e o776 7 input 7 INPUT FIELD 7 Q WIRING SLOT ADDRESS 10 INPUT 10 CONNEC bs S DIP SWITCH 11 12 1218 13 THRU 13 B id 14 ON 15 15 O 16 16 O 12 4 oo 17 NPU 17 1719 E 10 30VDC _ SUPPLY COM Typical User Wirin Board Outline 2 2K INPUT d el INPUT AW t STATUS LED fa 10 30VDC j SUPPLY 47K 5 gt y BUS COM INTERFACE S CIRCUITRY TO OTHER 9 INPUTS Typical Input Circuit M4500 User s Manual SYSTEMS Electronics Group A 10 APPENDIX A 4568 DIGITAL DC I O BOARD 4568 DIGITAL DC I O BOARD 8 IN 8 OUT 10 30VDC SOURCING FEATURES o 8 Digital Input Points And 8 Digital Output Points o 16 Individual Status LED s 1 Led Per Input Point o 0 5 Amp Drive Capability Per Output Point o Output Transient Protection o Removable Field Wiring Connector o Optical Isolation o Standard M4500 I O Form Factor GENERAL DESCRIPTION The 54568 10 30VDC I O Board for use with the M4500 series of modules contains 8 digital inputs and 8 d
31. FAULT DETECTION This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group 50 SECTION 7 HARDWARE CONFIDENCE TEST The hardware confidence test allows the internal M4500 module hardware to be verified for proper operation The test is resident in all modules and is initiated through SYSdev The hardware confidence test is the same test used at the factory to initially test the production M4500 modules and therefore provides the same hardware test as provided at the factory The test is provided to the user to verify whether the module hardware is functional or not Not as a tool to repair the modules If a fault is detected the module should be returned to the factory for repair Any attempt to repair an M4500 module will void the warranty 7 1 TESTS PERFORMED The following is a list of the tests performed by the hardware confidence test Microcontroller RAM test Internal Fault detection test RAM memory test BROWN RS 232 PROG PORT test Tests 1 3 and 4 are not optional and are always performed Test 2 is normally enabled but can be disabled if desired Note If test 2 is to be performed the FLT interlock output must be wired to the terminal of both the interrupt inputO and input inputs The terminals of both interrupt inputO and inputl must be wired to the terminal of the fault power input 24VDC Test 2 uses these two inputs to verify the FLT interlock output Failure
32. G PORT 2 RXD 3 TXD 5 sc RXD TXD sG RTS CTS DSR DTR POON OWN DB9 com1 to PROG Port Cable DB25 MALE DB9 FEMALE COMPUTER INTERFACE PROG PORT TXD 2 2 RXD RXD 3 3 TXD 56 7 5 sc RTS 4 CTS 5 DSR 6 20 DB25 com1 to PROG Port Cable M4500 User s Manual SYSTEMS Electronics Group B 1 APPENDIX B RS 232 PINOUTS CABLES This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group APPENDIX FIELD WIRING CONNECTOR PINOUTS 4 F INTERRUPT INPUT 10 30VDC f F INTERRUPT INPUT 1 10 30VDC L FAULT INTERLOCK OUTPUT SOOmAMP SINK 4 f _ FAULT INTERLOCK POWER 10 30VDC RET a M4500 PLC PLS MODULE RESOLVER gt O nd 0 o R2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 1 1 1 1 oli ol 1 L 1 Ld 1 2 jpg 2 ali gt L O LI 2 L s O O 7 O 7 O 7 Up 1 10 AINO m qug n COM a up 12 P4500 AINA SO 135 so POWER 14 O 14 O 14 O SUPPLY AOUTO s56 sE 153 165 hb hs AOUT1 17 Lj 17 LJ 17 O cov eL Ey SMS onds s4563 s4568 54573 54516 hz Wc stot stor SLOT 02 SLOT l
33. M4500 User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 07 2001 M4500 User s Manual Copyright 1995 Systems Engineering Associates Inc All Rights Reserved WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of printing however no responsibility is assumed for inaccuracies In the interests of a commitment to a policy of continuous development and improvement the manu
34. N Used to select the desired channel either to program or to search See section 4 6 SEARCH Used to search and display the set point on and off transitions in the currently selected channel See section 4 10 ESC Used to cancel the current command in progress The keys are mapped to the keypad as shown in figure 4 1 below F1 FA 10 2 m F2 F5 wE m 4 5 6 y F6 search 7 8 9 0 Figure 4 1 PLS Keypad Assignments M4500 User s Manual SYSTEMS Electronics Group 20 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY 4 4 PLS DISPLAY FIELDS The keypad displays contain either a 2 line by 20 character D4590 or 2 line by 40 character back lighted LCD display which normally displays a default channel message or various prompts while commands are entered The format of the default channel message is CH xx SETPT yyy RPM 0000 POS 888 1 is the currently selected channel in octal 2 yyy is the position where the set point transition is located 3 The after the set point position is the channel status indicator a Ifthe channel status indicator is a solid block the set point transitions on at the displayed position b Ifthe channel status indicator is blank the set point transitions off at the displayed position Ifthe channel is programmed either all on or all off
35. N connector on the 4563 fully mates with the DIN connector in the M4500 motherboard and that the top of the S4563 is seated correctly in the card guides at the top of the M4500 Install the M4500 cover back onto the M4500 making sure the LED s and Field connector protrude through the respective openings in the cover The M4500 cover will retain the 54563 both from the top and the front holding the 4563 in place during normal operation Tighten the captive screws that retain the cover on the M4500 Install the female field wiring connector to the corresponding male connector on the 4563 The 54563 is now installed and ready to run To remove the 54563 simply perform the previous steps in reverse M4500 User s Manual SYSTEMS Electronics Group A 8 APPENDIX A S4563 DIGITAL DC INPUT BOARD SPECIFICATIONS Board Size Length Height Width Number of Inputs Input Voltage Vin on min Vin on max Vin off min Input Current max Input Filter Delay typ delay min delay max delay Optical Isolation Power Requirements Icc typ M4500 BUS Temperature Ranges Storage Operating Relative Humidity M4500 User s Manual 6 50 4 25 0 80 16 10 0 volts 30 0 volts 5 0 volts 15 milliamps at Vin 30volts 0 50 milliseconds 0 35 milliseconds 0 80 milliseconds 1500 Vrms 50 milliamps 0 to 85 degrees C 0 to 60 degrees C 5 to 95 non condensing SYSTEMS Electronics Group A 9 APP
36. OF DOOR Figure 8 4 M4500 With Keypad Display Door Mount Detail M4500 User s Manual SYSTEMS Electronics Group 60 SECTION 8 INSTALLATION 8 3 MOUNTING P4500 POWER SUPPLY The P4500 power supply can either be mounted with the left hand mounting holes of the M4500 chassis or in separately drilled holes for the power supply In both cases the power supply must be located to the left of the M4500 chassis in close proximity to the chassis see appendix C If mounting the P4500 in separate mounting holes use 2ea 8 32 screws and lock washers to mount the P4500 Once mounted connect the power supply cable connector in the 5 C 12 C 12 connector of the M4500 The connector is polarized and will only mate one way Wire 115VAC 230VAC 40 400HZ power to the P4500 power connector The AC current rating is 0 5 amps at 115VAC and 0 3 amps at 230VAC 8 4 INSTALLING I O BOARDS IN M4500 CHASSIS Once the M4500 chassis is mounted the digital input and output boards as well as the S4516 Communications board are installed Refer to the individual data sheets for the I O boards in appendix A for complete details on installing and wiring the I O boards Once the I O boards are installed apply the I O identification labels to the respective slots where the I O boards are installed This specifies the I O board part number and slot that the I O board is addressed as M4500 User s Manual SYSTEMS Electronics Group 61 SECTION 8 INS
37. ON 8 8 SERIAL NETWORK INSTALLATION If the S4516 communications board will be used to communicate to other S3000 processors M4000 or M4500 modules the serial network will have to be installed The serial network installation consists of wiring the network and setting each S3000 board M4000 module on the network with a unique network address Up to 32 S3000 boards M4000 modules can be installed on one network 8 8 1 WIRING THE SERIAL NETWORK Refer to figure 8 8 for a typical schematic of the network and for the pin outs of the network interface connectors When wiring the network the following rules must be followed 1 Wire the network using Belden 9182 single shielded twisted pair cable or an equivalent data communications cable meeting the following spec Wire gauge 22AWG Nom impedance 150 ohms ft Nom attenuation at 1MHZ 004 db ft Twisted pair single shielded 2 The total wire length of the network cannot exceed 1000 ft if the network baud rate is set to 344KBPS 2000 ft for 229KBPS and 4000 ft for 106KBPS See section 8 8 2 for details on setting the network baud rate 3 The maximum number of nodes connected to one network is limited to 32 nodes 4 The shield of the cable should be carried through the entire network using the shield tie points on the interface connectors to achieve this The shield tie points on the connectors are not internally tied to anything they are strictly tie points One of these tie
38. TALLATION 8 5 WIRING INTERRUPT INPUTS Interrupt inputO and inputl are 10 30VDC differential inputs which can be wired as sourcing true high sinking true low or as true differential inputs driven by a differential output Each input is provided with a and terminal Figure 8 5 shows wiring examples of all three types of input configurations APPLICATION M4500 INPUT SOURCING INTERRUPT INPUT 12 30VDC 00 AN ANN Yo RETURN 9 M4500 INTERRUPT INPUT 12 30VDC ANN APPLICATION ve INPUT SINKING RETURN oO ZQ M4500 DIFFERENTIAL INTERRUPT INPUT LINE DRIVER Q NW T S INTERRUPT INPUT WIRED FOR SOURCING INPUT INTERRUPT INPUT WIRED FOR SINKING INPUT INTERRUPT INPUT WIRED FO DIFFERENTIAL INPUT Figure 8 5 Typical Interrupt Input Wiring M4500 User s Manual 62 SYSTEMS Electronics Group SECTION 8 INSTALLATION 8 6 WIRING ANALOG I O Two analog inputs and two analog outputs are built into the M4500 The analog inputs are 0 5 volt which can be used as 0 20ma and 0 10 volt inputs when external resistors are installed to perform the respective conversion The analog outputs are 0 10 volt which can be used to drive 0 10 volt analog inputs or 0 5 volt analog inputs using a similar external resistor conversion Figure 8 6 shows wiring examples of both the analog inputs and analog outputs M4500 User s Manual
39. Width Serial Network Port Type Comm Rate of nodes max Isolation Distance Protocol USER Port Type Comm Rate Start Bits Data Bits Stop Bits Parity Power Requirements Icc typ M4500 BUS Temperature Ranges Storage Operating Relative Humidity M4500 User s Manual 6 50 4 25 0 80 RS 485 344KBPS 229KBPS or 106KBPS 32 2000 VRMS 1 000 ft 2 000 ft 4 000 ft Proprietary RS 232 RS 422 selectable 9600 Baud 19 2K Baud 1 8 1 None 150 milliamps 0 to 85 degrees C 0 to 60 degrees C 5 to 95 non condensing SYSTEMS Electronics Group A 4 APPENDIX A S4516 SERIAL COMMUNICATIONS BOARD USER PORT RECEIVE DATA LED rxD USER PORT TRANSMIT DATA LED 3000 NETWORK COMM ACTIVE LED Ocom RS 232 RS 422 USER PORT SELECT o Ww RS 422 Tj RS 232 SW1 USER PORT RS 232 RX RS 232 RECEIVE S 1 TX RS 232 TRANSMIT 210 SG RS 232 SIGNAL GROUND 310 9 SLOT ADDRESS 4 R RS 422 RECEIVE G DIP SWITCH 5 R RS 422 RECEME 5 2 6 RS 422 TRANSMIT ON 7 T RS 422 TRANSMIT 9 m m RS 422 12 COMM PORT 2 L s3000 NETWORK 1 210 3 x 9 4 0 S SHLD
