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User Manual - Rockwell Automation

1. 4 Type the number of steps to be directed by the SDS instruction and press ENTER The system prompts you for the number of I O you are using Valid number of I O are 8 16 or 32 5 Type the number of I O you are using and press ENTER The system prompts you for the Program File number The program file number refers to the program file number of the SDS file in the online or offline program directory 6 Type the Program File number and press ENTER The I O Definition screen is displayed If you have a PLC 5 processor continue with Entering or Modifying I O Information on page 4 14 In the PLC 5 250 processor the system prompts you for the Message Control Block address 4 13 Chapter 4 Configuring SDS Instructions 7 If you have a PLC 5 250 processor type the Message Control Block address and press ENTER The Message Control Block address must be entered in the following manner OMSGX X where is the Resource Manager global memory must be set to zero XIX message control block number 0 9999 file number 0 9999 For example OMSG0 0 is a valid message control block address The I O Definition screen is displayed see below Entering or Modifying I O Information The inputs and outputs you enter into the I O Defines on the I O Definition screen are used by each step in the SDS instruction You can enter logical addresses and symbols into the I O Definition screen The fol
2. Extended Status Using I O Monitor The I O Monitor screen shows all inputs and outputs in the SDS instruction and inputs in the DFA instruction and the current status of each With the I O Monitor screen you can determine if inputs and outputs are actuating properly For example if the I O monitor screen says the forward motor is on but on the machine the motor is not activated check for a problem with your motor Likewise if the motor is supposed to go on and the output shows that the motor is off check your software for a problem 8 5 Chapter 8 Debugging Your DDMC 32 System To access the I O Monitor screen press F8 I O Monitor on the Step Directory of an SDS instruction or F5 Input Monitor on the Input Message screen of a DFA instruction The figure below shows the I O Monitor screen for the drill machine station 1 0 Monitor screen for Drill Machine Station SDS Instruction a I O MONITOR FOR DRILL MACHINE HEAD 1 N Input ID State No Output ID State o O 1 001 16 OFF O0 0 000 04 OFF 1 1 001 15 OFF 1 0 000 01 OFF 2 1 001 14 OFF 2 0 000 02 OFF 3 B3 2 OFF 4 B3 3 OFF Press a function key Program edit mode Current Step 0 PLC 5 12 Addr 4 Change Display Step Input Extnded Step Mode Comment History History Status Dirctry F1 F2 F4 F5 F6 F8 You can perform the following tasks from the I O Monitor screen If you want to Press this key Change between remote run program mod
3. 7 Press F10 Accept Rung Important You must accept the rung to save the information you entered into the SDS instruction Documenting the SDS The SDS instruction provides a documentation function that lets you describe Instruction the instruction and its associated addresses The documentation function also lets you assign symbols to addresses To document your SDS Press F5 Documnt from the I O Definition screen The system displays the SDS Instruction Documentation screen SDS Instruction Documentation Screen PLC 5 Smart Directed Sequencer I O Input Defines Output Defines Definition for Control Block 1 001 16 0 000 04 0 0 N10 0 Te Tr0p1715 1 0 000 01 2 I 001 14 2 0 000 02 3 B3 2 3 Ins Cmt Adr Cmt 4 B3 3 4 DRILL RETURNED L oe 5 MACHINE IS 6 6 HEAD 1 l TE 7 qaen Operator Interface Station Addr 77 Timebase for Step Timer z 0 01 Press a function key Program Forces None Data Decimal Addr Decimal PLC 5 25 Addr 1 Instr Address Modify Remove Display Save amp Comment Comment Symbol Symbol Symbol Contnue F2 F3 F6 F7 F9 F10 4 18 Chapter 4 Configuring SDS Instructions From SDS Instruction Definition screen you can perform the following documentation tasks If you want to Activate the cursor in the instruction F2 comment window and display the Instruction Comment E ditor Activate the cursor in the address comment
4. You can also use the NOT function although it is not as true an operand as the AND function is The NOT function is concerned with input state only This allows complex combinations or mechanisms that are not easily defined by individual state transitions to be accommodated more easily within the SDS framework with a minimum number of steps See the next page for an example of what is meant by combinatorial equations 4 3 Chapter 4 Configuring SDS Instructions Graphic Example of Combinatorial Equations LS2 ON AND LS1 ON LS3 OFF AND LS1 OFF LS2 OFF AND LS3 ON With traditional state based programming you need to take into account all of the probable states for the implementation The number of possible states is 2 to the nth power where n is the number of inputs The SDS instruction that uses combinatorial equations eliminates this need to account for all possible input states and provides a means to enter Boolean expressions similar to ladder logic In this case the SDS instruction will not advance to another step until all conditions defined in an equation are fulfilled regardless of their order or timing relationship with each other Using the SDS instruction in combinatorial mode also allows you to replace external ladder logic By using combinatorial equations in the SDS instruction you can get diagnostic information on the logical conditions not yet fulfilled This feature can be useful in generating operator gu
5. Copy DDMC32 Database From oo Browse To Cancel Browse e 6 3 Chapter 6 Creating and Updating the Message Database When you select a database you can also choose how many days of fault log data to keep If you have Auto Purging enabled fault log data will automatically be purged based on the value entered For all of the above screens you can type in the database name or click on Browse to find the required database Click on OK when complete and continue with your next function Deleting a Message Database 1 To delete a message database select Delete Message Database from the Database menu The Delete Database Selection screen appears Delete Database Selection Screen Delete DDMC32 Database Current Database DDMC32 Done Delete Database Cancel 2 Type in the database path or click on Browse to find the file and click on OK The Verify Delete screen appears prompting you to confirm that you want to delete the database Verify File Delete Verify File Delete 7 Do you wish to delete the database file 6 4 What to Do Next Chapter 6 Creating and Updating the Message Database 3 Click on Yes to verify or No to abort the delete Important Once you click on Yes to verify the delete there is no way to abort the process Ensure that the selected database is the correct file If you click on Yes to verify that you want to delete the databas
6. uw Delete the word the cursor is on from the current comment F6 Undel Word F8 Accept E xit Re insert the last deleted word from a comment Save the current comment and return to the 1 0 Definition screen For Address Comments Only F9 Next Address Save the current comment and or move the cursor to the next address Save the current comment and or move the cursor to F10 Prev Address the previous address 3 When you are finished press F8 Accept Exit 4 21 Chapter 4 Configuring SDS Instructions Configuring the SDS Instruction 4 22 Once you have entered your I O information into the I O Definition screen and accepted the rung you are ready to configure steps in the SDS instruction To do this you must first access the Step Directory Using the Step Directory The Step Directory is a list of all the steps in an SDS instruction and is accessed from the Ladder Editing screen The number of available steps in the directory correlates to the number of steps you entered in the Number of Steps field when programming the SDS instruction If you are configuring your SDS instruction the Step Directory contains Step 0 the Initialization step and an entry for each step Each time you configure a new step the Step Directory adds that step to its list by displaying a step s title To access the Step Directory 1 Cursor to the SDS instruction using the arrow keys 2 Press F10 Edi
7. OP123 TOOL CHANGE REQUIRED Accessing the Message This section tells you how to configure and edit diagnostic messages To Template Editor Functions access the Message Template Editor 1 Start on the WindowsNT desktop 2 Click on the DDMC32 icon 3 On the DDMC32 menu bar click on the DDMC32 tag to activate the drop down menu DDMC32 Drop Down Menu Option See Monitor Database Start DDMC32 Stop Mikeas Message Template Editor 4 Select the Message Template Editor option The DDMC32 Template Editor screen appears DDMC32 Template Editor mi DDMC32 Template Editor Oe x File Edit Type Help Current DB DDMC32 Type DFA 7 5 Chapter 7 Configuring Diagnostic Messages Message Template Editor Function 7 6 The DDMC32 Template Editor allows you to create or modify templates to fit your needs There are four menu items that provide access to the editing functions a File Edit Type Help These four items contain the following File At this time only the exit option is available Exit Exits the DDMC32 Template Editor and returns you to the main menu Edit From this selection you can create new templates edit existing templates or delete an existing template Edit Selections alm Type Help New Template Edit Template Delete Template New Template Enables you to create a new template using the New Template editor screen Edit Template Takes
8. wy Allen Bradley Distributed Diagnostics and Machine Control Cat No 6404 DDMC User Manual Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Allen Bradley publication ICCG 9 11 Software Licensing Agreement provides the licensing terms for the use of this software as both a developer s tool and a Runtime package
9. 4 15 Chapter 4 Configuring SDS Instructions To insert or modify information in the I O Definition screen follow the procedure below 1 Ifyou want to change the Operator Interface Station Address a Press F1 Station Address b Type the number of the Data Highway Plus node 0 77 where you want the diagnostic messages sent for example 77 and press ENTER Important If you want to send diagnostic messages to other operator interface stations use the Message Instruction in 6200 Series software For procedures on sending messages with the Message Instruction refer to PLC 5 Programming Software Documentation Set publication 6200 N8 001 or the PLC 5 250 Programming Software Documentation Set publication 6200 N8 002 2 Ifyou want to change the step timer timebase from 10 milliseconds to 1 second or vice versa do the following a Press F2 Timebas b Enter the new timebase 3 Ifyou have a PLC 5 250 and you want to change the port number a Press F3 Port b Enter the port number The following table shows the port number to enter for the specific link type Important The port number is not selectable on these PLC 5 processors PLC 5 20 PLC 5 30 PLC 5 40 PLC 5 11 PLC 5 40L PLC 5 60 PLC 5 60L PLC 5 80 4 16 Chapter 4 Configuring SDS Instructions Port Number Entries For this link Enter this port number ASCIl DF1 Master and Slave port 2A 2B for
10. All software that is part of this package is covered by the license including FIX Factory Link and RS View code screens PLC ladder functions a PanelView screens Reproduction of the contents of this copyrighted publication and software in whole or in part without written permission of Allen Bradley Company Inc is prohibited Throughout this manual we use these notes to make you aware of safety considerations circumstances that can lead to personal injury or death property A ATTENTION Identifies information about practices or damage or economic loss Attention statements help you to a identify a hazard a avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product Using This Manual Understanding How a DDMC32 System Works Installing DDMC32 Hardware Components Installing DDMC32 Software Configuring SDS Instructions Distributed Diagnostics and Machine Control Table of Contents Preface Manual Objectives 0 0 ccc eee eee P 1 Audien cso iw ee ees eire dearer tiea reki tes Kobe ia P 1 What this Manual Contains ssusauaenaanurn nra P 2 ATTENTION and Important Notes 00000 P 3 Terms and Conventions sssssu eenuur rreren P 3 Related Publications 0 0 0 0 cece eee P 5 Chapter 1 What this Chapter Contains 0 0 0 0 00 eee eee eee 1 1 How the
11. Fragment Length window Enter Fragment Length Cancel Finally each individual message can be configured as to where it will display the message Using selections from the Send To portion of the dialog box to select Banner Display Marquee Printer and Logger Send To W Display M Marquee 1 Marquee 2 I Printer Sindle Drop Single Drop M Logger Mult Drop e utia 6 Click on OK when you have completed and are satisfied with your selections 7 Repeat this procedure for each message template you create What to Do Next Now that you have configured your diagnostic messages you can debug any problems you may have encountered Chapter 8 describes the procedures for debugging your DDMC32 setup and how to configure your system and prepare to run DDMC32 Chapter 7 Configuring Diagnostic Messages Notes What this Chapter Contains Correcting Step Configuration Errors Debugging Your DDMC32 System Read this chapter to become familiar with the types of errors that can occur in your DDMC32 system and troubleshooting tips for correcting those errors Tools within the DDMC32 system that help you detect problems include a error list I O monitor display a step history a input history a extended status display Important As you debug your system we recommend that you use two operator interface terminals Use one terminal for running 6200 Series software so that you can debug any e
12. Port Number Entries For this link Enter this port number ASCII DF1 Master and Slave 1 port 2A 2B for DH and DH 2 port 3 for DH and DH 3 Chapter 5 Configuring DFA Instructions 3 Ifyou want to alter an existing address or enter a new address in a list of inputs a Press F7 Modify Inputs The system prompts you for an address b Type in your input address and press ENTER Valid entries include any logical address specified to the bit level with the exception of indirect addresses 4 After entering or modifying an input address cursor to the next field and repeat this step until you have completed all entries or changes 5 After entering all your addresses press esc to display the Input Definition screen function keys and then press ENTER The system returns to the DFA instruction 6 Press ENTER The system displays the Edit Rung screenseen below Edit Rung Screen i DFA I J DIAGNOSTIC FAULT ANNUNCIATOR EN I I Control File N10 0 I I INo of I O 8 ER I I Program File No 1CARO Ir I A E Ss Ss55 I has se a ee END OF FILE Press a function key for desired editing function or type a mnemonic 1STEPO 0 gt Program Forces Disabled Edits None Rung Insert PLC 5 25 Addr 5 Branch Append Insert Modify Delete Undel Accept Instr Instr Instr Instr Instr Run
13. The control file address must be local to the logic processor executing the associated DFA instruction Do not place this file in system memory 2 Type the number of I O you are using and press ENTER The system prompts you for the program file number The program file number refers to the number of the DFA CAR file in the online or offline program directory 3 Type the DFA CAR program file number and press ENTER In the PLC 5 processor the system displays the I O Definition screen If you have a PLC 5 processor continue with Enter or Modify Input Information on page 5 9 In the PLC 5 250 processor the system prompts you for the Message Control Block address 4 Ifyou have a PLC 5 250 processor type the Message Control Block address and press ENTER The Message Control Block address must be entered in the following manner OMSGX X where a is the Resource Manager global memory must be set to zero a X X message control block number 0 9999 file number 0 9999 For example OMSG0 0 is a valid control block address The system displays the Input Definition screen see the figure on the next page 5 8 Chapter 5 Configuring DFA Instructions Enter or Modify Input Information The inputs you enter into the Input Defines on the Input Definition screen are monitored by the DFA instruction You can enter logical addresses and symbols into the Input Definition screen The screen on the next pag
14. the report to run and then click on OK The DDMC Command Scheduler will display the scheduling information for the task You can then close the Scheduler by choosing Exit from the File menu When you choose Modify from the Schedule menu of the Report Generator the DDMC32 Command Scheduler is executed displaying a list of all the currently scheduled tasks You can modify these task schedules using by clicking on the Change button on the DDMC32 Command Scheduler see figure on previous page If you choose Login from the Schedule menu of the Report Generator the Scheduled Report Account Information screen appears Scheduled Report Account Information screen Scheduled Report Account Information x UserName Domain or Server Server Password aa Cancei _ You must supply the User Name and Password of a Login account with Administrative privileges on the computer where the Report Generator will run The Domain or Server field is optional and may be left blank This information is necessary for the Report Generator to acquire the resources to create and print a report without any user intervention 10 11 Chapter 10 Using the Report Generator Software Miscellaneous Operations What to Do Next 10 12 This section describes two additional procedures that can assist you in working with reports Copying Report Text From the Edit menu choose Copy to copy selected text from the Report Generator to the Windows
15. 1N10 0 gt Program Edit mode Insert Col 7 Line 3 PLC 5 25 Addr 5 Delete Undel Delete Undel Delete Undel Accept Comment Comment Line Line Word Word Exit F2 F3 F4 F5 F6 F8 J To activate the cursor in the address comment window press F3 Address Comment from the DFA Instruction Documentation screen The system displays the Address Comment Editor screen Address Comment Editor Screen Diagnostic Fault Annunciator Input Defines Definition for Control Block 0 I 001 16 N10 0 ts IT 001 15 2 I 001 14 3 18 003 02 Ins Cmt Adr Cmt 4 IS 003 03 DRILL RETURNED L Di MACHINE IS ji 6 HEAD 1 7 Operator Interface Station Addr 77 Enter address comment for 1 001 16 gt Program Edit mode Insert Col 2 Line 2 PLC 5 25 Addr 5 Delete Undel Delete Undel Delete Undel Accept Next Prev Comment Comment Line Line Word Word Exit Address Address Fl F2 F3 F4 F5 F6 F8 F9 F10 S e Chapter 5 Configuring DFA Instructions The function keys for both Editor screens are the same except that the Address Comment Editor screen has soft function keys for moving the cursor to the next or previous address If you want to Delete the current comment Re insert the last deleted comment where the cursor is Delete the line the cursor is on from the current comment Re insert the last deleted line from a comment Delete the word the cursor is on from the current
16. DDMC32 System Works 20200000 1 1 Understanding the SDS Instruction 04 1 3 Understanding the DFA Instruction 004 1 7 Implementing DDMC32 Instruction in Levels 1 8 DDMC32 System Components 0 0 0 0 e eee ee ee 1 8 What to Do N xt i ig esd hee eee bead veeses d teenka 1 12 Chapter 2 What this Chapter Contains 0 0 0 0 0 e eee eee eee 2 1 Hardware Configurations 0 0 c eee ee eee eee 2 1 Installing DDMC32 Components 000 000s 2 3 Whatto Do NeXt cs eien cane cis ceded who tonera elaw eae 2 4 Chapter 3 What this Chapter Contains 0 0 0 0 ee eee eee 3 1 Setting Up Your Operator Interface Terminal 3 1 Installing and Configuring the Software 3 1 Installing DDMC32 Software 0 000 e eee eee 3 2 Completing the DDMC32 Software Installation 3 8 What to Do Next ii csc weet dt odes Ewa doidoia oin 3 8 Chapter 4 What this Chapter Contains 0 0 00 000 e eee eee 4 1 Smart Directed Sequencer Overview 00 5 4 2 Programming the SDS Instruction 004 4 5 Documenting the SDS Instruction 200000 4 18 Configuring the SDS Instruction 200000 4 22 Exiting the SDS Instruction 0 0 00 000 020 4 31 Editing and Copying SDS Instructions 4 34 Whatto Do NERE eeraa e a Hehe
17. DEPTH 00 01 06 83 00 00 26 96 8 SLIDE RETURNING 00 01 07 83 00 00 01 00 9 SLIDE RETURNED 00 01 10 28 00 00 02 45 1 READY TO START Press a key for desired histogram function RUN Hist Started Mode Paged Disk Recording Off Current Step 1 Start Stop Contin Paged Step Write History History Mode Mode Trigger To Disk FI F2 F3 F4 F5 F8 Chapter 8 Debugging Your DDMC 32 System 8 8 You can perform the following tasks from the Step History screen If you want to Press this key Begin monitoring the current instruction F1 Start History Stop monitoring the current instruction F2 Stop History Display data continuously on the screen as new F3 Contin Mode data is collected If new data is generated faster that the display can be updated eventually the data buffers overflow and Data Overrun is displayed Display data one page ata time Press NextPage F4 Paged Mode or Previous Page to scroll through the data Specify a starting point at which to activate the timer F5 and display When the SDS instruction is in the Specified step the timer is waiting for a transition from the step When this occurs the timer is set to zero and the display screen is activated logging all steps from that point on Store the step history on disk F8 Write to Disk Step Trigger Using the Input History The input history shows inputs in your SDS and DFA instructions as they transition and the time it takes eac
18. F3 window and display the Address Comment Editor Assign a symbol to an address or change an existing symbol F6 Remove the symbol from the current F7 address Save your work in the data base If you are editing off line the archive file is updated and the comment and symbol files are saved If you are editing on line only the comment and symbol files are saved Press this key Instr Comment Address Comment Modify Symbol Remove Symbol F10 Save amp Contnue 4 19 Chapter 4 Configuring SDS Instructions Editing Instruction and Address Comments To activate the cursor in the instruction comment window From the SDS instruction screen 1 a Press F2 Instr Comment to edit instruction comments The system displays the Instruction Comment Editor screen below a Press F3 Address Comment to edit address comments The system displays the Address Comment Editor screen next page Instruction Comment Editor Screen PLC 5 i Smart Directed Sequencer I O Input Defines Output Defines 0 000 04 Definition for Control Block 0 I1 001 16 0 N10 0 1 I 001 15 1 0 000 01 2 I1 001 14 2 0 000 02 3 B3 2 3 Ins Cmt Adr Cmt 4 B3 3 4 DRILL FULL 53 5 MACHINE DEPTH LS 6 6 HEAD 1 7 Te l Operator Interface Station Addr 77 Timebase for Step Timer s 0 01 Enter instruction comment for SD
19. If you are editing cursor to EQx x is equal to the number of the equation within the step if you are adding the equation the equation field is blank Press F1 Equatn List The system displays the Equation List screen seen below Equation List Screen PLC 5 7 4 CLAMPING A Eq lEquation 1 0 ON gt OFF 2 ag OFF gt ON 3 2 EQ1 4 3 Press a function key Rem RUN 5 25 Addr 1 DB_TEST Equatn Cancel Toggle Edit Zoom Equatn Equatn Equatn Fl BS F9 F10 From the Equation List screen you can perform the following tasks If you want to Press this key View a large equation which will not fit in the equation list F1 Equatn Zoom Remove an equation from the equation list F5 Cancel E quatn View the equation in an alternate form abbreviated or expanded F9 Toggle E quatn Edit an existing or enter a new equation F 10 Edit E quatn 4 28 Chapter 4 Configuring SDS Instructions 2 Press F10 Edit Equatn The system displays the Equation Editor screen below If you are editing an existing equation that equation appears in the lower left corner of your screen If you are configuring the equation for the first time the lower left corner is empty Equation Editor Screen PLC 5 sm 4 CLAMP ING N Eq 1 0 amp 4 2 3 Equation 1 I 000 01 2 1 000 02 Press a function key 0 amp 4 Program Select Display amp 5 25 Addr 1 DB_TEST ON gt OF
20. Next Page F4 Paged Mode or Previous Page to scroll through the data Specify a starting point at which to activate the timer F5 Input Trigger and display When the SDS instruction is looking at a specified input the timer is waiting for a transition When this occurs the timer is setto zero and the display screen is activated logging all inputs from that point on Store the input history on disk F8 Write to Disk Chapter 8 Debugging Your DDMC 32 System Using Extended Status The Extended Status screen gives you information from the SDS data base in user friendly terms The fields on the Extended Status screen show the status of specific bits in the control file A message type field on the screen shows the type of error that occurs the last step the input ID and the state of the input These message types correspond to the messages you configured in the Diagnostic Message Configurator The messages are status error a step timeout a warning timeout a one valid exit timeout a input mismatch a zero step a init error DFA Refer to Chapter 7 Configuring Diagnostic Messages for information about messages in the Diagnostic Message Configurator To access the Extended Status screen press F6 Extnded Status on the I O Monitor screen The figure on page 8 11 shows a sample Extended Status screen when an input mismatch occurs Fields on the screen are described When this type of
21. PLC 5 or 5 250 Hardware User Manual If using a multiple PLC 5 configuration Pyramid Integrator Design Installation 5110 ISET Connect PLC 5 processors with cables and 3 pin Startup and Integration Manual connectors What to Do Next Now that you have installed your hardware components you can install your software Chapter 3 describes procedures for installing software for a DDMC32 system 2 4 What this Chapter Contains Setting Up Your Operator Interface Terminal Installing and Configuring the Software Installing DDMC32 Software Read this chapter to learn how to install your DDMC32 software To install your software you perform the following tasks set up your operator interface terminal a install 6200 Series software a install DDMC32 Monitoring Software This chapter contains the following sections Section Page Setting Up Your Operator Interface Terminal 3 1 Installing and Configuring the Software 3 1 Installing DDMC32 Software 3 2 Completing the DDMC32 Software Installation 3 8 What to do Next 3 8 Before you install your DDMC32 software you must power up the 6180 Industrial Computer or your PC with 6200 Series software v 4 5 or later Microsoft Windows NT 4 0 and RS Linx v 1 70 62 or later Using a 6180 Industrial Computer To power up the 6180 computer turn the system power switch on the rear of the computer to the ON position The system performs a series of self tests to determine if its
22. Processor and Control File for the SDS instruction whose messages you want to display Use Default for the Processor and or Control File if you want a particular message to be displayed for any Processor Control File combination Otherwise select only the Processor Control File combination you want to use with the template you are editing Important It is assumed that you have imported the SDS file into the database prior to editing these messages 7 9 Chapter 7 Configuring Diagnostic Messages Priority will assign a priority to the message with 1 being the highest and 10 being the lowest A message of higher priority will replace a message of lower priority on the Window Banner or Marquee Processor F DEFAULT i Control File DEFAULT Priority 10 z You can choose to Show or Suppress extra blanks in your message depending on how you want to format your message Estra Blanks Show i Suppress Multiple messages may be enabled or disabled for SDS instructions only for example multiple messages may be generated for a single SDS fault Multiple Messages C Enable Disable Chapter 7 Configuring Diagnostic Messages Message Fragments i e Processor Name Instruction Comment etc are selected from buttons on the right side of the screen When a fragment is selected you are prompted to type in the maximum length of the fragment This value will be inserted as part of the Message
23. SDS5 5672 9 06 91 10 10a 2 fase Sessss ese S555 55 55555555555 5555 SSeS SSS SSS SSeS SS SSS SS 55555555555 555555 p Press a function key or enter file name or move cursor to select file gt Program PLC 5 25 Series A Revision H 5 25 Addr 1 SDSC5 Begin Define Select Save Fl Conv Restore Dirctry Type Config Utility Ei ET F8 F9 F10 3 Press F8 Select Type until the CAR directory appears in the file directory window Chapter 5 Configuring DFA Instructions 4 Cursor to the desired CAR file Important The program file number for the DFA file must be different than that of the SDS file 5 Enter the CAR file If you are using a PLC 5 a Press F1 Begin Restore The system prompts you to enter a file number b Type the file number and press ENTER The system returns to the Program Directory If you are using a PLC 5 250 a Press F1 Begin Oper The system prompts you to enter a program descriptor b Type the program descriptor for example CARO and press ENTER In the program descriptor the first number refers to the number in the thumbwheel window on the logic processor in this case 1 A logic processor runs control logic which controls steps transitions processor input interrupts selectable timed interrupts and independent background programs CAR refers to the type of file O refers to the program file to download the CAR into The system retu
24. TODAY Message fan x DONT CARE C Mon SORTED Cencet_ 10 5 Chapter 10 Using the Report Generator Software Title This screen field gives your report a unique descriptive title which will appear on the report Directory This will default to the DDMC32 default that was set up when you installed your system If you want the report to be saved into a different directory type the complete directory name in this field File Name Type in the file name normally this would be the similar to your title with the rpt extension added for example you have titled your report Test your file name would then be Test rpt Print The Print field defaults to No This means that that the report will not be automatically printed to the default printer whenever the report is generated To have the report printed every time it is run click on the Yes radio button This selection is useful for printing scheduled reports at the time the report is generated Add Date to Name This option makes each report unique by appending the database name and date to the report name This report is always saved to disk named according to the following format Report Name Database Name Day of Year Hour of Day and Minute Processor Select the processor name to limit the report to only the selected processor or leave the default of All which will include all processors in your report Message Choose the messages
25. Use the mouse pointer to view a brief description of each function Hela ae Sl Configuring Reports Select Reports from the DDMC32 menu bar to run the Report Generation program The DDMC32 Report Generator screen appears Report Generator screen BE new rpt test MDB DDMC32 Report Generator File Edit View Schedule Help pelem e S 2 Monday 12 08 97 01 27 49 7 Chapter 10 Using the Report Generator S oftware Selecting a New Database You can select a new database for the report function by clicking on Database The Database Selection screen appears Database Selection Screen Open Look in E Ddme32 c ey Ddme32 mdb Default mdb test MDB Files of type Poo Cancel Highlight the database file you need and click on Open or double click on the database to open Your selection will be saved as the default database and will be used in the future until changed Selecting a New Format Selecting a New Format means that you can customize a report format to fit your specific needs The Edit Report Format screen seen below is used to prepare new report formats New Format screen Edit Report Format x widtk feo Title New Repor Dir C DDMc32 Old Report Report Type File Name new rpt OVERWRITE WRAP Print Add Date to Name APPEND C NOWRAP C oo me og Top 10 Days Processor fan x C DURATION C 7 DAYS C FREQUENCY
26. XCOPY IPDS ARCH PLC5 PROC1 SDS A IPDS ARCH PLC5 PROC1 SDS S M and press ENTER The system displays all the files being transferred The M in the xcopy command see above turns off the archive bit after a file is copied If you fill up one disk during the copying process re execute step 3 and the copying process on the next disk will pick up where you left off 5 Insert the disk in the system to which you are transferring the database 6 Type XCOPY disk drive IPDS ARCH PLC5 processor name SDS hard drive S and press ENTER For example XCOPY A IPDS ARCH PLC5 PROC1 SDS C s and press ENTER The system now copies the database to your disk 4 33 Chapter 4 Configuring SDS Instructions Editing and Copying SDS Instructions 4 34 To save time when configuring instructions you may want to copy information from one instruction to another To do this you can edit and copy information from steps that you have already configured You do this from the Extended Edit screen Editing Steps To access the Extended Edit screen next page press F6 Extnded Edit from the Step Directory Extended Edit Screen PLC 5 3 Step Directory for DRILL MACHINE HEAD 1 7 Control File N10 0 Step Description File N10 102 Step Step Name Step Step Name 0 INITIALIZATION 11 STOPPED 1 READY 12 2 READY TO ADVANCE 3 ADVANCING 4 ADVANCED 5 AT FULL DEPTH 6 FULL DEPTH DWELL 7 FWD amp RETURNING 8 ADV D a
27. accept it The system returns you to the Edit Step screen Press F4 Step Type This key toggles the step between a normal step and an error step see the upper left corner of your screen Select the appropriate option Enter the equation a Cursor to the equation field and press F8 Equatn Editor You see the transitional equation in the lower left corner of your screen if you are editing If you are configuring the step for the first time the lower left corner is empty b Press F8 ON gt OFF or F9 OFF gt ON to set the equation Cursor to the destination field You are prompted Enter destination step or INIT gt Type the destination step and press ENTER 4 25 Chapter 4 Configuring SDS Instructions 6 Cursor to the output field and press F9 Output State This key toggles the cursored output state which will be applied for control between ON OFF and LAST no changes 7 Press F6 Step Timer The system prompts you to enter your step timer preset value and your destination step number The destination step number can be astep an error step a warning The instruction displays a Warning message without stopping the program execution For example a warning message can be displayed to notify the operator that a transition is taking too long INIT Initialize Do not confuse INIT with Step 0 Initialization on the step directory These steps react differently as noted