40. Y Sdev using an IBM PC or Compatible or through the PLS commands of the D4590 or D4591 Display Keypad When using SY Sdev the PLS section can either be configured and the timing signals programmed off line and then down loaded to the M4500 or the PLS timing channels can be programmed on line while the M4500 is in operation The IBM PC or compatible is interfaced to the PLS section of M4500 via the PROG port of the M4500 using an RS 232 cable from the COM port on the computer The following PLS programming commands are available when using SY Sdev or the D4590 91 Display Keypad PLS Configuration including Scale Factor 2 4096 Offset Selected PLS Program 0 7 Number of Timing Channels 8 16 32 or 64 Timing Channel Speed Compensation Channels 00 thru 07 VVVVV On and Off line timing channel programming including gt Single set point programming gt pulse train channel programming gt timing channel fine tune SYSdev only Channel set points download to M4500 SYSdev only Channel set points upload from M4500 SYSdev only Configuration and channel set points print outs SYSdev only See section 4 for details on programming the PLS section using the keypad display See section 5 for details on programming the PLS section using SYSdev M4500 User s Manual SYSTEMS Electronics Group 16 SECTION 3 PLS FEATURES 3 4 IMPLEMENTING M4500 AS A STAND ALONE PLS The M4500 is fundamentally a PLC with built in PLS
41. Y Y 1 E 5 250 4 125 3 500 b 0 3125 j e i 0 250 218 DIA HOLE TYPICAL 4 PLACES m Figure 8 2 04590 Keypad Display Recommended Panel Cut Out 4475 ii 4415 0 250 e e 1 A i 000 3 500 4 875 1 875 e e S IN 0 475 1 775 Jl 4 450 0 218 DIA HOLE TYPICAL 7 PLACES Figure 8 3 D4591 Keypad Display Recommended Panel Cut Out M4500 User s Manual SYSTEMS Electronics Group 58 SECTION 8 INSTALLATION 8 2 MOUNTING THE M4500 CHASSIS The M4500 chassis were designed for either back panel mounting or mounting to the user s cabinet door behind the D4590 91 display 8 2 1 INSTALLING OPTIONAL CIRCULATION FAN In high power applications driving high current loads with outputs the optional circulation fan should be installed to draw the heat generated from the output boards out of the chassis If not already installed the fan is mounted in two mounting holes centered in the upper lip of the chassis and is cantilevered over the chassis such that air is drawn up from the chassis through the fan The fan is powered from 24VDC and should be connected to the fault power terminals of the M4500 The red led of the fan is the power lead while the blue lead is the 8 2 2 BACK PANEL MOUNTING THE M4500 CHASSIS If mounting to a back panel the chassis should be mounted using 4ea 8 32 screws and lock washers If the M45
42. YSTEMS Electronics Group CONTENTS 5 PLS Programming Using SYSdev 27 5 1 PLS Features of SYSdev 27 5 2 PLS Menus 28 5 2 1 Main Development Menu 28 5 2 2 Channel Edit Menu 32 5 3 PLS Configuration 34 5 3 1 PLS Program 34 5 3 2 Scale Factor 35 5 3 3 Number of PLS Channels 35 5 3 4 Speed Compensation 35 5 4 Channel Set Point Programming Commands 35 5 4 1 Single Set Point Programming Command 36 5 4 2 Fine Tune Set Point Command 37 5 4 3 Pulse train Command 38 6 Fault Detection 39 6 1 Fault Routine Execution 39 6 2 Viewing Fault Codes with SYSdev 39 6 3 Fault Codes 41 6 3 1 Watchdog Timer Timeout 40H 41 6 3 2 IBM PC to M4500 Communications Failure 42H 42 6 3 3 Invalid Program Faults 5cH and 5dH 42 6 3 4 User Program sfunc09 System Fault Call 45 _ 43 6 3 5 Internal M4500 Faults 44H 59H 5bH 43 6 4 Serial Network Communications Errors 43 6 4 1 Serial network Comm error Codes 44 6 4 2 Response from Slave 04H and 05H 44 6 4 3 Serial Network Integrity Error 03H 06H 0eH 10H 45 6 4 4 Address Outside Range 0fH 45 7 Hardware Confidence Test 47 7 1 Tests Performed 47 7 2 Performing the Hardware Confidence Test 48 7 2 1 Equipment Required 48 7 2 2 Executing the Test 49 M4500 User s Manual SYSTEMS Electronics Group zs CONTENTS 8 Installation IA 8 1 Mounting the D4590 D4591 Keypad Displays 51 8 1 1 Installing the Keypad Legend Behind the Overlay 51 8 1 2 Mounting the Keypad Displays in the Cabinet Door 52
43. allowed to overlap any existing set points already entered in the channel Example 1 The following key sequence enters the set point 020 040 at set point number 1 Key Depressed OA ON Enter lt CR gt Set point Field 2 lll 20 020 02024 020 40 020 040 Example 2 The following example programs the entire channel on by specifying both the on and off parameters to 000 Key Depressed 0 lt gt 0 lt gt M4500 User s Manual Set point Field HS ME 000 000 0 000 000 39 SYSTEMS Electronics Group SECTION 5 PLS PROGRAMMING USING SYSdev 5 4 2 FINE TUNE SET POINT COMMAND The fine tune set point command allows the user to increment or decrement by one the on or off parameter of an already existing set point The fine tune command is executed by selecting F6 Fine Tune from the channel edit menu When this is done the fine tune menu is displayed This menu contains the following commands 1 On Setpnt This is used to select the on parameter of the set point When selected the cursor will move to the least significant digit of the on parameter F2 Off Setpnt This is used to select the off parameter of the set point When selected the cursor will move to the least significant digit of the off parameter F3 Inc This command increments the selected parameter either on or off whichever was selected with the On Se
44. ater than 512 A typical application of using multiple PLS programs would be in stamping press applications where different die sets would be used for different stampings The timing signals for each die set up to 8 different die sets would be programmed and saved in a specific PLS program and then as the different die sets were used the specific PLS program would be called up and used for that die set saving the operator from having to re program all the timing signals every time that die set was used Speed Compensation is available for timing channels 0 through 7 This is used to compensate for the mechanical response time of a device activated by a particular timing channel The speed compensation algorithm leads the desired activation position by a time in milliseconds entered for that channel Thus as the speed increases the point at which the device is activated is advanced to compensate for the response time of the device Note The compensation parameter is entered in milliseconds not degrees per RPM which simplifies set up since the time that is be compensated for is in milliseconds M4500 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION The M4500 is generally interfaced with the RSV34 MSI resolver as the position transducer however virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals can be used 1 3 INTERRUPT INPUTS The M4500 modules contain
45. cabinet door in the same fashion as the D4591 display 8 1 1 INSTALLING THE KEYPAD LEGEND BEHIND THE OVERLAY Customization of the keypad legends is implemented with a keypad placard that is placed between the keypad overlay and the keys themselves Depending on the application the keypad displays are provided either with or with out the keypad placard The user can generate keypad placards using a word processor or desk top publishing software package If the keypad placard needs to be installed or changed perform the following to install the keypad placard 1 For the M4502 and M4503 only The D4591 must be removed from the module prior to performing the following steps To remove the D4591 from the M4502 03 remove the six 6 32 screws which retain the D4591 in the module and then disconnect the 26 pin ribbon cable at the back of the D4591 display 2 Remove the four 6 32 screws shown in figure 8 1 from the back of the D4590 91 These four screws hold the display bezel to the display body Do not remove any of the other screws 3 Place the keypad placard in the opening of the display bezel behind the overlay where the keypad is located aligning the placard with the keypad key openings 4 Install the display bezel back onto the display body and install the four 6 32 screws that hold the bezel to the display body The keypad placard will now be sandwiched between the overlay and the keys Prior to tightening the four screws align the disp
46. ccess to the serial network port is implemented via sfunc13 in the M4500 user s program while access to the USER port is implemented with sfunc10 USER port read and sfunc11 USER port write Configuration of the S4516 network address network baud and USER port baud is performed using sfunc19 in the M4500 user s program Refer to the M4500 Program Development Manual for complete details on these system functions INSTALLATION Prior to installing the S4516 the I O slot addressing dip switch on the board must be set for the slot the board will be addressed as Note Geographical addressing is not used in the M4500 The slot the S4516 is addressed as is solely defined by the dip switch settings on the S4516 itself not by the slot in the M4500 chassis that the board is placed in Two poles on the dip switch of the board set the binary slot address of the board as follows Dip Switch Slot Addressing SW2 2 1 Slot Address off off 0 off on 1 on off 2 on on 3 The SW2 Slot address dip switch is located in the lower right hand corner of the component side of the S4516 The respective switch pole is on when in either the on or close position and off when either in the off or open position depending on the type of dip switch used RS 232 RS 422 Dip Switch SW1 This must also be set depending on whether the RS 232 mode or RS 422 is used Two poles on SW1 define the mode Pole 1 is for the RS 232 mode pole 2 is for the RS 422
47. cover back onto the M4500 making sure the LED s and Field connector protrude through the respective openings in the cover The M4500 cover will retain the 54573 both from the top and the front holding the 4573 in place during normal operation Tighten the captive screws that retain the cover on the M4500 Install the female field wiring connector to the corresponding male connector on the 54573 The 54573 is now installed and ready to run To remove the 4573 simply perform the previous steps in reverse M4500 User s Manual SYSTEMS Electronics Group APPENDIX A S4573 DIGITAL DC OUTPUT BOARD SPECIFICATIONS Board Size Length Height Width Number of Outputs Output Voltage Voltage Range Vout on min Vout on max Vout off min Output Current lout on max continuous lout on max pulsed lout off max leakage Output Response Time max on time max off time Optical Isolation Power Requirements Icc max M4500 BUS Icc min M4500 BUS Temperature Ranges Storage Operating Relative Humidity M4500 User s Manual 6 50 4 25 0 80 16 10 30VDC VCC 2 00 volts VCC 0 25 volts 1 5 volts 0 5 amps DC 3 0 amps DC for 100msec 100 microamps 50 microseconds 75 microseconds 1500 Vrms 125 milliamps all outputs on 35 milliamps all outputs off 0 to 85 degrees C 0 to 60 degrees C 5 to 95 non condensing SYSTEMS Electronics Group APPENDIX A S4573
48. d in the least significant byte of the slot that the board is addressed as Inputs 0 through 7 are mapped in bits 0 through 7 of byte 0 of the slot The 8 output points are mapped in byte 1 of the slot that the board is addressed as Outputs 10 through 17 are mapped in bits 0 through 7 of byte 1 of the slot M4500 User s Manual SYSTEMS Electronics Group APPENDIX A 4568 DIGITAL DC I O BOARD INSTALLATION Prior to installing the S4568 the I O slot addressing dip switch on the board must be set for the slot the board will be addressed as Note Geographical addressing is not used in the M4500 The slot the S4568 is addressed as is solely defined by the dip switch settings on the 54568 itself not by the slot in the M4500 chassis that the board is placed in Two poles on the dip switch of the board set the binary slot address of the board as follows 4568 SW1 Dip Switch Slot Addressing 2 1 Slot Address off off 0 off on 1 on off 2 on on 3 The SW1 Slot address dip switch is located in the lower left hand corner of the component side of the S4568 The respective switch pole is on when in either the on or close position and off when either in the off or open position depending on the type of dip switch used To install the S4568 in the M4500 chassis turn power to the M4500 off and remove the cover plate of the M4500 by loosening the captive screws that retain it Install the S4568 in the respective slot of the M4500 ma
49. e main development menu and try the download again 5 Upload Channels from PLS This selection uploads the set points for each channel from the M4500 and saves it in the channel data file of the currently selected program Note The configuration data is also uploaded from the M4500 as well To upload the data from the M4500 perform the following 1 2 With both the PC running SYSdev and the M4500 powered up connect the COM port on the PC to the PROG port on the M4500 using the appropriate RS 232 cable Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the upload press ESC otherwise press any key to start the upload While the upload is in progress the channel number which is currently being uploaded will be displayed Once all channels are uploaded an upload complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu If the computer was unable to initiate the upload to the M4500 a message stating this will be displayed Verify the RS 232 cable connections between the COM port on the computer and the PROG port on the M4500 Press any key to return to the main development menu and try the upload again M4500 User s Manual SYSTEMS Electronics Group 31 SECTION 5 PLS PROGRAMMING USING SYSdev 6 Print Channels Both the PLS configuration data and channel set points data can be print
50. ed out through SYSdev When this selection is made a printer selection menu is displayed Select the appropriate printer to be used Once this is done the print outs selection menu is displayed The selections are 1 Print PLS Channel Set points This selection prints the set points for all the channels For each channel the following is printed CHANNEL number DESCRIPTION users documentation PULSE TRAIN yes no ON OFF START SET POINTS ON OFF de uer etc The above is the set points data for the respective channel as entered through the channel edit menu 2 Print PLS Configuration This selection prints the configuration parameters as entered in the PLS configuration menu 3 Enter PLS Program Title This selection allows the user to enter a title for the program This title is printed at the top of each page of both the PLS Channel Set points print out and the PLS Configuration print out The title can be up to 60 characters long and can be composed of any printable characters When entry of the title is complete press Enter lt CR gt to save the title If the title or changes to the title are not to be saved press ESC M4500 User s Manual SYSTEMS Electronics Group 32 SECTION 5 PLS PROGRAMMING USING SYSdev 7 File Utilities The SYSdev program allows you to back up restore make a new directory and to copy the current PLS program to another PLS program name all while inside SYSdev Selecting File Utilities bring
51. een obtained at address of fault Diagnostics test number for factory use only Once a fault occurs exit back to the Main Test Menu and re initiate the test to reset the fault code Once testing is complete exit back the Main Development Menu The user application program will now have to be re downloaded to the M4500 module M4500 User s Manual SYSTEMS Electronics Group 53 SECTION 7 HARDWARE CONFIDENCE TEST This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group 54 SECTION 8 INSTALLATION The following sections provide information on mounting and wiring the M4500 modules as well as a description of the power up sequence Note All wiring is implemented with removable field wiring connectors Refer to appendix C for the pin outs of the various connectors on the M4500 modules 8 1 MOUNTING THE D4590 D4591 M4502 M4503 KEYPAD DISPLAYS The D4590 and D4591 displays were designed to be mounted to the back of the M4500 01 or M4508 09 modules respectively Alternatively the M4500 modules could be mounted to the back panel with the D4590 91 mounted in the user s cabinet door The displays are interfaced to the M4500 via a 26 pin ribbon cable Communications is parallel at TTL levels therefore the display must be placed in close proximity to the M4500 maximum cable length is 8 feet The M4502 and M4503 are equipped with built in D4591 Display Keypads and are therefore mounted in the user s
52. epressed Display SET POINT ON SETPT _ 0 ON SETPT 0_ ENTER OFF SETPT _ 0 OFF SETPT 0_ ENTER CH xx SETPT 4 8 PULSE TRAIN PROGRAMMING COMMAND The pulse train command is used to program a channel with set points of a fixed on and off duration through out the entire channel in one simple command To program a channel with a pulse train perform the following 1 Press the PULSE TRAIN key to initiate the pulse train programming command 2 The display will prompt ON DUR _ Enter the desired on duration in degrees and press ENTER 3 The display will now prompt OFF DUR _ Enter the desired off duration in degrees and press ENTER 4 The display will now prompt START POS _ Enter the location in degrees were the first on set point will start and press ENTER 5 The entire channel will now be programmed with the on and off duration through out the channel starting at the specified start location M4500 User s Manual SYSTEMS Electronics Group 25 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY Example 1 The following key sequence programs the selected channel as a pulse train with multiple set points of an on duration of 2 degrees and an off duration of 4 degrees starting at position 001 Key Depressed PULSE TRAIN 2 ENTER 4 ENTER 1 Display ON DUR _ ON DUR 2_ OFF DUR OFF DUR 4_ START POS
53. esolution 0 255 and are updated every main scan M4500 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 5 DISPLAY KEYPAD Two Display Keypads are available for the M4500 the D4590 which incorporates a 2 line X 20 character display and the D4591 which incorporates a 2 line X 40 character display Both displays incorporate a 24 key keypad which is arranged in 3 rows by 8 columns Back lighted LCD technology at 0 19 character height provides both high visibility in low light conditions and high character density To minimize space utilization the keypad display can be mounted to the back of the M4500 in cases where the M4500 would be door mounted The D4590 15 designed to mount to the back of the M4500 M4501 while the D4591 is designed to mount to the back of the M4508 M4509 Note If the display is not mounted to the back of the module either display can be used with either module The Display is equipped with a gasket and is fully sealed to prevent the ingress of contaminates to the display or M4500 The displays can be used as a general purpose operator interface or can be used to implement the PLS programming commands When used as a general purpose interface complete control of the display is provided through commands accessed through the user program in the PLC section Commands such as position cursor clear display enter characters into display blink character as well as an ASCII string conve
54. ess ENTER The compensation for the next channel will then displayed If speed compensation for a particular channel is not to be used enter 0 for the compensation for that channel If the compensation value for a particular channel is not to be changed simply press ENTER to continue M4500 User s Manual SYSTEMS Electronics Group 22 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY 7 The CONFIG command is now complete the display will return to showing the last channel and set point selected 4 6 SELECTING A NEW CHANNEL NUMBER To select a new channel number either to search for set points or to program perform the following 1 Press the SELECT CHAN key 2 The display will prompt ENTER CHAN _ Enter the new channel in octal and press the ENTER key Note Valid channel numbers are 00 thru 07 10 thru 17 20 thru 27 30 thru 37 etc Example 1 The following example sets the working channel to 01 Key Depressed Display SELECT CHAN ENTER CHAN 1 ENTER CHAN 1 ENTER CH 01 SETPT xxx 4 7 SINGLE SET POINT PROGRAMMING COMMAND The single set point command is used to enter a unique on set point in the currently selected channel This command programs the channel on from a user specified on position to a user specified off position Note Programming a new set point in a channel does not clear out any previous set points This allows multiple set points to be programmed in a c
55. f the slot while Outputs 10 through 17 are mapped in bits 0 through 7 of byte 1 of the slot INSTALLATION Prior to installing the 54573 the I O slot addressing dip switch on the board must be set for the slot the board will be addressed as Note Geographical addressing is not used in the M4500 The slot the S4573 is addressed as is solely defined by the dip switch settings on the 54573 itself not by the slot in the M4500 chassis that the board is placed in Two poles on the dip switch of the board set the binary slot address of the board as follows 4573 SW1 Dip Switch Slot Addressing 2 1 Slot Address off off 0 off on 1 on off 2 on on 3 The SW1 Slot address dip switch is located in the lower left hand corner of the component side of the 54573 The respective switch pole is on when in either the on or close position and off when either in the off or open position depending on the type of dip switch used M4500 User s Manual SYSTEMS Electronics Group APPENDIX A S4573 DIGITAL DC OUTPUT BOARD To install the S4573 in the M4500 chassis turn power to the M4500 off and remove the cover plate of the M4500 by loosening the captive screws that retain it Install the S4573 in the respective slot of the M4500 making sure the DIN connector on the 4573 fully mates with the DIN connector in the M4500 motherboard and that the top of the S4573 is seated correctly in the card guides at the top of the M4500 Install the M4500
56. facturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 2001 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 PLC Section PLS Section Interrupt Inputs Analog I O Display Keypad Serial Communications Board Digital I O Boards Diagnostics Fault Detection LED Status Indications ae IX IX ee 2 PLC Features 7 2 1 PLC Program Structure 7 2 2 Special Function Variables SFVs directly addressed 8 2 3 Special Function Variables SFVs indirectly addressed 10 2 4 Memory mapped I O 11 3 PLS Features 13 31 Standard PLS Features 13 3 1 1 Timing Channels 13 3 1 2 Scale Factor 13 3 1 3 Offset electronic zero 13 3 1 4 PLS Programs 14 3 15 Speed Compensation 14 3 2 Advanced PLS Features 15 3 3 PLS Programming 16 3 4 Implementing M4500 as a Stand Alone PLS 17 4 PLS Programming Using the Keypad Display ___ 19 4 1 Channel Set Point Programming Commands 19 4 2 PLS Configuration Parameters 19 43 PLS Key Definitions 20 4 4 PLS Display Fields 21 4 5 Setting the PLS Configuration 21 4 6 Selecting a New Channel Number 23 4 7 Single SET POINT Programming Command 23 4 8 PULSE TRAIN Programming Command 24 4 9 CLEAR CHANNEL Command 25 4 10 Searching recalling a Channel 25 M4500 User s Manual S