28. below INIT vs Step 0 If you specify this This happens destination INIT Outputs remain in their current state The step timer is disabled For two program scans and beginning at Step 1 the system searches all normal steps with defined input transitions looking to match current input states with expected input states When current inputs match expected inputs that state is entered If no match is found in two program scans the program enters Step 0 Important INIT can not enter an error step or step with no defined input transitions Step 0 All outputs are turned off Starting at Step 1 the system searches all steps with defined input transitions looking to match current input states with expected input states When current inputs match expected inputs the program enters that step otherwise it stays in Step 0 You cannot configure Step 0 Important Step 0 can enter a status step or error step unless the step has no defined input transitions transitions when in INIT outputs may stay on for up to 2 program scans A ATTENTION Because the instruction does not recognize 4 26 Chapter 4 Configuring SDS Instructions 8 Press F7 Msg On Off This key is a toggle key which allows you to choose whether or not you want the message related to this step to appear on the operator interface display Important If you do not specify information for a field it is assigned a default setting Defaults settings for
29. clipboard This function is useful for including all or portions of a report into a word processor Viewing Report Information From the View menu choose Extended Info to display additional information about the selected line of a weekly default or Monday Tuesday Sunday report Click on a line of the report and then choose Extended Info to get detailed information about that line Once you have finished configuring and printing the log you can reference Appendix A Reference Information or Appendix B 7 DDMC32 Directory Structure for further information Appendix Overview Reference Information for the SDS Instruction Appendix Reference Information This appendix provides reference information about the SDS and DFA instructions This appendix shows SDS Information a execution times a control file size requirements a step description file requirements a how to determine the amount of data table memory for SDS instructions a how to determine the amount of program file memory for SDS instructions a maximum steps allowable without going over a file boundary a control file layout DFA Information a execution times a control file size requirements amount of program file memory needed for DFA instruction a control status bits Read this section for reference information for the SDS instruction Execution Times Tables A A and A B show the execution times per program scan for an SDS inst
30. components 2 Installing DDMC 32 Hardware Components Procedures for setting up your operator interface terminal 3 Installing DDMC32 Software procedures for installing 6200 Series and DDMC32 software Overview of the Smart Directed Sequencer instruction in the 4 Configuring SDS Instructions PLC 5 and the PLC 5 250 and procedures for entering data into the instruction screens naming steps editing step descriptions Overview of the Diagnostic Fault Annunciator instruction in the PLC 5 and the PLC 5 250 and procedures for entering data into the instruction screens configuring instruction messages documenting the instruction 5 Configuring DFA Instructions Procedures for importing the SDS instruction s documentation into 6 Creating and Updating the the operator interface data base message database options Message Database Overview of the parts of the diagnostic message and procedures 7 Configuring Diagnostic for configuring the format of diagnostic messages for display Messages Software tools and techniques for debugging your system error 8 Debugging Your DDMC32 list I O monitor step history input history extended status and I O System history screen displays Procedures for configuring output devices Clock Creep Option 9 Configuration and Operation of Start Stop and other related options the DDMC32 System Overview of the Report Generator configuring and scheduling 10 Using the Report Gene
31. cursor is in the output state field F8 Equatn Editor F9 Output State Select the one valid exit out of the step thatis select the F10 Marked Exit normal path for the operation See the following sections for information on configuring or editing transitional and combinatorial equations If you want to See page Configure or edit transitional equations 4 25 Configure or edit combinatorial equations 4 27 Chapter 4 Configuring SDS Instructions Configuring or Editing Transitional Equations To edit or configure steps based solely on transitional equations start at the Edit Step screen on page 4 23 1 Press F3 Step Name from the I O Edit screen The system prompts you to type in the name for your step When you enter the step name the Step Directory is automatically updated to contain that step name Important When assigning names to your steps use names that will fit into your expected diagnostic message layout The step name is used for the message generation and should be as descriptive as possible of the operation being performed in that step Think about how you intend to present diagnostic messages in DDMC32 and assign messages accordingly For example Step Name Possible Message WAITING FOR PART MOVING PART ON CONVEYOR LIMIT SWITCH 1 is ON while WAITING FOR PART LIMIT SWITCH 1 turned ON while MOVING PART ON CONVEYOR Type your step name and press ENTER to
32. diagnose faults and generate messages and how the SDS and DFA instructions work within the DDMC32 system In addition this chapter described the components that make up a DDMC32 system Chapter 2 contains information for installing the DDMC32 hardware components described in this chapter What this Chapter Contains Hardware Configurations One PLC 5 and the 6180 Industrial Computer Multiple PLC 5 multi drop peer communications Installing DDMC32 Hardware Components Read this chapter to learn how to install your DDMC32 hardware components when using a 6180 Industrial Computer In this chapter we overview DDMC32 hardware configurations and provide procedures for installing the hardware components In addition we reference specific hardware publications so that you can find more information if needed This chapter contains the following sections Section Page Hardware Configurations 2 1 Installing DDMC32 Components 2 3 What to do Next 2 4 You can have one or several PLC 5 processors in your DDMC32 hardware configuration in addition to a 6180 Series Industrial Computer The different DDMC32 hardware configurations are referenced in the following table and on the subsequent pages DDMC32 Hardware Configurations If your configuration uses Refer to figure DDMC32 Component Configuration with one PLC 5 Processor and a 6180 Industrial Computer DDMC32 Component Configuration with multiple PLC 5 Processors and a 6
33. diagnostic messages with the DFA instruction such as tool change messages and operating instructions Once you have determined where you want to apply the DFA instruction you can enter it into your ladder program and configure the instruction You perform the following tasks to program the DFA instruction a download the DFA CAR a enter the DFA instruction a enter the configuration information enter I O information Configuring DFA Instructions To enter the DFA instruction into your ladder program 1 Access the PLC 5 or PLC 5 250 Programming Software main menu below from the Allen Bradley Main Menu interface Programming Software Main Menu PLC 5 A 6200 Series Software Product Copyright 1986 1987 1988 1989 1990 1991 1992 Allen Bradley Company Inc All Rights Reserved Release 4 3 This software is licensed to Company Allen Bradley Co Location 747 Alpha Drive PSP Engineering Serial Number ZZOAAOPP essssssssss5555 555555555555 555 5555555555555 5 5555555555555 5 5555555555555 55555 55 Fri June 14 1992 9 39 09 am 4 5 eee Terminal Address 77 Current Device 1784 KT DH PLC Address 1 smnn Press a function key Online Online Offline Offline Who Sftware File Reports Compare Exit Program Configr Program Configr Configr Utils System Fl F2 F3 F4 FS F6 F7 F8 F9 F10 2 Press F1 Online Program The system displays the online program directory Pr
34. equations provides traditional state based control Essentially this type of SDS instruction is built around the state transition concept where each input transition directs the instruction to a unique next step using a logical OR structure In other words one input change directs the instruction to step A another to step B etc See the next page for an example of what is meant by transitional equations Chapter 4 Configuring SDS Instructions Graphic Example of Transitional Equations LS3 OFF gt ON LS ON gt OFF LS2 ON gt OFF PB ON gt OFF This type of SDS instruction operates from a series of step tables that define output states for each step and input transitions as either normal or abnormal Normal transitions direct the SDS instruction to another step abnormal transitions can cause the instruction to send a message to the operator interface terminal where DDMC32 software automatically assembles and displays the appropriate diagnostic message The SDS instruction also allows you to implement shadow mode diagnostics In shadow mode control is placed in the ladder logic the SDS simply monitors the I O performing the control and performs diagnostics on that I O Combinatorial Equations In addition to the transitional equation the SDS instruction can also use combinatorial conditions or equations which allow for the ANDing of inputs in addition to the OR function as seen in transitional equations
35. error occurs the screen displays information about the last step executed and the step to be performed Chapter 8 Debugging Your DDMC32 System Sample Extended Status Screen for an SDS Instruction SDS Instruction Message Instruction MSG output bits Status Information For information about this instruction Refer to PLC 5 Family Programmable Timed out 0 TO bit 8 SDS is enabled 1 EN To b tried 0 NR bit 9 Runti e 0 ER Controllers Processor ei ee DiE MER ee Oe eee Awaiting execution 0 EW bit 10 Program error step 0 ES Manual publication Continuous 0 CO bit 11 Input mismatch active 0 1785 6 8 2 Error 1 ER bit 12 Step timer enabled 0 TE Message done 0 DN bit 13 Step timer accum 0 0 Message transmitting 0 ST bit 14 Enabled inputs 15 0 1000 0111 1111 1111 Message enabled 0 EN bit 15 Message type Error message Last step 6 ADVANCING SLIDE Input ID 2 1 006 01 Input state ON Press a function key RUN monitor mode Current Step 13 PLC 5 12 Addr 4 Display Comment F2 The extended status screen for the DFA instruction is somewhat different from that of the SDS instruction The following figure shows an example of an Extended Status screen for a DFA instruction 8 11 Chapter 8 Debugging Your DDMC32 System Troubleshooting Problems in Your Operator Interface 8 12 Ladder program is not sending messages to System is displaying messages from the Extend
36. of steps per SDS instruction 8 76 16 45 32 23 Table A H Number of Steps Per SDS Instruction in the PLC 5 250 If you have this number of I O Then you can enter this number of steps per SDS instruction 8 250 16 250 32 232 Loading Considerations for Multiple PLC 5 Configuration The DDMC32 system does not limit the number of PLC 5s you can link to the operator interface However to maximize performance of the Data Highway Plus we recommend that you have no more than 20 PLC 5s linked to one Data Highway Plus Your messages do not get lost when using multiple PLC 5s they are however read on a first in basis Appendix A Reference Information Control File Layout The following table shows the SDS instruction control file layout 0 Control S tatus bits 1 WORD 1 Length 1 WORD 2 Number of Steps 1 WORD 3 Current Step N 1 WORD 4 Last Step N 1 1 WORD nputs 16 31 5 apped Inputs 2 WORDS nputs 0 15 6 apped Inputs nputs 16 31 7 apped Outputs 2 WORDS nputs 0 15 8 Mapped Outputs For Internal Use Appendix A Reference Information The control status bits are 15 14 13 12 1 10 09 08 07 06 05 04 03 02 0l 00 EN ES ER ST ME TE RS DV PC MR TB The following table defines the control status bits Bit Definition EN Rung Enable ES Error Step indicator if true sequencer is in an error step ER Error true if runtime error detected ST Step T
37. prompt and press ENTER If you are modifying an existing instruction SDS already appears at the prompt As an alternate method of entering the instruction you may a Press F10 Others Press F9 Seqncer from the Instruction Classes function keys a Press F6 sps from the Shift Sequencer function keys The system displays the SDS instruction seen below SDS Instruction PLC 5 SDS LN paserna SMART DIRECTED SEQUENCER EN Control File Step Desc File ST Length INo of Steps ER Position Step l INo of I 0 ES Program File No END OF FILE Enter the operand Enter the Control File address gt Program Forces Disabled Edits None PLC 5 25 Addr 5 XX a 4 10 Chapter 4 Configuring SDS Instructions Entering or Modifying SDS Instruction Information Once the SDS instruction is displayed the system prompts you to enter the Control File starting address To enter or modify parameters into the SDS instruction 1 Type the Control File address and press ENTER The control file must be expressed in the following manner For the Use this format Where PLC 5 Nfff eee fff an integer file between 10 999 and eee an element number between 0 999 PLC 5 250 Nffff eeee ffff an integer file between 10 9999 and ee
38. that will be displayed For more information on the DDMC32 Message Template Editor see the section on Accessing the Message Template Editor in Chapter 7 Configuring Diagnostic Messages Chapter 1 Understanding How a DDMC32 System Works The DDMC32 software also provides a a fault log that shows all fault messages generated by the software an interface for marquees to optionally display diagnostic messages a fault report which lets you see where and when each fault occurs by frequency and duration These selections are configured by the user who may direct the faults to some or all of the above devices 6200 Series Software This software provides the capability to program and monitor your PLC 5 family programmable controller using your operator interface terminal 6200 Series Software uses menu driven screens and configuration utilities that simplify entry You can use 6200 Series Software to develop ladder programs and configure DDMC32 instructions To learn more about 6200 Series Software refer to the PLC 5 Programming Software Documentation Set publication 9399 PLCSMAN or the PLC 5 250 Programming Software Documentation Set publication 9313 5250 PLC 5 Family of Programmable Controllers The PLC 5 family of programmable controllers is the heart of the DDMC32 system providing a flexible framework for processing You can create a a centralized configuration to control a large number of I O from one locati
39. to control process or machine operation T O Input Output State The current value of an input or output at a particular point in time P 3 Preface Using this Manual In this manual we use the following conventions to describe how you enter information The Enter key and Function keys look like this ENTER ESC F2 a Words or commands that you enter appear in bold For example SDS a Variables that you must enter appear in italics For example Nxx 00 a Messages on the screen look like this While DRILL STATION 32R was AT FULL DEPTH the RETURNED LIMIT SWITCH turned ON a Type means type in the information using your keyboard a Enter means type in the information and then press your keyboard s ENTER key Related Publications 1785 PLC 5 Family Programmable Controllers Installation Manual Data Highway Data Highway Plus Protocol and Command Set Peer Communication Link Interface Module cat no 1784 KT Preface Using this Manual For more information about DDMC32 components see the following publications Publication Title Publication Number DDMC32 User Manual PLC 5 Processors 6401 6 5 1 1785 6 6 1 1785 6 2 1 5000 6 2 1 9399 PLC5MAN 9313 5250 1785 PLC 5 Programmable Controller Design Manual Pyramid Integrator Design Manual PLC 5 Programming Software Documentation Set PLC 5 250 Programming Software Documentation Set Communications 1770 6 5 1
40. transition conditions are used the expected input states appear on the left side of the equation column and the transition states on the right The destination column is on the right of the equation column see the figure above At power up the SDS instruction starts out in an initialized step The instruction searches through each defined step to find a match based on the expected states of inputs If it cannot find a match the SDS instruction looks for a set of conditions defined by a combinatorial equation see the figure on page 1 5 If a transition is specified you must validate the entry state or you will not see a transition and will be locked into a step Because all input states in each step may be important you must consider the logical progression of I O sequencing when developing a step configuration These considerations differ from those you make with traditional ladder logic as the sequence of I O changes are not relevant Chapter 1 Understanding How a DDMC32 System Works For example in the figure below the expected input conditions for step 1 are in order off off off off don t care The instruction will enter this step only when inputs 0 1 2 and 3 are off This figure shows another example of the SDS instruction looking for a step to enter SDS Instruction Looking for a Step to Enter ACTUAL INPUTS When transition conditions are used the instruction looks for a match of actual and