57. field displays the program mode either OFFLINE or ONLINE depending on whether the channel edit menu was invoked from the Offline or Online selection of the main development menu SET POINTS This a 10 row by 5 column 50 element array where the set points are entered using the various set point programming commands Note If the channel is not programmed as a pulse train PULSE TRAIN NO that up to 50 unique set points can be entered in the channel If the channel is programmed as a pulse train PULSE TRAIN YES up to the scale factor divided by two number of set points ON 1 OFF 1 can be programmed in the channel In this case only the first 50 set points would be displayed in the channel however the channel would be programmed through out with the on and off duration specified See section 5 4 for complete details on the set point programming commands If the channel is not programmed as a pulse train a large block cursor is placed in the ON field of the currently selected set point to be edited This cursor can be moved to any set point number using the cursor arrow left right up and down keys Whichever set point the block cursor is located at is the set point that the various set point programming commands will operate on If the channel is programmed as a pulse train the cursor will not be display at all The only commands which are valid once a channel is programmed as a pulse train are the F5 Pulse Train and F8
58. ge at the output is low approximately zero An output will source current to the load when on thus the outputs are defined as sourcing Each output is rated at 0 5 amp DC continuous with an inrush pulsed current drive capability of 3 amps for 100msec The sum of all outputs current cannot however exceed 6 amps continuous The S4568 does not contain output fusing therefore external fusing at each output point and at the user s Vcc connection point should be provided Each output contains a transient suppression circuit which clamps any transient over voltage to a level that will not damage the output circuitry This allows solenoids and other inductive loads to be connected directly to an output point without connecting fly back diodes or other surge suppression devices to the load itself Outputs may be collector OR d such that applying 10 30VDC to an off output will not damage the output The on off status of each output is indicated with individual LED s located on the front of the board The LED s provide the status of the actual output points field side rather than the internal logic status A given LED shows the correct status of the respective output point whether or not a load is connected to the output No minimum load is required for proper output operation Input output and user power wiring is implemented with a removable 18 pin field wiring connector which allows easy board replacement The 8 input points are rea
59. hannel If a channel is to be moved the channel must first be cleared and then re programmed using the SET POINT command To program a single set point perform the following 1 Press the SET POINT key to initiate the single set point programming command 2 The display will prompt ON SETPT _ Enter the position the set point is to turn on and press ENTER 3 The display will now prompt OFF SETPT _ Enter the position the set point is to turn off and press ENTER 4 The M4500 PLS will now program the channel on from the entered on position to the entered off position Note Any number of unique set points may be entered in a selected channel In addition the entire channel can be programmed on simply by specifying the on and off prompts with the same position M4500 User s Manual SYSTEMS Electronics Group 93 2 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY M4500 User s Manual SYSTEMS Electronics Group 24 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY Example 1 The following key sequence programs the currently selected channel on from 20 degrees to 40 degrees Key Depressed Display SET POINT ON SETPT _ 2 ON SETPT 2_ 0 ON SETPT 20_ ENTER OFF SETPT _ 4 OFF SETPT 4_ 0 OFF SETPT 40 ENTER CH xx SETPT 020 Example 2 This example programs the selected channel entirely on by entering 000 for both the on and off prompts Key D
60. hannels 00 through 07 Download Channels to PLS this allows channels edited in off line mode or previously uploaded channels to be downloaded to the M4500 module This feature allows quick replacement of an M4500 module by eliminating the need to reprogram the channel set points by hand Upload Channels from PLS uploads channel set points and configuration parameters from the M4500 module to disk files Print outs the set points of all channels as well as the PLS configuration can be printed out to provide hard copy documentation Refer to the SYSdev Programming Manual for details on installing SYSdev on the hard drive of your computer M4500 User s Manual SYSTEMS Electronics Group 29 SECTION 5 PLS PROGRAMMING USING SYSdev 5 2 PLS MENUS The following sections are a description of the various PLS menus of SY Sdev In general the PgUp PgDn Home End and cursor left right up and down keys all function as defined 5 2 1 MAIN DEVELOPMENT MENU 1 Online Channel Setpoint Programming This selection is used to edit the channel set points in an M4500 module directly To initiate the on line programming mode connect the COM port on the PC running SYSdev to the PROG port on the M4500 to be programmed Select 1 Online Channel Setpoint Programming The channel edit menu will be invoked and the existing channel set points in the M4500 will be uploaded and displayed in the menu See section 5 2 2 for a description
61. he serial network port conforms to the S3000 N1 network protocol This network is a high speed up to 344K BPS twisted pair serial network configured in a master slave topology Up to 32 M4500 S3000 or M4000 modules processors nodes can be connected on one network Communications between the nodes on the network is controlled via commands sfunc13 in the user application program resident in the node acting as the master USER PORT This port is available as a general purpose RS 232 RS 422 port accessed under software control of the user program Typical uses of this port are connection to other control equipment data acquisition to a host PLC etc Drivers are available for this port that implement the MODBUS protocol and the Allen Bradley DF1 protocol 1 7 DIGITAL I O BOARDS Digital I O boards are added to the M4500 by the user as required by the application All I O boards incorporate removable field wiring arms for ease of replacement I O slot addressing is implemented via dip switches on the I O boards Any mix of I O boards can be installed in an M4500 all input boards all output boards inputs and outputs etc 1 8 DIAGNOSTICS FAULT DETECTION The M4500 contains comprehensive fault detection routines which verify the proper operation of the module at all times Each detected fault has a corresponding fault code which can be viewed using SYSdev providing a description of the fault and recommended corrective action In addit
62. igital outputs One half of the board utilizes the circuitry of an 54563 10 30VDC input board while the other half utilizes the circuitry of an S4573 10 30VDC output board The Input section contains 8 identical solid state input circuits which accept the on off status of user devices such as push buttons limit switches and proximity sensors The inputs sense the voltage levels of digital DC input signals with the devices driving the inputs being defined as sourcing positive current into the input When the voltage at the input is high above the input on threshold the input is read as 1 When the input is low approximately zero the input is read as a 0 The on off status of each input is indicated with individual LED s located on the front of the board The LED s provide the status of the actual input points field side rather than the internal logic status M4500 User s Manual SYSTEMS Electronics Group APPENDIX A 4568 DIGITAL DC I O BOARD The output section contains 8 identical solid state circuits which convert the logic status of a byte written from the M4500 processor to the appropriate voltage in order to drive user devices such as solenoids relays and lamps On any given output point writing a 1 to the point turns the output on writing a 0 turns the output off When the output is on the voltage at the output is high approximately equal to the user s supply voltage When the output is off the volta
63. int for that channel by a time in milliseconds entered for that channel Thus as the speed increases the point at which the device is activated is advanced to compensate for the response time of the device Note The compensation parameter is entered in milliseconds not degrees per RPM which simplifies set up since the time that is be compensated for is in milliseconds The speed compensation feature is enabled with bit 1 in the System Enable Byte B161 When enabled the speed compensation for channels 00 through 07 can all be set independently to any value between 0 and 255 milliseconds If speed compensation for a particular channel is not to be used set the compensation value to 0 M4500 User s Manual SYSTEMS Electronics Group 4 SECTION 3 PLS FEATURES 3 2 ADVANCED PLS FEATURES The PLS is fully integrated with the PLC What this means is that the actual resolver position current RPM and every other PLS parameter can be accessed by the PLC section The PLC can even execute the PLS programming commands that would normally be executed through SY Sdev or the D4590 91 Display Keypad This allows virtually any PLS feature that can be dreamed of to be implemented Examples of this are Brake Wear Compensation The brake wear compensation algorithm is used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop With these presses a timing signal is used to de clutch the press for TD
64. ion the M4500 contains a fault interlock output 24 500mAMP sinking which can be interlocked to the control system for system shut down or annunciation when a fault is detected In addition to the fault detection a hardware confidence test is resident in the module to provide a complete test of the internal module hardware This test is initiated through SYSdev and can be used to verify the M4500 for proper operation M4500 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 9 LED STATUS INDICATIONS The following three status LED s are located on the front M4500 PWR RUN and FLT The definitions of these LED s are as follows PWR On when 5VDC power is applied to the M4500 RUN On steady when the M4500 is running a valid user s application program Off when an internal fault is detected or when a valid user s program has not been loaded The RUN led is flashed during program download and also when the hardware confidence test is executed FLT On when an internally detected fault has occurred in the M4500 See section 6 for more details on the fault routines and error codes M4500 User s Manual SYSTEMS Electronics Group SECTION 2 PLC FEATURES 2 1 PLC PROGRAM STRUCTURE The PLC section of the M4500 is programmed with SYSdev The SYSdev programming language is a combination of Ladder High level subset of C and Assembly MCS 96 All the files which comprise a SYSdev program are p
65. king sure the DIN connector on the 4568 fully mates with the DIN connector in the M4500 motherboard and that the top of the S4568 is seated correctly in the card guides at the top of the M4500 Install the M4500 cover back onto the M4500 making sure the LED s and Field connector protrude through the respective openings in the cover The M4500 cover will retain the 54568 both from the top and the front holding the S4568 in place during normal operation Tighten the captive screws that retain the cover on the M4500 Install the female field wiring connector to the corresponding male connector on the 4568 The 54568 is now installed and ready to run To remove the 54568 simply perform the previous steps in reverse M4500 User s Manual SYSTEMS Electronics Group APPENDIX A 4568 DIGITAL DC I O BOARD SPECIFICATIONS Board Size Length Height Width Number of Inputs Input Voltage Vin on min Vin on max Vin off min Input Current max Input Filter Delay typ delay min delay max delay Number of Outputs Output Voltage Voltage Range Vout on min Vout on max Vout off min Output Current lout on max continuous lout on max pulsed lout off max leakage Output Response Time max on time max off time Optical Isolation Power Requirements Icc typ M4500 BUS Temperature Ranges Storage Operating Relative Humidity M4500 User s Manual 6 50 4 25 0 80
66. lay body display and keypad with the bezel Now tighten the four screws M4500 User s Manual SYSTEMS Electronics Group 55 SECTION 8 INSTALLATION 8 1 2 MOUNTING THE KEYPAD DISPLAYS IN THE CABINET DOOR The D4590 and D4591 keypad displays are designed to mount from the front in the user s cabinet door Use the recommended cut outs in figures 8 2 and 8 3 for the D4590 and D4591 respectively Remove the ribbon cable from the D4590 91 With the gasket installed on the keypad display mounting studs slide the D4590 91 into the cut out from the front Attach the D4590 91 to the door with supplied hardware Install the 26 pin ribbon cable back in the D4590 91 connector the ribbon cable connector is polarized and will mate with the connector only one way Once the keypad display is installed a lugged earth ground wire should be installed on one of the mounting screws to insure that the keypad display is grounded M4500 User s Manual SYSTEMS Electronics Group 56 SECTION 8 INSTALLATION 2 REMOVE THESE FOUR SCREWS TO REMOVE BEZEL FROM D4590 C N o REMOVE THESE FOUR SCREWS TO REMOVE BEZEL FROM D4591 Figure 8 1 D4590 D4591 Keypad Display Bezel Removal M4500 User s Manual SYSTEMS Electronics Group 57 SECTION 8 INSTALLATION a i ES
67. lue For Single set point command B213 Channel to program set point W214 ON setpoint in degrees W216 OFF setpoint in degrees B218 Program state 0 off 1 on For Pulse Train command B213 Channel to program set point W214 START position in degrees B216 ON Duration B217 OFF Duration M4500 User s Manual SYSTEMS Electronics Group SECTION 2 PLC FEATURES 2 3 SPECIAL FUNCTION VARIABLES SFV s Indirectly addressed Address 2100H 2126H 2127H 2128H 2129H 212aH 212bH 212cH 212dH 2200H 2207H 2208H 220fH 2210H 2217H 2218H 221fH 2220H 2227H 2228H 222fH 2230H 2237H 2238H 223fH M4500 User s Manual Description Number of PLS Channels 8 16 32 64 CHO Speed Compensation active CH1 Speed Compensation active CH2 Speed Compensation active CH3 Speed Compensation active CH4 Speed Compensation active CH5 Speed Compensation active CH6 Speed Compensation active CH7 Speed Compensation active Speed Compensation array Speed Compensation array Speed Compensation array Speed Compensation array Speed Compensation array Speed Compensation array Speed Compensation array Speed Compensation array ON nnn 10 PLS program 0 PLS program 1 PLS program 2 PLS program 3 PLS program 4 PLS program 5 PLS program 6 PLS program 7 SYSTEMS Electronics Group SECTION 2 PLC FEATURES 2 4 MEMORY MAPPED I O X and Y variables are not supported in the M4500 Ins
68. mand is used to enter a unique on set point in a channel This command programs the channel on from a user specified on position to a user specified off position The pulse train command is used to program a channel with set points of a fixed on and off duration through out the entire channel The clear channel command is used to clear all set points from the currently selected channel 4 2 PLS CONFIGURATION PARAMETERS In addition to channel programming the keypad displays are used to set the M4500 PLS configuration This includes setting the PLS scale factor and offset select the PLS program and set the speed compensation for channels 00 through 07 M4500 User s Manual SYSTEMS Electronics Group 19 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY 4 3 PLS KEY DEFINITIONS The keypad displays contain a 24 key keypad with 10 numerical keys and 6 command keys The command keys are defined as follows SET POINT Used to enter single set points in the currently selected channel See section 4 7 PULSE TRAIN Used to program a channel with set points of a fixed on and off duration through out the entire channel See section 4 8 CLEAR CHAN Used to clear all set points from the currently selected channel CONFIG Used to set the PLS configuration parameters including the scale factor offset select the PLS program and set the speed compensation for channels 00 through 07 See section 4 5 SELECT CHA
69. mpt and select the user program currently loaded in the module 3 From the main menu select 6 Target Board Interface 4 From the Target Board Interface menu select 4 Target Board Fault Codes Status M4500 User s Manual SYSTEMS Electronics Group 43 SECTION 6 FAULT DETECTION The SY Sdev fault display reads the fault codes from the module and displays the following Target Board Internal Fault Code 1 Curr Fit 2 Last Fit 3 Co cpu slot 4 Corrective action Communications Network Error Codes 5 Current comm error 6 Last comm error Curr Fit This is the M4500 fault code corresponding to the current detected fault along with a short description of the fault This fault code is cleared at power up or optionally by the user after 1t is displayed in the SYSdev fault display Last Flt This is the last M4500 fault code detected shown just as the Curr Flt is shown Unlike the Curr Flt this fault code is not cleared at power up This field retains the last detected fault even when power to the module is cycled This fault code can only be cleared after it is displayed in the SYSdev fault display Co cpu slot Not used by the M4500 modules Corrective action This field contains a short description of the action which can be taken to correct the particular fault that was detected Current comm error This field displays the current serial network comm error along with a short description describing the error Thi
70. n loaded with BASICPLS the M4500 will simply perform as a programmable limit switch The timing channels can be programmed with either SYSdev or through the keypad of the D4590 91 All PLS features are enabled including speed compensation etc M4500 User s Manual SYSTEMS Electronics Group 17 SECTION 3 PLS FEATURES This Page Intentionally Left Blank M4500 User s Manual SYSTEMS Electronics Group 18 SECTION 4 PLS PROGRAMMING USING THE KEYPAD DISPLAY The D4590 and D4591 are keypad displays that can be used as general purpose operator interfaces as well as PLS programmers for the M4500 The PLS programming commands and menu displays are built in into the firmware of the M4500 and active when the display is not used as a general purpose operator interface When used as a PLS programmer the keypad displays are used to configure and program the timing channels of the M4500 The keypad displays incorporate a built in 2 line by 20 or 40 character alphanumeric display which displays command prompts set point data configuration data as well as the resolver position or speed RPM in real time Of the 24 keys of the keypad 18 of the keys are used to select the PLS programming commands and enter data 4 1 CHANNEL SET POINT PROGRAMMING COMMANDS Three channel set point programming commands are available with the keypad displays single set point programming pulse train programming and clear channel The single set point com
71. nfiguration menu is automatically activated This selection allows the user to modify the system configuration at any time M4500 User s Manual SYSTEMS Electronics Group 30 SECTION 5 PLS PROGRAMMING USING SYSdev 4 Download Channels to PLS This selection downloads both the PLS configuration and channel data files for the selected program to the M4500 module To download the data to the M4500 perform the following Note Each channel is cleared prior to downloading the set points for that channel thus machine operation should be ceased prior to initiating the download 1 2 With both the PC running SYSdev and the M4500 powered up connect the COM port on the PC to the PROG port on the M4500 using the appropriate RS 232 cable Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the download press ESC otherwise press any key to start the download While the download is in progress the channel number which is currently being downloaded will be displayed Once all channels are downloaded a dump complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu If the computer was unable to initiate the download to the M4500 a message stating this will be displayed Verify the RS 232 cable connections between the COM port on the computer and the PROG port on the M4500 Press any key to return to th
72. ny way desired M4500 User s Manual SYSTEMS Electronics Group 13 SECTION 3 PLS FEATURES 3 1 4 PLS PROGRAMS The PLS supports up to 8 PLS programs A typical application of using multiple PLS programs would be in stamping press applications where different die sets would be used for different stampings The timing signals for each die set up to 8 different die sets would be programmed and saved in a specific PLS program and then as the different die sets were used the specific PLS program would be called up and used for that die set saving the operator from having to re program all the timing signals every time that die set was used The number of PLS programs which can be used is a function of the number of channels used and the scale factor used The matrix below outlines how many PLS programs are available as a function of the scale factor and number of channels The numbers in the matrix are the number of PLS programs available An indicates an invalid scale factor number of channels combination Number of Channels Scale Factor 8 16 32 64 0 511 8 4 2 1 512 1023 4 2 1 t 1024 2047 2 1 di y 2048 4096 1 id d 3 1 5 SPEED COMPENSATION Speed Compensation is available for timing channels 0 through 7 This is used to compensate for the mechanical response time of a device activated by a particular timing channel The speed compensation algorithm causes the timing channel to lead the programmed timing set po