41. you to the Edit Template editor for the highlighted selection Delete Template Click here to select an existing template to delete from the database You will be prompted to verify the delete before it occurs Chapter 7 Configuring Diagnostic Messages Type Click on Type to select a message type see below When you select one of the listed message types it becomes the default and displays templates with only that message type Type Selection ER DF Error Exit Init Err Mismatch Status Step From Timeout Warming Help The Help function displays the following information Help Le About DOMC32 Template Editor About DDMC32 Template Editor DDMCS2 Template Editor Version 1 00 October 20 1997 Copyright 1996 1997 7 7 Chapter 7 Configuring Diagnostic Messages Configuring Diagnostic To configure diagnostic messages follow the procedure below Fragment Messages options for the message vary depending on the type of message you are creating We use the Error Message as an example through all steps 1 From the DDMC32 Template Editor menu select the Type option The drop down list displays all available message types 2 Click on the type of message you want to configure in this case the Error message The selected Template Editor screen appears DDMC32 Template Editor Screen for an Error Message 28 DDMC32 Template Editor File Edit Type Help Current DB DD
42. you want to be displayed Selecting All will display the report messages for both SDS and DFA messages To display only the sds or dfa messages click on the arrow and select from the drop down list Width This is the number of characters per report line The Width defaults to 80 characters Chapter 10 Using the Report Generator Software Old Report Selecting Append will append the current report to an existing report of the same name Report Type Determines whether each line of the report will wrap to the next line or be truncated if it is longer than the width field Top 10 Determines the major style of the report The Don t Care selection simply displays the contents of the Message Log This is the format of the weekly default and Monday Tuesday Sunday reports Days Selects the time span of the report Choose Sorted to display the entire contents of the database Modify a Format To Modify a Format select Modify from the drop down File menu and open the file you want to modify From this point see Selecting a New Format The steps used to modify a format are the same as those previously described The Report Generator contains formats for several standard reports a Daily a Duration a Frequency a Weekly Default a Monday Tuesday Sunday Chapter 10 Using the Report Generator Software Generating Reports To generate a report select Generate Report from the File men
43. your decision Display error list 1 F9 Display Err Lst 1 F9 is displayed only as a result of pressing F10 Accept Edits when errors exist in the configuration Configuring or Editing Steps From the Step Directory cursor to the appropriate step and press F5 Edit Step you cannot edit Step 0 You see the Edit Step screen as shown below Edit Step screen PLC 5 1 LOADING TIMER 5 00s STEP 11 MSG ON No Input ID Equation Destination No Output ID State 0 PART IN POSITION ON gt OFF x STEP 2 1 VALVE 4 OFF 1 CLAMP LS1 2 CLAMPS OPEN ON 2 CLAMP LS2 3 CLAMPS CLOSED OFF 3 CLAMP LS3 4 SOLENOID LAST 4 CLAMP LS4 5 LIGHT LAST 5 HAND 6 MOTOR 2 ON 6 AUTO 7 JOG PB 8 PERMISSIVE Press a function key Enter destination step number or INIT gt Prog edit mode 5 25 Addr 5 SDSTEST Equatn Display Step Step Edit Step Msg Equatn Output Marked List Symbol Name Type Step Timer off Editor State Exit F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 4 23 Chapter 4 Configuring SDS Instructions 4 24 You can perform all of the tasks necessary to configure steps from the Edit Step screen If you want to Press this key Display all equations related to a particular step and enter F1 Equatn List your equations Toggle between address comment symbolic name or F2 Display Comment Symbol LogAdr logical address of I O The function key always displays the next format for example if address comments are be
44. 0 01 LUBE LEVEL LOW 3 I 000 06 NO PARTS PRESENT 4 I B3 03 LOAD PARTS IN STA 5 5 1 000 04 PLACE MACHINE IN AUTO MODE 6 0 000 05 TIME TO CALL MAINTENANCE 7 T5 1 0N MACHINE OVER CYCLE Enter the desired comment Press lt CR gt to accept the comment lt ESC gt to return TOOL CHANGE REQUIRED Rem Prog 5 25 Addr 5 DB_TEST J 5 Cursor to the message you wish to edit or to the number of the input where you wish to enter a new message and type the new message Any message you enter may have a total length of up to 50 characters 5 17 Chapter 5 Configuring DFA Instructions Exiting the DFA Instruction What to Do Next 5 18 Once you have completed your changes press ENTER to accept the comment Press esc to return to the DFA Message screen Cursor to the state column of the desired input and press F8 Input State F8 is a toggle key which allows you to choose from OFF ON or NONE if you select NONE a message is never sent for the state in which you want your message to be sent Continue to press this key until you reach the state in which you want your message to be sent Once you have configured your diagnostic messages you can exit the DFA instruction To exit the DFA instruction 1 Press ESC The system displays the DFA Message screen Press F10 Accept Edits The system prompts you to confirm your decision Press F8 Yes Press F3 Exit Once you ve entered and
45. 0 represented by the word ON step comment dest step the SDS instruction was moving to when the message was generated logical address dest data type file number offset and bit number of the bit which did not match the expected inputs for example 007 3 symbolic address dest 10 character symbolic string entered in the PLC 5 programming software which represents the bit which did not match the expected inputs for example LEDO02 short address comment portion of the destination address comment that was delimited dest by asterisks when the comment was entered in the PLC 5 programming software address comment dest full description of the bit address which did not match the expected inputs DFA Message Fragment Options All definitions of fragment options for the DFA message are the same as for the SDS message unless otherwise specified processor name instruction comment DFA bit message a logical address a symbolic address a short address comment a address comment ON OFF state OFF ON state Ithe DFA message which is associated with a change in this bit s value The Message Template Editor contains screens for you to assign your own connector words and to determine the length of each fragment letting you customize your own diagnostic messages You can configure nine different types of messages for display The following table contains examples of the default messages that will be displayed i
46. 180 Industrial Computer link and the 6180 Industrial Computer 2 1 Chapter 2 Installing DDMC32 Hardware Components DDMC32 Component Configuration with one PLC 5 Processor and a 6180 Industrial Computer Peer Communiceion Link Module 1 784 KT Data Highway Plus cable 1784 GP BADI Sees Sothware DDMC32 Software DDMC32 Component Configuration with Multiple PLC 5 Processors and 6180 Industrial Computer Feer Conimuricagion Lins Module 1784 KT Bata Highway Flus E cabi 1784 CF T z io E BE TAD Industrial Comparten fata FLES Higa i Plus a paces Tih Fama Lal 6200 Seriea Soft PLC mioa me DDMC32 Software Installing DDMC32 Components Chapter 2 Installing DDMC Hardware Components ATTENTION If you are using your DDMC32 software A cat no 6404 DDMC with a PLC 5 250 processor you must make certain that the Remote Scanner Module cat no 5150 RS has a daughterboard cat no 5150 MRS with a part number of 960456 05 or later For example 05 06 07 etc You can locate this part number along the bottom edge of the removable 5150 MRS daughterboard Failure to observe this caution could result in erroneous data appearing in the input image table or internal storage table Contact your local Allen Bradley support office or call Technical Support at 216 646 6800 to arrange for shipment of updated modules The procedure for ins
47. 250 processor There are some minor differences in the procedures for programming and configuring the instruction depending on which processor you are using We note these differences where applicable This chapter contains the following sections Section Page Diagnostic Fault Annunciator Overview 5 2 Programming the DFA Instruction 5 2 Documenting the DFA Instruction 5 12 Configuring Messages for the DFA Instruction 5 16 Exiting the DFA Instruction 5 18 What to do Next 5 18 5 1 Chapter 5 Configuring DFA Instructions Diagnostic Fault Annunciator Overview The Diagnostic Fault Annunciator DFA instruction is a monitoring only instruction that is it monitors inputs you define but it cannot control outputs Valid inputs can be storage points such as binary bits a counter timer done bits a discrete outputs real or logical a any valid bit address a fault bits set by another device like an IMC motion controller or by ladder logic The following figure shows a DFA instruction in a ladder program A DFA Instruction PLC 5 250 ASSEMBLY MACHINE DFA DIAGNOSTIC FAULT ANNUNCIATOR Control File 1N10 0 No of I O 16 Program file number 1 Msg Control Block OMSGO0 0 Programming the DFA Instruction If you currently have diagnostics programmed in ladder logic you can use the DFA instruction to generate messages when a fault occurs In addition you can create other types of operational and
48. 6 User s Manual 1784 2 3 Product Data P 5 Preface Using this Manual Notes P 6 What this Chapter Contains How the DDMC32 System Works Understanding How a DDMC32 System Works This chapter provides an overview of Distributed Diagnostics and Machine Control DDMC32 It contains the following sections Section Page How the DDMC32 System Works 1 1 Understanding the SDS Instruction 1 3 Understanding the DFA Instruction 1 7 Implementing DDMC32 Instructions in Levels 1 8 DDMC32 System Components 1 8 What to do Next 1 12 Distributed Diagnostics and Machine Control DDMC32 for WindowsNT is an industrial automation system built around programmable controllers operator interfaces communications and software The system architecture lets you configure DDMC32 to your manufacturing needs Ideal in transfer line and other machine applications DDMC32 can be configured for other industrial applications such as material handling packaging and assembling DDMC32 is a flexible system based on the PLC 5 family of programmable controllers You can use single or multiple PLC 5 processors to create either a centralized or distributed configuration Processors communicate with each other over the Data Highway Plus Special instructions in the PLC 5 processor a Smart Directed Sequencer SDS and a Diagnostic Fault Annunciator DFA provide diagnostic machine fault detection and automatic messaging capabilit
49. 9 Chapter 5 Configuring DFA Instructions Display the Documentation screen for the F5 Documnt DFA instruction odify an input address at the cursored F7 Modify Inputs location nsert an input address at the cursored F8 Insert Inputs location Delete an input address at the cursored location F9 Delete Inputs Remove an input address at the cursored location F10 Remove Inputs 1 These function keys do not appear on the screen if you are modifying the instruction To insert or modify information in the Input Definition screen follow the procedure below 1 Ifyou want to change the Operator Interface Station Address a Press F1 Station Address b Type the number of the Data Highway Plus node 0 77 where you want the diagnostic message sent for example 77 and press ENTER Important If you want to send diagnostic messages to other operator interface stations use the Message Instruction in 6200 Series software For procedures on sending messages with the Message Instruction refer to PLC 5 Programming Software Documentation Set publication 9399 PLSMAN or the PLC 5 250 Programming Software Documentation Set publication 9313 5250 2 Ifyou have a PLC 5 250 and you want to change the port number your screen has an additional option a Press F3 Port b Enter the port number The following table shows the port number to enter for the specific link type
50. DH and DH 2 port 3 for DH and DH 3 4 Ifyou want to alter an existing address or enter a new address in a list of T O points a Press F7 Modify IO Addr The system prompts you for an address b Type in your I O address and press ENTER Valid entries include any logical address specified to the bit level with the exception of indirect addresses c After entering or modifying an I O address cursor to the next field and repeat this step until you have completed all entries or changes 5 After entering all your I O addresses press Esc to display the I O Definition screen function keys and then press ENTER The system returns to the SDS instruction 6 Press ENTER The system displays the Edit Rung screen Edit Rung Screen PLC 5 T DRILL I kii MACHINE 2 ki HEAD 1 k T nS S T SS I LeSoSS SSSR SSSR SSeS oS RSS SSS SSS SSE SSeS SSS SMART DIRECTED SEQUENCER EN I T Control File N10 0 T I Step Desc File N11 0 ST I I Length 156 I I INo of Steps 12 ER I I Position Step Ol I I INo of I O 8 ES I I Prog file number 3j I A PSSs pl sSSs SSS SSS SSeS SaaS SS I Press a function key for desired editing function or type a mnemonic file 2 rung 8 Program Forces None Edits None Rung Modify PLC 5 25 Addr 1 Branch Append Insert Modify Delete Undel Accept Instr Instr Instr Instr Instr Rung Fl F3 F4 F5 F6 F F10 4 17 Chapter 4 Configuring SDS Instructions
51. E OVER CYCLE Press a function key or enter input number gt Rem Prog 5 25 Addr 5 DB_TEST Change Display Exit Input Edit Input Accept Mode Symbol Monitor Message State Edits Fi F2 F3 F5 F7 F8 F10 Chapter 5 Configuring DFA Instructions You can perform the following tasks from the DFA Message screen If you want to Switch between program mode test mode and run mode Switch between address comment symbolic name or logical address of input The function key always displays the next format for example if address comments are being displayed then F2 reads Display Symbol Exit the configuration utility Display the Input Monitor screen Refer to the chapter entitled Debugging Your DDMC32 System for information on the Input Monitor screen Display the Edit Message screen for the cursored message so that the message can be edited Define change the input state for the selected input Accept all entries edits The system prompts you to confirm your decision Press this key F1 Change Mode F2 Display Comment Symbol Log Adr F3 Exit F5 Input Monitor F7 Edit Message F 8 Input State F10 Accept Edits 4 To enter your messages press F7 Edit Message The system displays the Edit Message screen Edit Message Screen N DFA for DFA 1 AT N9 0 State Input ID Input Message 0 C4 01 0N TOOL CHANGE REQUIRED 1 I 000 02 LUBE FAULT 2 1 00
52. F OFF gt ON Accept Input Symbol AND NOT Equatn F1 F2 F4 F6 F8 F3 F10 Cursor to an input in the selection window that you want to place in your equation and press F1 Select Input All available input operands appear in the selection window As you select an input it disappears from this window The system displays the input you select in the lower left corner of the screen Select the operator you want to use in your equation If you want to Do this combine 2 or more inputs 1 Select an input and press F1 Select Input 2 Press F4 AND 3 Select the next input and press F1 Select Input See the Important note on page 4 30 1 Combine the inputs as shown above 2 Place the cursor on the input you wish to negate and press F6 NOT negate an input 4 29 Chapter 4 Configuring SDS Instructions 4 30 Important Since it is concerned with state only the NOT function is used to negate the state associated with that particular input For example 1 amp 4 means that if the state in equation 1 is NOT true AND the state in equation 4 is true then proceed to the destination step The system displays the operator in the window on the lower left corner of the screen next to the input forming your equation as you continue Important The following procedure is another method by which you can AND your inputs From the Equation Edit screen a Press F1 Select Input to select the first input of
53. IATOR EN Control File I INo of I O ER Program File No l f SS SSS SSS SS SS SS SS eS SS SS SS END OF FILE s osse esse cases secs cssecssss Enter the operand Enter the Control File address gt Program Forces Disabled Edits None PLC 5 25 Addr 5 i J Enter or Modify DFA Instruction Information Once the DFA instruction is displayed the system prompts you to enter the Control File Starting Address To enter parameters into the DFA instruction 1 Type the Control File address and press ENTER The control file must be expressed in the following manner Use this format Where Nfff eee fff an integer file between 10 999 and eee an element number between 0 999 Nffffieeee ffff an integer file between 10 9999 and eeee an element number between 0 9999 In the PLC 5 250 when you enter the control file address the system displays a number 1 2 3 or 4 in front of the address This number represents the logic processor in the PLC 5 250 The PLC 5 250 chassis supports up to four logic processor modules For more information on logic processors refer to the PLC 5 250 Programming Software Documentation Set publication 9313 5250 5 7 Chapter 5 Configuring DFA Instructions When the control file address is entered the system prompts you to enter the number of I O Valid entries of I O are 8 16 or 32 Important