73. oblem persists replace the 84516 in the slave M4500 module where the problem is occurring Next replace the 84516 in the M4500 master module M4500 User s Manual SYSTEMS Electronics Group 48 SECTION 6 FAULT DETECTION 6 4 3 SERIAL NETWORK INTEGRITY ERROR 03H 06H 0EH 10H The serial network integrity errors occur when corruption of the transmitted frame is detected The sources of these errors range from multiple masters attempting communications on the network to excessive induced EMI on the network Trouble Shooting 1 Verify that only one master is communicating on the network The master is defined as the node which is executing the sfunc13 system functions If two nodes are executing sfunc13s simultaneously a network collision will occur with the corresponding corruption of data 2 Verify that the network wiring is isolated from other high voltage wiring which could induce EMI into the network The network should be routed in a conduit separate from other wiring 3 Replace the 84516 in the slave M4500 module with which the error occurred If the problem persists replace the 84516 in the M4500 module at the master node 6 4 4 ADDRESS OUTSIDE RANGE 0FH This error occurs when an attempt to write to memory outside the data memory range occurs in either the master or slave Verify the corresponding sfunc13 call specifies the proper data range M4500 User s Manual SYSTEMS Electronics Group 49 SECTION 6
74. ogram name using the MS DOS conventions for directory and file names Do not enter an extension with the program name This copies all the files associated with the program to the different directory and program name This selection can be used to copy the current name to another drive and directory when the program name entered is the same as the current program name This is also used to copy the program to a new program name For instance when one program is similar to another completed program simply copy the old program to the new program name and edit as required M4500 User s Manual SYSTEMS Electronics Group 33 SECTION 5 PLS PROGRAMMING USING SYSdev 5 2 2 CHANNEL EDIT MENU This menu is invoked for both off line and on line programming and provides a mechanism to enter and edit the set points for the channels The menu contains both information fields and function key commands The information fields are defined as follows CHANNEL This is the number in octal of the currently selected and displayed channel When the channel edit menu is initially invoked channel number 00 is selected and displayed The F1 Next Chan F2 Prev Chan and F3 Select Chan commands are used to select a different channel number DESCRIPTION This field contains the user entered description or channel name which is associated with the channel number The F4 Doc Chan command is used to enter or edit this description PROG MODE This
75. on the M4500 module It may be desirable to remove the suspect module from the system and to install another module to get the application being controlled back up and running See section 7 for details on the test 2 Based on the results of this test return the module for repair or re install the module in system 6 4 SERIAL NETWORK COMMUNICATION ERRORS The serial network communications occur in conjunction with the network port on the optional S4516 Communications board Unlike the system faults the serial network communication errors do not cause the M4500 module to shut down but instead are simply logged into the Current and Last comm error registers with user program execution continuing The Current comm error represents an error that is present at the time the fault codes are viewed while the Last comm error represents the last comm error detected The comm error codes are viewed from the SYSdev fault display see section 6 2 for more details The error codes saved in the Current and Last comm error registers are the same error codes returned from the sfunc13 call The return values from the sfunc13 calls should be saved in separate B variables such that when a comm error occurs the slave that it occurred with can be determined M4500 User s Manual SYSTEMS Electronics Group 47 SECTION 6 FAULT DETECTION 6 4 1 SERIAL NETWORK COMM ERROR CODES The following is a list of the detected serial network communication er
76. pability of 3 amps for 100msec The sum of all outputs current cannot however exceed 6 amps continuous The S4573 does not contain output fusing therefore external fusing at each output point and at the user s Vcc connection point should be provided Each output contains a transient suppression circuit which clamps any transient over voltage to a level that will not damage the output circuitry This allows solenoids and other inductive loads to be connected directly to an output point without connecting fly back diodes or other surge suppression devices to the load itself Outputs may be collector OR d such that applying 10 30VDC to an off output will not damage the output M4500 User s Manual SYSTEMS Electronics Group APPENDIX A S4573 DIGITAL DC OUTPUT BOARD The on off status of each output is indicated with individual LED s located on the front of the board The LED s provide the status of the actual output points field side rather than the internal logic status A given LED shows the correct status of the respective output point whether or not a load is connected to the output No minimum load is required for proper output operation Output and user power wiring is implemented with a removable 18 pin field wiring connector which allows easy board replacement The 16 output points are mapped in the two least significant bytes of the slot that the board is addressed as Outputs 0 through 7 are mapped in bits 0 through 7 of byte 0 o
77. ps where the exit condition of the loop can never be satisfied This can occur in for while and do while loops Also check for any goto jumps that cause the program to jump to a previous location in the program with no condition to stop executing the jump 2 Check for any loop instructions that may take longer than 50 milliseconds to execute a large number of iterations through the loop 3 Ifthe problem persists try another M4500 module to verify if a hardware problem exists M4500 User s Manual SYSTEMS Electronics Group 45 SECTION 6 FAULT DETECTION 6 3 2 IBM PC TO M4500 COMMUNICATIONS FAILURE 42H If an attempt to read the fault codes from the M4500 module results in an error code of 42H Cannot communicate with target board the PC cannot communicate with the module This is not an internal M4500 fault but instead a fault detected by SY Sdev The cause of this fault ranges from catastrophic failure of the module to a misconnection of the PC to the module Trouble Shooting 1 Verify the PWR LED on the module is on If not verify that 5VDC power is applied to the module 2 Verify that the RS 232 cable is connected to the proper COM port on the PC and PROG port on the module 3 Verify that the RS 232 cable connecting the PC to the module is wired correctly See appendix B for the pin out of the cable 4 Ifthe above verifies replace the M4500 module and try again If the problem still persists
78. r should be set to 360 To change the scale factor enter the new scale factor and press ENTER To continue without changing the scale factor simply press ENTER CAUTION Changing the scale factor after timing channels have been previously programmed will result in invalid set points It is recommended that all timing channels be re programmed after setting the scale factor The display will now read NUMBER CHANNELS xx where xx is the currently specified number of channels The M4500 PLS supports either 8 16 32 or 64 timing channels Enter the number of channels to be used 8 16 32 or 64 and press ENTER If the number of channels are not to be changed simply press ENTER to continue The last set of configuration parameters that will be prompted for are the speed compensation presets for channels 00 through 07 Each of these channels can be programmed to have from 0 to 255 milliseconds of timing signal lead see section 3 1 5 The values entered for the speed compensation are in milliseconds This is the amount of time that the timing signal will lead the programmed timing set point as the speed of the machine is varied The speed compensation for each channel is independently set The display will prompt CHxx SPEED COMP yyy where xx is the channel 00 to 07 and yyy is the currently programmed speed compensation in milliseconds for that channel To change the compensation value enter the new number from 0 to 255 and pr
79. rm the following steps Power up the M4500 module to be tested Power up PC and enter SYSdev Enter any user program name to proceed to the SYSdev Main Development Menu Connect Interface cable to the COM port on the PC and PROG port on module Select 6 Target Board Interface from the Main Development Menu then select 7 Target Board Hardware Confidence Test from the Target Board Interface menu Select M4500 Confidence test from the confidence test menu A prompt will be displayed verifying to proceed with the test Note Proceeding with the test will clear the program and data memory in the module The user application program will have to be re downloaded to the module once the test is complete Press ESC to abort the test any other key to proceed Select Perform Test from the Test Functions Menu to start the test Once the test is initiated all tests enabled will be executed repeatedly starting with test1 thru the last enabled test until any key is depressed If no faults are detected the tests will continue to execute repeatedly displaying test passed messages after the successful completion of each test If a fault does occur the test will stop and display the following Fault Code XX test fault code and description Address of fault memory address or I O address where fault occurred Actual data at fault data actually obtained at address of fault Expected data at fault data that should have b
80. rogrammed in the same language format Each file can be written in any combination of the language types The typical M4500 PLC program consists of the following files 1 Initialization file optional executed once at power up POWER UP 2 Main Program file required scanned continuously TIMED 3 Timed Interrupt file optional executed once every 0 250 INTERRUPT to 65 000 milliseconds as set by the user 4 User Function file optional up to 100 user defined subroutines which can be called from any of the above files 5 Input Interrupts optional the two input interrupts can be enabled or disabled independently When the interrupts are enabled InputO interrupt calls ufunc00 when activated off to on transition of inputO while input1 interrupt calls ufuncO1 Note ufunc00 must be created by the user if the inputO interrupt is enabled and ufunc01 if the input1 interrupt is enabled Each file is executed sequentially from beginning to end The main program file is executed scanned continuously unless interrupted by the timed interrupt or either of the input interrupts When this occurs main program execution is suspended while the interrupt file is executed At the completion of the interrupt program execution resumes at the point in the main program where the interrupt occurred Each file is implemented as a series of consecutive blocks Each block is defined as one of the three programming languages Ladder High
81. rors Code Description 00H No network comm error 03H More than one bus master detected 04H sfunc13 xmitt timeout no response 05H sfunc13 receive timeout no response 06H Invalid command received from master 07H Receive overflow 08H Receive collision detected 09H Receive alignment error bad frame OAH Receive CRC error OBH Unknown undefined error OCH Transmit no acknowledge Transmit under run error Transmit collision detected OFH Address error outside data memory 10H Unexpected slave responding 6 4 2 NO RESPONSE FROM SLAVE 04H and 05H The no response errors occur when the master executes an sfunc13 addressed to a particular slave but receives no response from that slave For every execution of sfunc13 the slave will always respond to the request even if no data is to be sent from the slave to the master This verifies that the slave did in fact receive the data sent to it Trouble Shooting 1 Verify that the network continuity is good between the master and the slave This can be done by observing the COMM LED s on the network interface boards Every time sfunc13 is executed the COMM LED s will flash or be on solid for continuous communications 2 Verify that the master and all slaves on the network are set to the correct network address they have been assigned For each node on the network the address must be a number between 1 and 32 and must be unique See section 8 8 2 3 Ifthe pr
82. rsion system function allow easy and complete control of the display directly in the M4500 user s program The PLS program commands are resident in the firmware of the M4500 and can either be enabled or disabled in the user s program The keypads are 3 row by 8 column sealed keypads which can either be used as a general purpose operator interface or to implement the PLS programming commands Key depressed decode is performed automatically by the M4500 with the key number depressed mapped directly to an internal memory location of the M4500 The keypad overlay itself simply contains clear windows over the keys Customization of the keypad is performed by placing a placard behind the overlay between the overlay and the keys with the desired key legends The keys on the D4590 display keypad are spaced at 0 5 while the keys on the D4591 are spaced at 0 75 spacing The D4591 Display Keypad is built directly into the M4502 and M4503 modules M4500 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 SERIAL COMMUNICATIONS BOARD Serial communications to other equipment is implemented with the S4516 Serial Communications board The S4516 contains one S3000 serial network interface port and one RS 232 RS 422 User port Multiple S4516 boards can be installed in one M4500 up to the number of slots for that particular model to allow the use of multiple S3000 network ports or RS 232 RS 422 User ports SERIAL NETWORK PORT T
83. s can be installed in one M4500 up to the number of slots for that particular model to allow the use of multiple S3000 network ports or RS 232 RS 422 User ports The serial network port conforms to the S3000 N1 network protocol This network is a high speed up to 344K BPS twisted pair serial network configured in a master slave topology Up to 32 M4500 S3000 or M4000 modules processors nodes can be connected on one network Communications between the nodes on the network is controlled via commands sfunc 13 in the user application program resident in the node acting as the master The serial network baud rate is software configurable via the user s program in the M4500 for either 106KBPS 229KBPS or 344KBPS M4500 User s Manual SYSTEMS Electronics Group APPENDIX A S4516 SERIAL COMMUNICATIONS BOARD The USER port is available as a general purpose RS 232 RS 422 port accessed under software control of the user program Typical uses of this port are connection to other control equipment data acquisition to a host PLC etc Drivers are available for this port that implement the MODBUS protocol and the Allen Bradley DF1 protocol The USER port is dip switch selectable for either RS 232 mode or RS 422 mode The USER port supports a frame format consisting of 1 start bit 8 data bits 1 stop bit and no parity An addition the baud rate is software configurable via the user s program in the M4500 for either 9600 Baud or 19 2K Baud A
84. s field is cleared as soon as the current comm error clears Last comm error This field displays the last error displayed in the Current comm error field Unlike the Current comm error this field retains the error code even after the error condition clears This provides a history of the last comm error to occur The user has the option of clearing the fault codes when exiting the SYSdev fault display M4500 User s Manual SYSTEMS Electronics Group 44 SECTION 6 FAULT DETECTION 6 3 FAULT CODES The following is a list of the fault codes and descriptions as displayed in the SYSdev fault display detected by the M4500 modules Code Description 00H No internal fault has occurred 40H Watchdog timer timeout 42H Cannot communicate with target board 44H Program memory checksum error 45H User program system fault sfuncO9 call 59H Program execution out of bounds 5 Address out of program memory range 5BH Invalid interrupt 5CH Program invalid execution suspended 5DH Program dump timeout program not sent 6 3 1 WATCHDOG TIMER TIMEOUT 40H The watchdog timeout fault occurs when the main program scan time exceeds 50 milliseconds The cause of this fault ranges from an error in the user program unintentional loop entered in the user program unintentional indirect access to program memory to a hardware failure of the M4500 module Trouble Shooting 1 Check the program for any unintentional loops These are loo
85. s up a sub menu with the following choices 1 Back up Program This allows the current program to be backed up on a diskette in drive A Install the back up diskette in drive and press any key when ready This copies all the files associated with the program to the root directory of the A drive Note The files will be stored at the root directory of the diskette not within a sub directory This selection provides a convenient way to back up your program Restore Program This copies the current program name from the root directory of the A drive to the drive and directory specified with the current program name Install the diskette with the program on it in the A drive and press any key when ready This copies all the files associated with the program name on the A drive to the path specified with the program name Note The program files on the diskette in drive A must be at the root directory This selection along with the back up selection above provides a convenient way to copy programs from one computer to another Make new directory This provides a way to make a new user program directory while inside SYSdev Enter the drive and directory name following the MS DOS conventions of directory names Copy program to another program name This provides a way to copy the current program name to any disk and directory while also allowing the user to copy to a different program name Enter the drive directory and new pr
86. se train See section 5 4 for details F6 Fine Tune Used to fine tune increment or decrement the selected set point See section 5 4 for details M4500 User s Manual SYSTEMS Electronics Group 35 SECTION 5 PLS PROGRAMMING USING SYSdev M4500 User s Manual SYSTEMS Electronics Group 36 SECTION 5 PLS PROGRAMMING USING SYSdev F7 Clear SetPnt Clears the currently selected set point set point designated with cursor No other set points are affected by this command F8 Clear Chan Clears all the set points in the channel Also used to clear the channel and reset the pulse train mode to no when a channel has been programmed as a pulse train F9 POS RPM Active only in the on line mode Used to display the current resolver angular position and RPM When pressed a prompt in the message field will display both the position and RPM This data is updated continuously To exit the position and RPM display simply press lt ESC gt F10 Set Offset Used primarily in the on line mode to electronically zero the resolver shaft at the machine zero To set the offset locate the machine at machine zero Read the resolver shaft position select F10 Set Offset and enter the position read into the offset field The actual offset number required to make this the zero position will than be calculated by SYSdev and downloaded to the M4500 The actual offset which may not equal the entered position will be displayed in the offse
87. se train of a fixed on and off duration through out M4500 User s Manual SYSTEMS Electronics Group 38 SECTION 5 PLS PROGRAMMING USING SYSdev 5 4 1 SINGLE SET POINT PROGRAMMING COMMAND The single set point command is used to enter unique set points in a channel when that channel is not programmed as a pulse train PULSE TRAIN NO Note When the channel is programmed as a pulse train the single set point command cannot be used to modify individual set points in the channel To program a single set point locate the set point cursor large block cursor at the set point to be modified the large cursor will always be located in the on parameter of the set point Enter the set point as follows 2 Press Enter lt CR gt or to enter the on parameter 3 Type in off parameter in degrees 4 Press Enter lt CR gt to enter the off parameter Type in on parameter in degrees cursor will change to the small data entry cursor 5 The cursor will change back to the large set point cursor and automatically advance to the on parameter of the next set point The set point has now been entered 6 Ifan invalid set point number is entered a message stating this will be displayed in the message field of the channel edit menu Re enter a proper set point value or press ESC to abort the set point entry Note The set point values entered must be less than the scale factor Set points are also not
88. sy board replacement The 16 input points are read in the two least significant bytes of the slot that the board is addressed as Inputs 0 through 7 are mapped in bits 0 through 7 of byte 0 of the slot while inputs 10 through 17 are mapped in bits O through 7 of byte 1 of the slot M4500 User s Manual SYSTEMS Electronics Group 7 APPENDIX A S4563 DIGITAL DC INPUT BOARD INSTALLATION Prior to installing the S4563 the I O slot addressing dip switch on the board must be set for the slot the board will be addressed as Note Geographical addressing is not used in the M4500 The slot the S4563 is addressed as is solely defined by the dip switch settings on the S4563 itself not by the slot in the M4500 chassis that the board is placed in Two poles on the dip switch of the board set the binary slot address of the board as follows 4563 SW1 Dip Switch Slot Addressing 2 1 Slot Address off off 0 off on 1 on off 2 on on 3 The SWI Slot address dip switch is located in the lower left hand corner of the component side of the S4563 The respective switch pole is on when in either the on or close position and off when either in the off or open position depending on the type of dip switch used To install the S4563 in the M4500 chassis turn power to the M4500 off and remove the cover plate of the M4500 by loosening the captive screws that retain it Install the 54563 in the respective slot of the M4500 making sure the DI