54. MC32 Type ERROR 3 Select one of the templates from the Template Editor screen and click on Edit on the Template Editor menu bar Edit Select List Type Help New Template Edit Template Delete Template 4 Select Edit Template from the drop down list or double click the selection in the Template Editor window 7 8 Chapter 7 Configuring Diagnostic Messages The Edit Template screen appears Edit Template Screen Edit Template ERROR Template Size 80 PN Processor Name jal Processor F DEFAULT x IC Instruction Comment f or ST Step Comment src es Control File DEFAULT z LA Logical Address src j Priority 10 v 5A Symbolic Address src j SC Short Addr Comment sre Eaj AC Addr Comment src mj p Extra Blanks QN ON OFF State 1 0N src _J C Show Suppress OF OFF ON State 1 OFF src a SP Step Comment dest ea DD logical Address dest a Multiple Messages 6D Symbolic Address dest I C Enable Disable GD ShortAddress Comment dest E mj A Address Bonnen dest m Send To MV Display M Marquee 1 I Marquee 2 IM Printer SingleDrop Single Drop M Logger MultiDrop full Drop Cancel m Marquee Drops Drop 1 Drop2 Drop3 Drop4 Drop5 Drop6 5 Click on the required template selection buttons that you want to use to configure your error message See the figures below for examples Select the corresponding
55. PLC 5 Processor To determine the amount of program memory used per SDS instruction in the PLC 5 processor use the following formula 22 words 3 words per I O programmed For example consider that we have 2 SDS instructions with 4 inputs and 2 outputs each 2 SDS instructions 22 words 4 inputs 3 2 outputs 3 2 22 124 6 2 40 80 words of program file memory PLC 5 250 Processor To determine the amount of program memory used per SDS instruction in the PLC 5 250 processor use the formula from Table A F depending on your number of I O Table A F Formulas for Determining Amount of Program File Memory for SDS Instructions in the PLC 5 250 Number of I O Formula 8 226 words number of I O points defined x 20 x 16 258 words number of I O points defined x 20 x 32 322 words number of I O points defined x 20 x For example consider that we have 2 SDS instructions with 8 I O 4 inputs defined and 2 outputs defined 2 SDS instructions 226 words 4 inputs 20 2 outputs 20 2 226 80 40 2 346 692 words of program file memory Appendix A Reference Information Maximum Number of Steps per SDS Instruction Tables A G and A H list the number of steps you can enter per SDS instruction in the PLC 5 and PLC 5 250 depending on the number of I O you have Table A G Number of Steps Per SDS Instruction in the PLC 5 If you have this number of I O Then you can enter this number
56. PLC5 CAF Sessssssss t File Name Type Name Size Date Time Res eS eS aS Sasa a SoaeSsosasseS eee ea reese ee Sees e Fej 0 SDS5 5672 5 04 90 12 50p 1 2 3 PRS SSS SSS SSS SSS SSS SSS SSS SS SSS SSS S55 fp SSS SSS SS SSS SS SSS SSS SSS SSS SSS SSS SSS SSSSSSH54 Press a function key or move cursor to select file gt Program PLC 5 25 Addr 5 Begin Define Select Oper Dirctry Type Fl ET F8 3 Press F8 Select Type until the CAR files appear in the file directory window 4 Cursor to the desired CAR file Important Program file numbers for the SDS and DFA instruction must be unique You need to specify only one SDS and one DFA CAR program file number per processor regardless of the number of SDS or DFA instructions you use Chapter 4 Configuring SDS Instructions 5 Download the CAR file If you are using a PLC 5 a Press F1 Begin Restore The system prompts you to enter a file number b Type the file number and press ENTER The system returns to the Program Directory If you are using a PLC 5 250 a Press F1 Begin Oper The system prompts you to enter a program descriptor b Type the program descriptor for example CARO and press ENTER In the program descriptor the first number refers to the number in the thumbwheel window on the logic processor in this case 1 A logic processor runs control logic which
57. Press F1 Online Program The system displays the online program directory see the figure below Online Program Directory PLC 5 PROGRAM DIRECTORY FOR PROCESSOR SDSDEMQ ONLINE File Name Type Size words SSeS eS So SSeS SSS Saas SSeS l l 0 system 4 1 undefined 0 2 ladder 259 3 SDSS custom routine 1350 PRSSSS SSS SSS Ss sss SSS SSS SSS SSeS SSS SSS SSS SSS SSS SSS SS SS SSS SSS SSS SSS 5555 555555555554 Press a function key or enter a program descriptor gt Program PLC 5 25 Addr 5 Proc Save Return Change Who Memory Monitor Monitor Functns Restore to Menu Station Map File SFC Fl F2 F3 F4 FS F6 F8 F9 The cursor is placed on the first user accessible file If the program directory does not list the SDS CAR file you will need to download it to the PLC 5 otherwise your can go to the Entering or Modifying an SDS Instruction on page 4 9 Downloading the SDS CAR File Important To download the SDS CAR file you must be in online programming mode Do the following to download the SDS CAR file into your program 1 Press F2 Save Restore The system displays the Save Restore function keys Chapter 4 Configuring SDS Instructions 2 Press F4 Restore Program The system displays a window containing a file directory of a specific type see the figure below File Directory Window PLC 5 PROGRAM DIRECTORY FOR PROCESSOR C IPDS ARCH
58. S turned ON 4 Concatenated message 120 is displayed on CRT and passed out COM 1 port Far sexy lt UDICICI O p gt Understanding the SDS Instruction Chapter 1 Understanding How a DDMC32 System Works An integral part of the DDMC32 system is the Smart Directed Sequencer SDS instruction see the figure below The SDS instruction provides state based control and resides in ladder logic The SDS instruction lets you develop control and diagnostic programs using state logic The SDS instruction is provided as a custom application routine CAR which is downloadable into the PLC 5 processor through 6200 Series software prior to instruction entry The CAR occupies one program file and is declared when entering an SDS instruction it is referenced by the SDS instruction at runtime Smart Directed Sequencer Instruction Terminal Display PLC 5 processor DRILL MACHINE HEAD 1 SDS SMART DIRECTED SEQUENCER Control File N10 0 Step Desc File N11 0 Length 144 No of Steps 12 Position Step No of 1 0 Prog file number Each SDS instruction contains a sequence of user defined steps which guide the logical flow of the instruction for example Ready Advancing Advanced etc Each step represents a un
59. S N10 0 Program Edit mode Insert Col 1 Line 1 PLC 5 25 Addr 1 Delete Undel Delete Undel Delete Undel Accept Comment Comment Line Line Word Word Exit Fl F2 F3 F4 F3 F6 F8 4 20 Configuring SDS Instructions Address Comment Editor Screen PLC 5 Smart Directed Sequencer I O Input Defines Output Defines Definition for Control Block I 001 16 0 000 04 N10 0 I1 001 15 0 000 01 0 0 L 1 2 1 001 14 2 0 000 02 3 83 2 ae Ins Cmt Adr Cmt 4 B3 3 4 DRILL FULL 5 5 MACHINE DEPTH LS 6 6 HEAD 1 if 7 l l l Operator Interface Station Addr 77 Timebase for Step Timer 0 01 Enter address comment for 1 001 14 Program Edit mode Insert Cols Line 1 PLC 5 25 Addr 1 Delete Undel Delete Undel Delete Undel Accept Next Prev Comment Comment Line Line Word Word Exit Address Address Fl F2 F3 F4 F5 F6 F8 F9 F10 2 Edit the instruction or address comment The function keys for both Editor screens are the same except that the Address Comment Editor screen has function keys for moving the cursor to the next or previous address If you want to Press this key F1 Delete Comment F2 Undel Comment F3 Delete Line Delete the current comment Re insert the last deleted comment where the cursor is Delete the line the cursor is on from the current comment F4 Undel Line F5 Delete Word Re insert the last deleted line from a comment
60. ashesa Working prompt indicating that a 6200 database export file is being created Later you will need to import this file The processor name is used as the name of the export file with an extension of sps For example if your processor name is DRILL the system creates an export file DRILL SDS Export files are stored in the directory C IPDS ARCH PLC5 or C IPDS ARCH PLC5250 Press F3 Exit to exit the SDS instruction configuration utility If your edits produced errors in your configuration the system prompts you to save your work Press F8 Yes The system displays the Ladder Editor main menu If you have other SDS instructions to configure or edit you can do so as described in the Enter or Modify SDS Instructions section in this chapter If not you may exit the program as described in the next chapter Chapter 4 Configuring SDS Instructions Copying the SDS Instruction Database After you update the message database you may want to copy it to disk to be used at another workstation To do this 1 Insert a disk into the disk drive 2 Exit to DOS 3 From any directory on the hard drive type ATTRIB A IPDS ARCH PLC5 processor name SDS S and press ENTER This command turns on the archive bit of all files so the next command knows which ones to copy 4 Type XCOPY IPDS ARCH PLC5 processor name SDS disk drive IPDS ARCH PLC5 processor name SDS S M and press ENTER For example
61. atch Important This type of error is not used for ANDed conditions 8 2 Input 0 Input 1 Input 2 Input 3 Step 1 ON gt 0FF OFF gt 0N OFF gt 0N OFF gt 0N Chapter 8 Debugging Your DDMC32 System The format for the input state mismatch error in the error list looks like this Step xxx Input xx transition condition results in an input state mismatch for specified destination step This condition occurs when a user specified transition along with the other specified condition of the inputs for the current step do not match the expected input conditions for the destination step See the following step configurations for an example Step 2 STEP 2 Input 0 ON gt 0FF ERSTEP 15 STEP 10 Input 1 OFF gt 0N STEP 10 ERSTEP 15 Input 2 ON gt 0FF STEP 3 ERSTEP 15 Input 3 OFF gt 0N ERSTEP 15 If input 0 goes off the system would display the following error Step 1 Input 0 transition condition results in an input state mismatch for specified destination step To correct the error you must change the input transition so that the exit conditions from one step match the entry conditions of the destination step In our example the inputs from Step 1 to Step 2 show that inputs 1 through 3 in Step 1 must be OFF however the entry conditions for Step 2 require inputs 1 and 3 to be OFF and input 0 to be ON Timer Destination Step Not Configured The format for the timer destination step not configured error in th
62. athe reaa ae 4 37 Distributed Diagnostics and Machine Control Table of Contents Configuring DFA Instructions Creating and Updating the Message Database Configuring Diagnostic Message Debugging Your DDMC32 System Chapter 5 What this Chapter Contains 0 0 0 0 eee eee eee 5 1 Diagnostic Fault Annunciator Overview 0 5 2 Programming the DFA Instruction 0004 5 2 Documenting the DFA Instruction 000000 5 12 Configuring Messages for the DFA Instruction 5 16 Exiting the DFA Instruction 00 00 00 0 eee eee 5 18 What to Do Next ercsresrirerse atien nE see aoe te 5 18 Chapter 6 What this Chapter Contains 0 00 00 eee eee eee 6 1 Importing the SDS and DFA Documentation 6 1 Message Database Options 0 0 0 e eee ee eee eee 6 3 What to Do Next wis ceva cost een eed aucune pen cene ceba ces 6 6 Chapter 7 What this Chapter Contains 2 2 0 0 0 2 reuera 7 1 Understanding the Parts of a Diagnostic Message 7 1 Diagnostic Message Types 0 0 0 0 e eee ee eee eee 7 3 Accessing the Message Template Editor Functions 7 5 Message Template Editor Function 00000 7 6 Configuring Diagnostic Messages 0 0002 eee eee 7 8 What t D NEXt 0s 464cegei suede eiiean iaaa 7 11 Chapter 8 What this Chapter Contains 0 0 00 00 e eee eee 8 1 Correcting St
63. comment Re insert the last deleted word from a comment Save the current comment and return to the Input Definition screen For Address Comments Only Save the current comment and or move the cursor to the next address Save the current comment and or move the cursor to the previous address F1 F2 F3 F4 F5 F6 F8 F9 Press this key Delete Comment Undel Comment Delete Line Undel Line Delete Word Undel Word Accept Edits Next Address F10 Prev Address 5 15 Chapter 5 Configuring DFA Instructions Configuring Messages for the DFA Instruction 5 16 The DFA instruction provides a feature which lets you enter the equivalent of pre stored text messages to relate to your inputs When an input or inputs change to the defined state ON or OFF the DDMC32 software automatically generates the message on the operator interface terminal To enter your messages follow the procedure below 1 Start on the Ladder Editing screen 2 Cursor to the DFA instruction and press F10 Edit 3 Press F2 I O Edit The system displays the DFA Message screen DFA Message Screen DFA for DFA 1 AT N9 0 No Input ID Input Message State 0 C4 01 0N TOOL CHANGE REQUIRED 1 1000 02 LUBE FAULT 2 1 000 01 LUBE LEVEL LOW 3 1 000 06 NO PARTS PRESENT 4 1 B3 03 LOAD PARTS IN STA 5 5 1 000 04 PLACE MACHINE IN AUTO MODE 6 0 000 05 TIME TO CALL MAINTENANCE 7 T5 1 0N MACHIN
64. components are properly installed and operating You do not have to change the 6180 setup information to run the DDMC32 software Install and configure Windows NT on your PC according to your product information Next install and configure RSLinx on your operator interface terminal refer to the Rockwell Software Installation Guide for Windows based products for further information 3 1 Chapter 3 Installing DDMC32 Software Installing DDMC32 Software Finally install your 6200 Series software on your PC reference the PLC 5 Programming Software documentation publication 6200 N8 001 Once you have the software installed you must configure the 1784 KT address to correspond with the switch assembly setting For the 6180 Industrial Computer set the 1784 KT address to 001011 a This address is a recommended station address only If you have conflicting hardware installed you must find your own settings There are several DDMC32 disks in the installation disk set To install your DDMC32 software follow the procedure below At this point we assume that you have formatted your hard disk and installed Windows NT 1 Insert the first DDMC32 disk into the appropriate drive 2 From the Start menu on the Windows NT Taskbar choose Run to begin the DDMC32 setup program 3 In the Run dialog box enter the drive letter and name of the DDMC32 setup program e g A setup exe 4 Ensure the drive letter is correc
65. controls steps transitions processor input interrupts selectable timed interrupts and independent background programs CAR refers to the type of file 0 refers to the program file number into which the CAR will be downloaded The system returns to the Program Directory 4 8 Chapter 4 Configuring SDS Instructions Entering or Modifying an SDS Instruction To enter or modify an SDS instruction in your ladder program 1 Cursor to the program you want to edit in the Program Directory and press F8 Monitor File The system displays your ladder program and the Ladder Editor main menu Cursor to the rung where you want to position the SDS instruction If you are modifying an existing rung cursor to the SDS rung Important When cursored on the R rung of an IR Insert Replace rung pair the SDS configuration utility uses the configuration information from the I rung Press F10 Edit The system displays the Ladder Editing screen If you are editing an existing rung press F5 Modify Rung If you are entering a new rung press F4 Insert Rung The system displays the Edit Rung screen If you want to change an existing instruction press F5 Modify Instruction If you are entering a new instruction press F4 Insert Instruction The system prompts you for the instruction you want to add 4 9 Chapter 4 Configuring SDS Instructions 6 Type SDS if it does not already appear at the
66. ct the error select a valid destination step Invalid Configuration The format for the invalid configuration error in the error list looks like this Invalid configuration no valid steps This condition occurs when you attempt to accept edits without configuring any steps or when the data table is somehow altered outside of the configuration utility To correct the error configure steps you need for your application 8 4 Locating Sequencing and Timing Errors Chapter 8 Debugging Your DDMC32 System Marked Exit The marked exit error looks like this in the error list Marked exit destination cannot be 0 init or error step This error occurs when you designate a marked exit for a step with a destination of 0 init or an error step To correct the error you must change the destination step of the marked exit to a non error step Warning Timeouts The warning timeouts error looks like this in the error list Warning timeouts require at least one non error input transition destination This error occurs if you designate the destination of a step timeout as WARNING and all of the transitions in that step go to error steps step 0 or INIT To correct the error you must provide a non error destination for at least one of the inputs in the step configuration DDMC32 offers various utilities for showing sequence and timing of inputs and outputs These are a I O Monitor a Step History a Input History
67. ctions and continue with the setup as described Chapter 3 Installing DDMC32 Software 3 6 10 Click on the Next button The Add DDMC32 to Startup Folder screen appears Add DDMC32 to Startup Folder screen Setup lt Back Cancel 11 Select Yes to add DDMC32 to your Startup folder The default is No in which case DDMC32 will not be added to your Startup folder 12 Click on the Next button The Start Copying Files screen appears Start Copying Files x Setup has enough information to start copying the program files If you want to review or change any settings click Back If you are satisfied with the settings click Next to begin copying files Current Settings Destination C DDMC32 Program Folder Rockwell Automation DFA Option selected ia Cancel Chapter 3 Installing DDMC32 Software Your selections up to this point are listed You can either go back and change them or click on the Next button to accept your selections and begin copying files to your hard drive While files are being copied the Progress screen is displayed Setup DDMC32 Progress screen Setup PSY DY LOED This screen shows the progress the installation disk is making Follow the instructions on the screen to complete the setup The following window will appear each time a new disk is required for the setup Follow the instructions and click on the OK button to cont