89. t field and the M4500 will then display zero as the position Alternatively the resolver can be zeroed simply by entering the number 0 for the offset The M4500 PLS contains an auto zero algorithm which will calculate the offset required to make the current position zero 5 3 PLS CONFIGURATION The PLS configuration is used to define the following PLS parameters in the M4500 PLS program selected scale factor number of PLS channels and speed compensation for channels 00 through 07 The parameters are all set through the Edit PLS Configuration menu selection 5 3 1 PLS PROGRAM The M4500 supports up to 8 PLS programs These can be called up by the user and mapped to the active timing channels From SYSdev s point of view each PLS program is one SYSdev PLS file Thus if an M4500 was to be loaded with multiple PLS programs to be used multiple files would be created saved on disk and down loaded to the M4500 This selection simply specifies which PLS program the currently selected file is If the M4500 is to use only one PLS program as is generally the case PLS PROGRAM should be set to 0 See section 3 1 4 for details on PLS programs M4500 User s Manual SYSTEMS Electronics Group 37 SECTION 5 PLS PROGRAMMING USING SYSdev 5 3 2 SCALE FACTOR The scale factor is the desired number of divisions per revolution This is programmable from 2 to 4096 For 360 degrees per revolution the scale factor should be set to 360
90. tead the I O slots of the chassis are mapped into the memory space of the M4500 accessed as Byte B variables The addresses of the different slots are assigned as follows Group Slot Byte Address 0 0 0 B7424 1 B7425 2 B7426 3 B7427 0 1 0 B7488 1 B7489 2 B7490 3 B7491 0 2 0 B7552 1 B7553 2 B7554 3 B7555 0 3 0 B7616 1 B7617 2 B7618 3 B7619 1 0 0 B7680 1 B7681 2 B7682 3 B7683 1 1 0 B7744 1 B7745 2 B7746 3 B7747 1 2 0 B7808 1 B7809 2 B7810 3 B7811 1 3 0 B7872 1 B7873 2 B7874 3 B7875 M4500 User s Manual SYSTEMS Electronics Group 1 SECTION 2 PLC FEATURES Unlike the S3000 and M4000 the M4500 does not automatically perform the I O update at the beginning of the program The I O update on the M4500 is performed by the user s program Internal Byte B variables serve as the I O image Input boards are read and stored in the input image B bytes while output image B bytes are used to store the value of the outputs and then are written to the outputs See the M4500 Program Development Manual for more details M4500 User s Manual SYSTEMS Electronics Group 12 SECTION 3 PLS FEATURES 3 1 STANDARD PLS FEATURES The following are the standard PLS features built into the M4500 firmware These features are available independent of the user s PLC application program 3 1 1 TIMING CHANNELS The M4500 is configurable for 8 16 32 or 64 timing channels These are mapped to internal memory locations of the
91. ted to provide the greatest degree of flexibility in accessing the I O boards Programming of the PLC section is implemented with SYSdev an IBM PC or compatible software package that allows the user to create document and compile the user logic program as well as directly interface to the M4500 for program down load and on line monitoring Complete program printouts including the user program listing cross reference and memory map can also be generated 1 2 PLS SECTION The PLS section is a high speed programmable limit or cam switch which accepts angular position information in the form of resolver format signals and converts these to digital The M4500 is configurable for 8 16 32 or 64 timing channels These are mapped to internal memory locations of the M4500 for use by the PLC section or can be written to output boards for use in general PLS applications The timing channels can be programmed on and off at user defined position set points Each timing channel can be programmed with up to 50 unique on off set points or with a pulse train of fixed on and off divisions throughout the entire channel The scale factor of the PLS is programmable from 2 to 4096 divisions per revolution while the offset is programmable from 0 to one minus the scale factor The PLS supports up to 8 PLS programs when 8 timing channels are used and the scale factor is less than 512 less PLS programs when more channels are used or the scale factor is gre
92. the channel is programmed as a pulse train M4500 User s Manual SYSTEMS Electronics Group 4 SECTION 6 FAULT DETECTION The M4500 modules contain comprehensive fault detection routines which verify the proper operation of the module at all times If the module detects a fault condition the FLT LED on the front of the module is illuminated and the fault routine is executed The sources of these faults range from a hardware failure of the module to an error in the user s program infinite loop etc 6 1 FAULT ROUTINE EXECUTION When a fault is detected the following fault routine is executed User program execution is suspended If possible all outputs in the system are disabled FLT LED on the front of the module is illuminated RUN LED is extinguished Fault interlock is opened Fault code representing the detected fault is saved in internal memory of the module for viewing with SYSdev The first step in correcting a fault condition FLT LED in M4500 module is viewing the fault code saved inside the module with SY Sdev 6 2 VIEWING FAULT CODES WITH SYSDEV When a fault occurs an IBM PC or compatible running SYSdev can be connected to the PROG port of the module to view the fault codes To view the fault codes perform the following 1 Connect PC COM port to M4500 PROG port using the appropriate cable see appendix B 2 Initiate SYSdev from the DOS pro
93. the pulse train Starting location of the pulse train The Channel will be programmed through out with the on and off durations starting at the Start location The function key commands of the channel edit menu are defined as follows F1 Next Chan Selects the next highest numbered channel for editing When selected the channel number will increment by one and the set points and data for that channel will be displayed The PgDn key also performs the same function as the F1 Next Chan key F2 Prev Chan Selects the next lowest numbered channel for editing When selected the channel number will decrement by one and the set points and data for that channel will be displayed The PgUp key also performs the same function as the F2 Prev Chan key F3 Select Chan Used to select any channel number for editing When selected the current channel number will be cleared and the cursor will be placed in the CHANNEL field Simply type in the desired channel number in octal and press Enter lt CR gt to accept The set points and data for that channel will then be displayed F4 Doc Chan Used to enter the channel description or name in the DESCRIPTION field This is a user definition of the channel and will be associated with the channel at all times print outs etc Up to 20 printable characters can be entered in this field Once the name is entered press Enter lt CR gt to accept F5 Pulse Train Used to program the channel as a pul
94. to the M4502 and M4503 The Serial Communication board is available for communications with other S3000 M4000 products or with other manufactures PLC or host computers A typical M4500 system consists of the PLC Processor Chassis M4500 M4509 Power Supply P4500 digital I O boards S45XX as required Serial Communications boards S4516 as required and optional Display Keypad D4590 or D4591 The M4502 and M4503 contain a built in power supply and the D4591 Display Keypad 1 1 PLC SECTION The PLC section of the M4500 is a high performance programmable logic controller which incorporates a built in processor user program memory user data memory RS 232 programming port interface to the Display Keypad and interface to the I O slots motherboard The scan time of the PLC section is on the order of 0 25 milliseconds per K with scan times as low as 80 microseconds for short programs Two additional interrupt inputs allow through puts even less than 80 microseconds Program memory consists of 32K bytes of battery backed CMOS RAM memory Data memory consists of 8K bytes RAM memory M4500 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION The PLC section supports addressing of up to 12 I O slots Note Geographical addressing is not used The slot addresses are specified by dip switches on the I O board themselves The PLC section is capable of addressing up to 64 bytes at each slot Memory mapped I O is incorpora
95. tpnt or Off Setpnt commands by one F4 Dec This command decrements the selected parameter either on or off whichever was selected with the On Setpnt or Off Setpnt commands by one The fine tune command is primarily used in on line mode to fine tune set points while the machine is in operation M4500 User s Manual SYSTEMS Electronics Group 40 SECTION 5 PLS PROGRAMMING USING SYSdev 5 4 3 PULSE TRAIN COMMAND The pulse train command is used to program a channel with a fixed on and off duration through out the entire channel in one simple command To program a channel with a pulse train perform the following 1 Select F5 Pulse Train from the channel edit menu 2 The cursor is located in the ON field of the channel edit menu Enter the on duration in degrees and press Enter lt CR gt 3 The cursor is located in the OFF field of the channel edit menu Enter the off duration in degrees and press Enter lt CR gt 4 The cursor is now located in the START field Enter the location that the pulse train will be initially started at in degrees and press Enter lt CR gt 5 The entire channel will be programmed with the on and off duration through out the entire channel starting at the start location The first 50 set points or less will be displayed in the set point array Note The set point cursor will not be displayed since the single set point and fine tune commands are not valid if
96. two 10 30VDC differential interrupt inputs The inputs are 10 30VDC differential inputs which can be enabled as interrupt inputs or disabled and used as standard inputs When enabled as interrupts an off to on transition of the enabled input activates an interrupt call to a user programmed file ufunc00 for inputO and ufuncO1 for inputl This suspends the main program file until the interrupt file execution is completed at which time program execution resumes at the place in the main file where the interrupt occurs This mechanism allows ultra fast through puts to be implemented if required The interrupt inputs are true differential inputs which can be wired as either sinking true low or sourcing true high depending on the device used to drive the input Individual LED status indication is provided for each input 1 4 ANALOG I O Two analog inputs and two analog outputs are built into the M4500 The analog inputs are 0 5 volt which can also be used as 0 20ma and 0 10 volt inputs when external resistors are installed to perform the respective conversion 250ohm for 0 20ma two resistors as a voltage divider for 0 10VDC The analog outputs are 0 10 volt which can also be used to drive 0 5 volt inputs using a similar external resistor conversion The analog inputs are of 10 bit resolution 0 1023 incorporating high speed conversion less than 25 microsecond and are updated once every other main scan The analog outputs are of 8 bit r

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