68. currence e g use an to precede the start of your message each time it creeps across the display a Enter how quickly you want the message to move across the screen a Enter the display width Use this value to determine the width of your message a Enter the actual text of the message you want to be displayed a Enter the direction of the creep Choose from Left to Right or Right to Left 9 4 Selecting Instruction Types Auto Starting DDMC32 Auto Hiding the Banner Chapter 9 Configuration and Operation of the DDMC32 System Select this option to configure the DDMC32 software to look for DFA and or SDS messages 1 From the Configure menu choose Select Instruction Type s The Select Instruction Type s screen appears Select Instruction Type s Select Instruction Type s Eg Please select the type s of instructions that you will be using with DDMC32 IV DFA Instructions IV SDS Instructions Cancel 2 Check the DFA and or SDS Instruction checkboxes as appropriate for your needs 3 Click on OK to finish You can elect to Auto Start DDMC32 software whenever you log in to your Windows NT system To enable this option from the Configure menu choose Auto Start DDMC32 The software will then automatically be launched every time you log in To disable this option simply choose it from the Configure menu again The DDMC32 system enables you to enable or disable the screen banner each tim
69. documented all of your input information the system asks if you want to save your work Press F8 Yes The system displays the Ladder Editor main menu If you have other DFA instructions to configure or edit you can do so as described in the Enter or Modify DFA Instructions section in this chapter If not you may exit the program as described in the next chapter Chapter 6 describes how to create a message database with the documentation imported from the DFA instruction What this Chapter Contains Importing the SDS and DFA Documentation Creating and Updating the Message Database Read this chapter to learn how to import the documentation from the SDS instruction s and the DFA instruction s into the message database so it can be used by the DDMC32 software This chapter contains the following sections Section Page Importing the SDS and DFA Documentation 6 1 Message Database Options 6 3 What to do Next 6 5 When you are done configuring your ladder program or making changes in the Ladder Editor you are ready to exit the program If you want the DDMC3 software to reflect any of the documentation changes or additions made to the program you must import the information into the DDMC32 message database At this point all SDS and or DFA documentation has been written to an ASCII file To import SDS and or DFA instruction information to the DDMC32 message database follow the procedure on the following pag
70. dress comment window and display the Address Comment Editor Assign a symbol to an address or change and existing symbol Remove the symbol from the current address Switch between address comment symbolic name or logical address of input The function key always displays the next format for example if address comments are being displayed then F2 reads Display Symbol Save your work in the database If you are editing off line the archive file is updated and the comment and symbol files are saved If you are editing on line only the comment and symbol files are saved F3 F6 F9 Press this key Instr Comment Address Comment Modify Symbol Remove Symbol Display Comment S ymbol Log Adr F10 Save amp Contnue Editing Instruction and Address Comments To activate the cursor in the instruction comment window press F2 Instr Comment from the DFA Instruction Documentation screen Chapter 5 Configuring DFA Instructions 5 14 The system displays the Instruction Comment Editor screen Instruction Comment Editor Screen Diagnostic Fault Annunciator Input Defines Definition for Control Block 1 001 16 N10 0 I 001 15 0 a 2 1 001 14 3 I8 003 02 Ins Cmt Adr Cmt 4 IS 003 03 DRILL RETURNED L 53 MACHINE l IS 6 HEAD 1 T I l 4 Operator Interface Station Addr 77 Enter instruction comment for SDS
71. dress comments For example Start Stop 1 AND All Sta s Returned 1 AND Start Auto 1 You can use the F9 Toggle Equatn key from the Equation List or Equation Zoom screens to view the different forms of your equation 8 Press Esc again and the system returns you to the Edit Step screen Exiting the SDS Instruction Once you have configured all of your steps you can save and exit the SDS instruction To save the SDS instruction 1 Press ESc The system displays the Step Directory 2 Press F10 Accept Edits The system prompts you to confirm your decision 3 Press F8 Yes If your configuration is correct the system returns to the Step Directory Continue with Step 4 Chapter 4 Configuring SDS Instructions 4 32 If your configuration contains errors the system displays an error list that describes each error in the configuration To correct errors a Press ESC The system displays the Step Directory which now contains F9 Display Err Lst To view the list at any time press F9 b Reconfigure steps from the Edit Step screen as needed to correct the errors and repeat Steps 1 2 and 3 Refer to the chapter entitled Debugging Your DDMC32 System for correcting step configuration errors Important If this is a new SDS instruction or if you updated an existing instruction changed an address comment or step name press F2 Update Msg DB update message database The system fl
72. e shows the Input Definition Screen for entering inputs Important If you are modifying information you see fewer function key options see the table on pages 5 9 and 5 10 Input Definition Screen for entering inputs a Diagnostic Fault Annunciator Input Defines b Definition for Control Block 0 N27 0 1 I 001 10 2 SWITCH1L 3 B3 30 Ins Cmt Adr Cmt 4 0 002 02 ASSEMBLY new input 55 0002301 MACHINE 6 T 001 11 l 7 8 9 10 ADs Operator Interface Station Addr 77 12 13 14 15 Press a key to change a parameter or lt ENTER gt to accept parameters gt Program Forces None Edits None PLC 5 25 Addr 5 Station Documnt Modify Insert Delete Remove Address Inputs Inputs Inputs Inputs Fl FS F7 F8 F9 F10 E The Ins Cmt Instruction Comment window on the Input Definition screen displays the name of the instruction from the ladder program The Adr Cmt Address Comment window displays the address comment for the cursored address in the Input Defines field The number of inputs in the Input Defines field correlates with the number of inputs you entered when programming the DFA instruction You can perform the following tasks from the Input Definition screen If you want to Press this key Enter an operator interface station address F1 Station Address Enter the port number for the message F3 Port PLC 5 250 only 5
73. e the file is deleted and the File Delete Complete screen appears File Delete Complete File Delete Complete Database File Delete completed 4 Click on OK to close this window Now that you have completed creating and or updating your message database you can configure the Diagnostic Message Utility Chapter 7 describes the procedures for Configuring Diagnostic Messages 6 5 Chapter 6 Creating and Updating the Message Database Notes 6 6 What this Chapter Contains Understanding the Parts of a Diagnostic Message Configuring Diagnostic Messages Read this chapter to learn about diagnostic messages provided in the DDMC32 system and procedures to configure the format for diagnostic messages To configure diagnostic messages you a build the message out of fragments and link the text with your own words a select options for message display This chapter contains the following sections Section Page Understanding the Parts of a Diagnostic Message 7 1 Diagnostic Message Types 1 3 Accessing the Message Template Editor Functions 7 5 Configuring Diagnostic Messages 7 8 What to do Next 7 11 The DDMC32 software contains a routine that generates messages as faults occur When a fault is detected by the SDS or DFA instruction the operator interface terminal automatically displays a message in a window reserved for messages if configured by the user That same message can also be broadcast t
74. e and test mode F1 Change Mode Select between address comment symbolic name F2 Display Comment S ymbol or logical address of I O The function key always Log Adr displays the next optional format for example if address comments are being displayed then F 2 reads Display Symbol Exit the configuration utility F3 Exit For SDS Instructions only F 4 Step History Display the step history screen Display the input history screen F5 Input History F6 Extnded Status F8 Step Dirctry Display the extended status screen Display the Step Directory 8 6 Chapter 8 Debugging Your DDMC 32 System Using the Step History The step history shows the steps in your SDS instruction as they occur and the time it takes each step to occur You can use the step history to determine if steps are taking too long or occurring at the wrong time To access the step history press F4 Step History on the I O Monitor screen The following screen shows a step history for a transfer line station Step History for a Transfer Line Station Step History for STATION 7R accumulated time duration step stepname 00 00 00 36 00 00 00 36 READY TO START 1 00 00 02 36 00 00 02 00 2 PART IN PLACE 00 00 04 35 00 00 01 99 3 CLAMP ING 00 00 07 36 00 00 03 01 4 STARTING SPINDLES 00 00 07 86 00 00 00 50 5 CYCLING IMC AXIS 00 00 36 86 00 00 29 00 6 ADVANCING SLIDE 00 00 39 87 00 00 03 01 3 SLIDE FULL
75. e error list looks like this Step xxx timer specified destination step is not configured This condition occurs when the step timer destination step is not a valid step To correct the error you must either configure the specified step or change the step to an already configured step 8 3 Chapter 8 Debugging Your DDMC 32 System Timer Destination Step Out of Range The format for the timer destination step out of range error in the error list looks like this Step xxx timer specified destination step is out of range This condition only occurs if changes were made outside of the configuration utility resulting in an invalid configuration To correct the error you must select a valid destination step Destination Step Not Configured The format for the destination step not configured error in the error list looks like this Step xxx Input xx specified destination step is not configured This condition occurs when an input transition destination is not a configured step To correct the error you must either configure the specified step or change the step to an already configured step Destination Step Out of Range The format for the destination step out of range error in the error list looks like this Step xxx Input xx specified destination step is out of range This condition only occurs if changes were made outside the configuration utility resulting in an invalid configuration To corre
76. e providing access to vital plant floor data that can be used to support decision making throughout the enterprise ASIA PACIFIC CANADA LATIN AMERICA HEADQUARTERS HEADQUARTERS HEADQUARTERS Allen Bradley Hong Kong Allen Bradley Canada Allen Bradley Limited Limited 1201 South Second Street Room 1006 Block B Sea 135 Dundas Street Milwaukee WI 53204 USA View Estate Cambridge Ontario NIR Tel 1 414 382 2000 28 Watson Road 5X1 Telex 43 11 016 Hong Kong Canada FAX 1 414 382 2400 Tel 852 887 4788 Tel 1 519 623 1810 Telex 780 64347 FAX 1 519 623 8930 FAX 852 510 9436 PN955130 93 Printed in USA
77. e step description file for an SDS instruction with 8 16 and 32 I O Table A E Step Description File Size Requirements for both PLC 5 and PLC 5 250 Number of I O Number of Words Needed for Each Step in Step Description File 8 13 16 22 32 43 Determining Amount of Data Table Memory Needed for SDS Instructions When used for control and diagnostics as opposed to monitoring only the SDS instruction requires at least twice as much memory as the original ladder logic You must take this into account when planning your program To calculate the amount of memory required for an SDS instruction use the following formula size of control file number of steps defined x words needed per step For example consider that we have 4 SDS instructions in the PLC 5 with 10 steps each Each instruction has 8 inputs and 8 outputs 68 words needed for control file 10 steps x 13 words needed per step 198 words per SDS x 4 SDS instructions 792 words of data table memory Determining Amount of Program File Memory Needed for SDS CAR File An SDS instruction uses program memory for the contents of the CAR file The SDS CAR uses 1267 words of program memory in the PLC 5 processor and 1280 words of program memory in the PLC 5 250 processor The total amount of program memory used is different depending on if you are using a PLC 5 processor or a PLC 5 250 processor A 3 Appendix A Reference Information A 4
78. e you start DDMC32 To enable this option from the Configure menu choose Auto Hide Banner Checking this option automatically minimizes the message banner if there are no messages If you select this option you must restart the DDMC32 application before the new changes will take place To disable this option simply choose it from the Configure menu again 9 5 Chapter 9 Configuration and Operation of the DDMC32 System Auto Purging the Database Starting and Stopping DDMC32 9 6 The DDMC32 system enables you to automatically purge the Fault table of the current DDMC32 database To enable this option from the Configure menu choose Auto Purge Database The frequency with which the database is purged depends upon the number of days you entered when selecting your database If you select this option you must restart the DDMC32 application before the new changes will take place To disable this option simply choose it from the Configure menu again The DDMC32 system is started from your Windows NT main menu or desktop Once the DDMC32 main screen appears click on DDMC32 to get the following drop down menu DDMC32 system menu options BBSS Monitor Database Start DDMC32 Stop While Message Template Editor Starting the DDMC32 system From the DDMC32 menu choose Start DDMC32 to begin The DDMC32 main screen will be minimized and the Message Banner if enabled appears Once the system is started it be
79. ed Status Screen for a DFA Instruction gt Message Type 0 PLC Type 0 Processor Name Control File Number 0 Control File Element Number 0 Message Active Bits 0000 0000 0000 0000 15 0 0000 0000 0000 0000 31 16 Mapped Inputs 0000 0000 0000 0000 15 0 0000 0000 0000 0000 31 16 Message Clear Bits 0000 0000 0000 0000 15 0 0000 0000 0000 0000 31 16 Press a function key gt 5 250 Addr 5 DB_TEST E The Extended Status screen for the DFA instruction gives you information about your inputs at the bit level The information is less complex than that of the Extended Status screen for the SDS instructions because DFA is a monitoring only function While in the Extended Status screen you can use F2 Display Comment Symbol Adr to select between address comment symbolic name or logical address of I O The function key always displays the next format for example if address comments are being displayed then F2 reads Display Symbol Certain problems could occur while you are configuring your operator interface The following table lists some problems that could occur Troubleshooting Operator Interface Problems If this is happening Then you should Check each SDS instruction to make sure the operator interface station address specified is the correct address operator interface terminal or annunciator panel Import or update the message database SDS but they are printing with the database re
80. ee an element number between 0 9999 In the PLC 5 250 when you enter the control file address the system displays a number 1 2 3 or 4 in front of the address This number represents the logic processor in the PLC 5 250 Important The control file and the step descriptor file addresses must be local to the logic processor that is executing the associated SDS instruction Do not place either of these files in system memory Do not reference this step descriptor file in other logic processors The PLC 5 250 chassis supports up to four logic processor modules For more information on logic processors refer to the PLC 5 250 Programming Software Documentation Set publication 9313 5250 When the Control File address is entered the system prompts you to enter the Step Description File address 4 11 Chapter 4 Configuring SDS Instructions 2 Determine the Step Description File address The Step Description File address must be expressed in the manner shown in the following table For the Use this format Where PLC 5 Nfff eee fff an integer file between 10 999 and eee an element number between 0 999 PLC 5 250 Nffff eeee ffff an integer file between 10 9999 and eeee an element number between 0 9999 If you want to start your step description file at the end of the control file you need to leave enough memory for the control file The amount of memory used by the control file depends on the number
81. elow show the levels of implementation Levels of DDMC32 Implementation Level 3 The DFA instruction can be used on all levels since it is used for global type errors Unlike the SDS instruction which e SDS Instruction for Control is constructed around a given mechanism and its associated and Diagnostics I O the DFA instruction is constructed around constantly e DFA Instruction for Messages monitored conditions that do not fit into a state structure Level 2 e Ladder Logic for Control e SDS Instruction for Messages and Diagnostics e DFA Instruction for Messages Level 1 e Ladder Logic for Control and Diagnostics e DFA Instructions for Messages Important A Level 3 Implementation does not limit you to only using the SDS instruction for control and diagnostics You may also include Level 1 and Level 2 Implementations for diagnostics outside of the Level 3 SDS instruction for example lube faults or overloads Description of DDMC32 Levels This level Uses this Control is handled by Diagnostics are Message DDMC32 handled by Generation is instruction handled by 1 ladder logic ladder logic DFA 2 SDS and DFA ladder logic SDS and DFA 3 SDS and DFA SDS and ladder logic SDS SDS and DFA DDMC32 System Components A typical DDMC32 system applies the following system components 6400 Series Software Monitoring software 6404 DDMC 6200 Series Software a PLC 5 family of programmable controlle
82. ep Configuration Errors 200000 8 1 Locating Sequencing and Timing Errors 8 5 Troubleshooting Problems in Your Operator Interface 8 12 What to Do Next 0 cece cece eee ee eee eens 8 13 Configuration and Operation of the DDMC32 System Using the Report Generator Software Reference Information Distributed Diagnostics and Machine Control Table of Contents Chapter 9 What this Chapter Contains 0 0 00 ruuan eee ee ee 9 1 Configuring Output Devices sussuusaurrrrrurn eee 9 2 Configuring the Clock Creep Option 04 9 2 Selecting Instruction Type s to Use 000 9 5 Auto Starting DDMC32 0 2 eee eee 9 5 Auto Hiding the Banner 0 0 0 0 e eee eee eee ee 9 5 Auto Purging the Current Database 0 4 9 6 Starting and Stopping DDMC32 Software 9 6 Monitoring the Fault Log 0 0 0 eee eee eee ee 9 7 Clearing the Fault Log cres cire cocrcrs cresrorciesrereria 9 7 What to Do Next vce ste cease ewsd eas tE deeds ee eee 9 7 Chapter 10 What this Chapter Contains 0 0 0 0 0 eee eee ee 10 1 Becoming Familiar with the Report Generation Options 10 1 Menu Selections 0 0 0 cece 10 3 Configuring Reports 0 0 0 cece eee eee 10 4 Generating Reports 0 0c cece eee eee 10 8 Scheduling Reports 0 0 0 0 e eee eee eee ee eee 10 10 Miscellaneous Operation
83. es 6 1 Chapter 6 Creating and Updating the Message Database 1 From the Database menu choose the appropriate command for the type of instruction information you want to import into the database For DFA Instruction Information Select Import 6200 DFA File The Import 6200 DFA File screen appears Current Database TEST Done Import File Browse cme Import Progress 0 100 For SDS Instruction Information Select Import 6200 SDS File The Import 6200 SDS File screen appears Current Database TEST Done Import File Browse Cancel Import Progress 0 100 2 Enter the import path file or click on Browse to locate the file to import 3 Click on OK The Import Progress bar will show you the progress of the file import process Repeat this process for each SDS and or DFA file you want to import 4 Click on Done when complete 6 2 Chapter 6 Creating and Updating the Message Database Message Database Options You may select create or Copy a DDMC32 database by clicking on the desired option from the menu The following screens are displayed according to the option you have chosen Select Database Select DDMC32 Database Current Database DDMC32 Select a DDMC32 Database Cancel DDMC32 Keep last 7 days of Fault Log data Create Database Create DDMC32 Database Current Database DDMC32 Done Create Database Browse Carcel Copy Database
84. et accuracy is limited to 16 bits The other 16 bits are not lost by the PLC 5 they are just not used 4 36 Chapter 4 Configuring SDS Instructions To retrieve an SDS instruction from a file 1 Press F4 Change Config from the Extended Edit screen The system displays the Change Configuration screen below Change Configuration Screen PLC 5 a 06 08 90 09 35 26 b DRILL MACHINE HEAD 1 NUMBER OF STEPS 12 NUMBER OF IO 8 Use up or down arrow to choose a configuration and RETURN to select PLC 5 25 Addr 1 J Cursor to the file you want to copy and press ENTER If the file contains too many steps or I O the system displays a message telling you that you cannot copy the configuration Otherwise the configuration is copied The system returns to the Step Directory screen What to Do Next Once you have configured all of your steps save the SDS instruction Chapter 5 describes how to configure a DFA instruction Chapter 6 describes how to create and or update a message database with the documentation you import 4 37 Chapter 4 Configuring SDS Instructions Notes 4 38 What this Chapter Contains Configuring DFA Instructions Read this chapter to learn about the DFA instruction and procedures that describe a programming the DFA instruction a configuring the DFA instruction Important You can use the DFA instruction in either the PLC 5 processor or the PLC 5
85. expected inputs If inputs do not match the instruction continues its a search When the instruction finds a match it enters the step STEP 1 EXPECTED INPUTS STEP 2 EXPECTED INPUTS ead gt ON ad gt ON gq gt ON Nm gt OFF Od gt ON olad gt ON ONE gt OFF OE gt OFF During runtime an input change or a step timer timeout directs the SDS to another step If the instruction detects a mismatch the actual inputs do not match the expected inputs it generates a mismatch fault To aid you with programming the software looks for obvious programmed mismatches before you accept an instruction How the Combinatorial SDS Instruction Handles Inputs Combinatorial equations define destination steps based on input state values and the relationship between a collection of inputs The combinatorial equation lets you accommodate complex combinations in the instruction while keeping the number of steps within a configuration to aminimum You can define up to 4 logical AND combinations in an 8 input SDS instruction You can define up to 8 ANDed conditions in a 16 or 32 input instruction Chapter 1 Understanding How a DDMC32 System Works 1 6 The instruction scans the inputs from the top of the input list to the bottom looking for a transition When the actual inputs do not match the expected inputs the instruction begins scanning the combinatorial equations for a match and remains in the step unt
86. f you choose not to configure your own message fragments 7 3 Chapter 7 Configuring Diagnostic Messages Message Description Step from 0 A step 0 message is displayed when an SDS instruction moves from a step 0 to any other step The destination step must have MSG S ON one valid exit timeout A one valid exit timeout message is displayed when the step timer causes an exit condition and the destination step has MSG s ON This message is displayed when the step has only one valid exit A valid exit is a destination step that is not an error step or Step 0 Example configuration instruction comment timeout while step bit or input device didn t turn bit state For example ASSEMBLY MACHINE TIMEOUT WHILE LOADING PARTPRESENT DIDN T GO ON error An error message is displayed when an error step ERSTEP is entered with the message function turned ON The message remains on the display until the SDS instruction passes through Step 0 Example configuration instruction comment was step when bit or input device turned bit state For example DRILLSTA 2 WAS ADVANCING WHEN RETURNEDLS TURNED ON init error An INIT error message occurs when an instruction can not leave the initialization step after two program scans because the inputs do not match any steps in the instruction input mismatch A mismatched step message occurs when a transition condition either input transition or step timer occurs but the inputs taken from t
87. fer to chapter 6 tag instead of the address comments you entered in the SDS instruction What to Do Next Chapter 8 Debugging Your DDMC32 System Once the system is fully configured and free of bugs the operator can monitor and operate the system Chapter 9 Configuration and Operation of the DDMC32 System tells you how to configure start and run the DDMC32 system Chapter 8 Debugging Your DDMC32 System Notes What this Chapter Contains Configuration and Operation of the DDMC32 System Read this chapter to become familiar with configuring starting and running the DDMC32 system This chapter contains the following sections Section Page Configuring Output Devices 9 2 Configuring the Clock Creep Option 9 3 Selecting Instruction Type s to Use 9 5 Auto Starting DDMC 32 9 5 Auto Hiding the Banner 9 5 Auto Purging the Current Database 9 6 Starting and Stopping DDMC 32 Software 9 6 Monitoring the Fault Log 9 7 Clearing the Fault Log 9 7 Chapter 9 Configuration and Operation of the DDMC32 System Configuring Output Devices From the Configure menu you can set the output for your marquee and or banner select the type of instructions to be displayed and enable auto start for several options Configuring Marquees 1 From the Configure menu choose Output Devices The Configure Output Devices screen appears Configure Output Devices screen Configure Output Devices T Marquee 1 T Ma
88. fields are This setting Has this default outputs off type of step normal step destination step timer destination step timer 0 00 disabled messaging off Configuring or Editing Combinatorial Equations With the addition of the combinatorial function the step configuration utility lets you use AND and NOT functions in addition to the traditional ON gt OFF and OFF gt ON transitions This lets you a enter an equation that will solve steady state conditions and expressions select the traditional transition conditions Important The order in which you configure your steps is important Step assignment should reflect as closely as possible the order that operations occur on the particular machine e g step 1 machine startup step 2 first machine operation step 3 second machine operation etc This will help you organize your SDS instruction in a format that can be understood at a later date if troubleshooting is necessary More important than organizational considerations is the functional impact that order has on the SDS instruction By logically presenting your steps in order of machine operation you will avoid going to improper destinations when step destinations are zero or initialize 4 27 Chapter 4 Configuring SDS Instructions To configure or edit combinatorial equations you must enter some additional information not needed in transitional equations 1 Access the Edit Step screen seen below
89. g Fl F3 F4 F5 F6 F7 F10 a 7 Press F10 Accept Rung Important You must accept the rung to save the information you entered into the DFA instruction 5 11 Chapter 5 Configuring DFA Instructions Documenting the DFA The DFA instruction provides a documentation function that lets you Instruction describe the instruction and its associated addresses The documentation function also lets you assign symbols to addresses To document your DFA instruction press F5 Documnt from the Input Definition screen The system displays the DFA Instruction Documentation screen next page DFA Instruction Documentation Screen Diagnostic Fault Annunciator Input Defines Definition for Control Block 1 001 16 0 N10 0 1 I 001 15 2 I1 001 14 3 I8 003 02 Ins Cmt Adr Cmt 4 IS 003 03 DRILL RETURNED L 5s MACHINE l IS 6 HEAD 1 Ti l 4 Operator Interface Station Addr 77 Press a function key gt Program Forces Disabled Edits None Addr Decimal PLC 5 25 Addr 5 Instr Address Modify Remove Display Save amp Comment Comment Symbol Symbol Symbol Contnue LS F2 F3 F6 EF F9 e 5 12 Chapter 5 Configuring DFA Instructions From this screen you can perform the following documentation tasks If you want to Activate the cursor in the instruction comment window and display the Instruction Comment Editor Activate the cursor in the ad
90. g amount of data table memory needed A 3 determining amount of program file memory needed A 3 documenting 4 18 entering 4 9 entering I O addresses 4 17 entering I O information 4 14 entering instruction information 4 11 entering the control file address 4 11 entering the step description file address 4 12 importing 6 1 maximum number of steps allowable A 5 message control block address 4 14 modifying 4 9 overview 1 3 4 2 for the PLC 5 4 2 program file number 4 13 programming 4 5 in the PLC 5 250 4 5 reference information A 1 step description file size requirements A 3 step directory 4 22 transitional 1 4 4 2 Smart Directed Sequencer SDS instruction execution times A 1 inputs within transitional 1 4 message generation 1 6 outputs within 1 6 Smart Directed Sequencer Instruction copying editing 4 34 status messages 7 4 Step 0 vs INIT 4 26 step comment 7 2 Step Configuration Errors 8 2 Step Description File Address for the SDS instruction 4 12 step description file address 4 12 Step Description File Size Requirements for the SDS instruction A 3 Step directory screen 4 22 Step History 8 7 Step Name 4 25 step timeout messages 7 4 Step Timer 4 26 Step Timer Timebase 4 16 Suppressing Displaying blanks in DDMC32 messages 7 9 T T60 Industrial Workstation 1 11 Template Editor 7 6 Edit templates 7 7 File exit Menu bar 7 6 Configuring the template Message Edit
91. g and timing 8 5 destination step not configured 8 4 destination step out of range 8 4 in the step configuration 8 2 input state mismatch 8 3 invalid configuration 8 4 marked exit 8 5 timer destination step not configured 8 3 timer destination step out of range 8 4 warning timeouts 8 5 for the SDS instruction A 1 exiting the DFA instruction 5 18 Extended Edit screen 4 34 Extended Status 8 10 Execution Times for a DFA instruction A 7 F Fault Log daily 10 11 Display Fault Log 10 11 Editing Configuring 10 6 printing a report 10 12 Faults displaying by duration 10 12 Fragment Length 7 11 H Help 7 8 l T O monitor display 8 5 Importing DFA Instructions 6 1 Importing SDS Instructions 6 1 INIT vs Step 0 4 26 Initialization 4 26 Input History 8 8 Input Information for the DFA instruction 5 9 Installation DDMC32 system components using a 6180 Industrial Computer 2 3 Installing DDMC32 software 3 2 Instruction Comment 4 15 5 9 editing 4 20 5 13 instruction comment 7 2 K KT switch settings for a 6180 Industrial Computer 2 4 L levels of SDS instruction implementation 1 8 M Message Control Block Address entering for the DFA instruction 5 8 entering for the SDS instruction 4 14 Message Database copying 4 33 importing DFA documentation 6 1 importing SDS documentation 6 1 Diagnostics 7 2 Message Fragments 7 11 Configuring and editing dia
92. ges are cleared when the instruction moves to the next step Chapter 1 Understanding How a DDMC32 System Works Understanding the DFA The Diagnostic Fault Annunciator DFA instruction is a monitoring only Instruction instruction that is it monitors inputs you define but it cannot control outputs Valid inputs can be a storage points such as binary bits counter timer done bits a outputs real or logical a lube level sensors alarms a fault bits set by another device or by ladder logic a any valid bit address The following figure shows a DFA instruction in a ladder program A DFA Instruction PLC 5 250 ASSEMBLY MACHINE DFA DIAGNOSTIC FAULT ANNUNCIATOR Control File N27 0 No of I O 16 Program file number 3 Msg Control Block OMSGO0 0 If you currently have diagnostics programmed in ladder logic you can use the DFA instruction to generate messages when a fault occurs In addition you can create other types of operational and diagnostic messages with the DFA instruction such as tool change messages and operating instructions Chapter 1 Understanding How a DDMC32 System Works Implementing DDMC32 You can implement DDMC32 instructions at three different operational Instruction in Levels levels depending on the amount of diagnostics and control that you need for your application Each level provides incremental increases in terms of diagnostic coupling with the control The figure and table b
93. gins displaying messages from the PLC processor and outputting formatted messages to the selected output devices Stopping the DDMC32 system From the DDMC32 menu choose Stop DDMC32 to remove the Message Banner if enabled and stop the output of formatted messages to the selected output devices Note If the Message Banner is displayed you will have to minimize it in order to be able to access the menu options Monitoring the Fault Log Clearing the Fault Log What to Do Next Chapter 9 Configuration and Operation of the DDMC32 System If you have enabled the logging function you can monitor the fault log to see which faults have occurred To monitor the fault log from the Monitor menu choose Monitor Fault Log To clear the fault log of all faults from the Monitor menu choose Clear Fault Log You must stop the DDMC software first Once you select this option you will be prompted to confirm that you wish to finish the clear process Once you confirm you will see a message indicating that all faults have been cleared Once the system is fully configured the operator can monitor the system Chapter 10 Using the Report Generator Software tells you how to monitor the system reports and faults 9 7 Chapter 9 Configuration and Operation of the DDMC32 System Notes 9 8 What this Chapter Contains Becoming Familiar with the Report Generation Options Using the Report Generator Software Read t
94. gnostic messages 7 5 mismatched step messages 7 4 MMS diagnostic messaging instruction comment 7 2 step comment 7 2 Formatting Fault Log 10 8 Modify 10 9related publications P 5 N Number of I O entering for the DFA instruction 5 8 0 One Valid Exit Timeout Messages 7 4 Operator Interface Station Address 4 16 5 10 Operator Interface Terminal set up of 6180 Industrial Computer 3 1 Output State 4 26 P PLC 5 1 10 Port Number 4 16 5 10 Print Fault Log 10 12 Printing Reports 10 12 Program File Memory amount needed for a DFA instruction A 9 determining amount needed for an SDS instruction A 3 Program File Number I 3 L 4 entering for the DFA instruction 5 8 entering for the SDS instruction 4 13 Programming SDS instruction in the PLC 5 250 4 5 Programming the DFA Instruction 5 2 downloading the CAR utility 5 4 entering an instruction 5 5 in a PLC 5 processor 5 5 in a PLC 5 250 processor 5 5 Programming the SDS Instruction 4 5 Programming the SDS instruction downloading the CAR utility 4 6 R related publications P 5 Report Open 10 10 Report Generation 10 10 Report Generation Software becoming familiar with 10 1 Report Generator software 10 1 S Schedule 10 4 Smart Directed Sequencer SDS Instruction combinatorial 1 5 4 3 completing entry of 4 31 configuring 4 22 control file layout A 6 control file size requirements A 2 determinin
95. h input to transition The input history is similar to the step history Use the input history to determine if inputs are transitioning at the right time or taking too long to transition See page 8 9 for an example of an input history for a transfer line station Chapter 8 Debugging Your DDMC 32 System Input History for a Transfer Line Station SDS Instruction Input History for STATION 7R accumulated time duration input state address 00 00 00 53 00 00 00 53 2 1 006 01 I 00 00 01 81 00 00 01 28 2 0 I 006 01 00 00 02 04 00 00 00 23 3 1 I 006 02 00 00 03 03 00 00 00 99 3 0 1 006 02 00 00 03 05 00 00 00 02 9 1 I 001 04 00 00 03 75 00 00 00 70 9 0 1 001 04 00 00 03 99 00 00 00 24 t a I 006 00 00 00 07 03 00 00 03 04 1 0 1 006 00 Press a key for desired histogram function RUN Hist Started Mode Paged Disk Recording Off Current Step 13 Start Stop Contin Paged Input Write History History Mode Mode Trigger To Disk Fl F2 F3 F4 P5 F8 You can perform the following tasks from the Input History screen If you want to Press this key Begin monitoring the current instruction F1 Start History Stop monitoring the current instruction F2 Stop History Display data continuously on the screen as new F3 Contin Mode data is collected If new data is generated faster that the display can be updated eventually the data buffers overflow and Data Overrun is displayed Display data one page ata time Press
96. he PLC data table do not match the expected inputs for the destination step This message remains on the display for as long as the input mismatch lasts Example configuration instruction comment can t enter step D because bit or input device D bit state D For example PALLITZER CAN T ENTER LOADING BECAUSE GATE4SENSOR DIDN T TURN OFF Status A status message is displayed when a normal step is entered with the message function turned ON The message remains on the display until the current step is exited Example configuration the processor name instruction comment is step For example THE AREA2 BATCHING OPERATION IS MIXING step timeout A step timeout message is displayed when the step timer causes an exit condition and the destination step has the message function turned ON Example configuration processor name instruction comment timed out while step For example OP150 STATION 25L TIMED OUT WHILE RETURNING warning timeout A warning timeout messages occurs when a transition is taking too long to occur The SDS remains in the same step while the message is displayed 7 4 Chapter 7 Configuring Diagnostic Messages Message Description Example configuration Warning instruction comment is step too long For example WARNING WELDING FIXTURE 171S CLAMPING TOO LONG DFA The DFA message occurs when a message is sent from the DFA instruction Example configuration DFA bit message For example
97. his chapter to learn how to access screens within the DDMC32 Report Generator software to analyze your DDMC32 databases DDMC32 Report Generator software offers several options to help you maintain and troubleshoot your system Some of the ones you may use include predefined and custom reports a scheduled automatic reports a multiple report display This chapter contains the following sections Section Page Becoming Familiar with the Report Generation Options 10 1 Menu Selections 10 3 Configuring Reports 10 4 Generating Reports 10 8 Scheduling R eports 10 10 Miscellaneous Operations 10 12 What to Do Next 10 12 Your point of access to the Report Generation software is the Menu bar of DDMC3 ie Help Report Generation Chapter 10 Using the Report Generator Software Click on Report Generation The New Report screen appears New Report screen E new_rpt DDMC32 MDB DDMC32 Report Generator File Edit View Schedule Help piela e Sl Tuesday 11 04 97 04 15 59 4 From this screen you may select from File Edit View Schedule and Help File Selection Menu gem Edt View Schedule Help Database Alt D New Format AlN Modify Format Alt hM Generate Report Alt D Open Report Alt 0 Save As Print Alt P Print Setup See the next section for a description of these options Menu Selections Chapter 10 Using the Report Generator S oftware Reference the following tables fo
98. hould you choose to install the Software on additional computers or increase user access via a network server you must first acquire a license for each additional user who will use the Software with the understanding that at any one point in time and regardless of the number of media sets included with the Software the number of users who are permitted to use the Software may not exceed the number of single user licenses you have acquired If this Software is an upgrade from a previous version of a Rockwell Automation product may not transfer the prior version to another user This Agreement supersedes any x Do you accept all the terms of the preceding License Agreement If you choose No Setup will close To install DDMC32 you must accept this agreement lt Back 3 3 Chapter 3 Installing DDMC32 Software 6 Click on Yes to accept or Back to return to the Welcome screen Click on No to terminate the program installation Once you have accepted the Software License Agreement the Choose Destination Location screen appears Choose Destination Location screen Setup Choose Destination Location Setup will install DDM C32 in the following folder To install to this folder click Next To install to a different folder click Browse and select another folder You can choose not to install DDMC32 by clicking Cancel to exit Setup Destination Folder _cxwomex 7 Click on the Browse button t
99. idance messages as well as diagnostic messages 4 4 Configuring SDS Instructions Programming the SDS Once you have determined where you want to apply the SDS instruction you Instruction can enter it into your ladder program and configure the instruction Perform the following tasks to program the SDS instruction a download the SDS CAR enter the SDS instruction enter the configuration information a enter I O information To program the SDS instruction into your ladder program 1 Access the PLC 5 or PLC 5 250 Programming Software main menu shown below from the Allen Bradley main menu interface Programming Software Main Menu PLC 5 H PLC 5 PROGRAMMING SOFTWARE A A 6200 Series Software Product Copyright 1986 1987 1988 1989 1990 1991 Allen Bradley Company Inc All Rights Reserved Release 4 3 l This software is licensed to Company Allen Bradley Co Location 747 Alpha Drive PSP Engineering Serial Number ZZQOAAOPP smmnnnnnnnnn Fri June 14 1991 9 39 09 am 4 5 Terminal Address 77 Current Device 1784 KT DH PLC Address 1 PSS SSS SSS SSS SS SSS SSS SSS SSS SSS SS SS SSS SSS SS SS SS SS SSS SS SSS SS SSS SSS SSS SSS SS SSS SSS SSH Press a function key Online Online Offline Offline Who Sftware File Reports Compare Exit Program Configr Program Configr Configr Utils System Fl F2 F3 F4 F5 F6 F7 F8 F9 F10 Chapter 4 Configuring SDS Instructions 2
100. ies in the DDMC32 Monitoring system You enter SDS and DFA instructions into ladder logic in 6200 Series software When a fault is detected the SDS instruction sends a message over the Data Highway Plus to the operator interface terminal where the Monitoring software automatically assembles the appropriate diagnostic message This diagnostic message helps reduce downtime associated with troubleshooting your equipment because it specifies the device that caused the fault condition and the step in the sequence when the fault occurred 1 1 Chapter 1 Understanding How a DDMC32 System Works The DDMC32 System illustration seen below shows how DDMC32 uses the SDS instruction to detect a fault condition and send the diagnostic message to the operator interface DDMC32 System 1 SDS instruction detects a fault condition SDS m PLC 5 20 IMC 123 Ti FE U I j EMSG Inputto PLC 5 CH 2 PLC sends encoded 3 Background task extracts information from data base and constructs message message to operator interface on Data Highway Plus ov r C 5 20 While SLIDE was Operator Interface ADVANCING the HH returned L
101. il all conditions for the equation s are met The combinatorial SDS instruction ignores the expected entry states so that even if possible no mismatch error is generated When a valid transition a set of conditions as specified by an equation or a timeout occurs the instruction moves to the destination step to verify the inputs before entering the step this occurs for transition equations only not ANDed conditions See the following section for information on how the SDS handles outputs How the SDS Instruction Handles Outputs The SDS instruction sets or resets outputs as it enters each step based on how you define outputs in the configuration template The table below shows what happens to outputs when the SDS enters an error step step 0 or the initialization step States of Outputs Based on Destination Steps If the SDS instruction enters Then outputs anerorstep Ss faresetasdefinedinthatstep stepo reset off Message Generation The SDS instruction generates an error message or status message when it enters a new step which has its message bit enabled This message is displayed on the operator interface terminal and or an annunciator panel if you so specify The figure on page 1 4 shows where you can turn messages on and off using the F7 key Error messages are cleared from the display device operator interface terminal or annunciator panel only when the instruction goes to step 0 All other types of messa
102. in the I O Defines field The order of I O assignments can make a significant difference in the performance of the DDMC32 system The order in which an SDS instruction checks I O information is based on the equations assigned in a given step the current step The order of evaluation is as follows a single bit transitions This includes all inputs that have an equation assigned to them as ON gt OFF or OFF gt ON a combinatorial equations This includes any operations that contain multiple inputs with either an AND or NOT operand a timers This includes any transitions that are generated by a timer no inputs are used for this transition You can perform the following tasks from the I O Definition screen If you want to Press this key Enter an operator interface station address F1 Station Address Enter a new timebase for the step timer F2 Timebas Enter the port number for the message PLC 5 250 F3 Port only Display the Documentation screen for the SDS F5 Documnt instruction odify an I O address at the cursored location F7 Modify IO Addr nsert an I O address at the cursored location F8 Insert 10 Addr Delete an I O address at the cursored location F9 Delete 10 Addr Remove an I O address at the cursored location F10 Remove IO Addr These function keys do not appear on the screen if you have accepted edits once for example if you are modifying the instruction
103. ing displayed then F2 reads Display Symbol Enter or modify step name Step name may be up to 20 F3 Step Name characters long Select between normal step label or error step label F4 Step Type Normal is displayed as STEP error is displayed as ERSTEP See chapter 7 Configuring Diagnostic Messages for details regarding selection of this field as it relates to diagnostics Switch to another step without leaving the Edit Step F5 Edit Step screen System prompts you for step you want to edit Enter or change the timer preset value and destination step F6 Step Timer of step timer The step timer can be used as a watchdog timer to ensure an input transition occurs within a specified time by entering WARN as a destination step or as a dwell timer You can enter up to 10 characters in the step timer field Valid ranges for step timers are time base 1 0 32767 seconds time base 0 01 327 67 seconds Select between message ON and message OFF on the F7 Msg On Off operator interface display Function key displays the Opposite function The function is normally off for a normal step and on for an error step to generate a message Switch between the input transitions of ON gt 0FF OFF gt 0N AND or NOT Function key is active only when cursor is in input transition field Switch between output state of ON OFF and LAST LAST maintains the last state of the output This key is active only when the
104. int Setup 2 Change the parameters as desired and click on OK Chapter 10 Using the Report Generator Software Scheduling a Report You can schedule a report by selecting Schedule from the Report Generation main menu Using the Scheduler you can set dates and times for the generation of a specific report type You can also view the scheduled reports you have previously set up through the Command Scheduler interface Selecting the login will allow you to specify the account the report will be associated with When you choose Add from the Schedule menu the Open screen appears with all the available report types listed for you to choose from Open screen Open Look in E Ddme32 c E a daily fmt 38 sunday fmt a duration fmt thursday fmt frequency fmt x tuesday fmt a friday fmt wednesday fmt a monday fmt wklpdflt frt a saturday fmt Files of type 7 Cancel Once you select a report type the DDMC32 Command Scheduler appears with its associated Add Command screen displayed DDMC Command Scheduler ax DDMC32 Command Scheduler px File Help Add Command WE Cancel Remove m This Occurs yas wo C Tomorrow Even C Next 10 10 Chapter 10 Using the Report Generator S oftware The Command field of the Add Command screen contains the command required to run the chosen report You must specify the time and days for
105. inue Setup Needs the Next Disk screen Setup Needs The Next Disk x Please insert the next disk Disk 2 If the files on this disk i can be found in another location for example in another drive enter its full path or click the Browse button to select its path Path Browse Cancel Chapter 3 Installing DDMC32 Software Completing the DDMC32 Once the installation of the software is complete the Setup Complete Software Installation screen appears Setup Complete screen erita fos ee ma iy PP ar ei deman cars bec is Died ie es ed Chee i ei peed bebe be Diese eee Lear eae From this screen you may choose to read the latest release notes concerning the DDMC32 software and or to launch the program by clicking on the required box Important It is recommended that you read the release notes before proceeding 13 Click on the Finish button to complete the setup and activate your selections What to Do Next Now that you ve installed the software on your computer you can begin to set up the software for your particular application Configuring SDS Instructions What this Chapter Contains Read this chapter to learn about the SDS instruction and procedures that describe programming and configuring the SDS instruction Important You can use an SDS instruction in either the PLC 5 processor or the PLC 5 250 processor There are some minor differences in the procedures for programming and co
106. ique collection of I O input output and subsequent step conditions or destination steps you define according to your application Information for each step is easily configured through a fill in the blanks configuration template see next page This template contains fields for the following inputs and outputs you enter actual names for control items rather than obscure addresses a transitions of the inputs or equations for combined inputs a destination steps output states step timer how long until a timeout occurs a message on or off Chapter 1 Understanding How a DDMC32 System Works 1 4 Sample Step Configuration Template With SDS Instruction y 1 READY TIMER 0 0s DISABLED Ni Input ID Equation Destination No Output ID State o 0 RET D LS OFF gt ON STEP 0 0 FORWARD MOTOR 1 OFF 1 ADV D LS OFF gt ON STEP 10 1 REVERSE MOTOR 1 OFF 2 FULL DEPTH LS OFF gt ON STEP 0 2 DRILL MOTOR OFF 3 ADVANCE COMMAND OFF gt ON STEP 2 4 RETURN COMMAND Press a function key Program edit mode PLC 5 25 Addr 1 Display Step Step Edit Step Msg Input Output Marked Symbol Name Type Step Timer On Transit State Exit F2 F3 F4 F5 F6 F7 F8 F9 F10 How the Transitional SDS Instruction Handles Inputs Transitional equations provide state based control Each transitional equation defines the destination step based on the transition of a particular input ON gt OFF or OFF gt ON When input state
107. lowing figure shows the screen you see if you are modifying I O information If you are entering new information you have additional function key options Modify I O Definition Screen PLC 5 250 Smart Directed Sequencer I O Input Defines Output Defines Definition for Control Block I1 001 16 0 000 04 N10 0 1 001 15 0 000 01 0 0 ul 1 2 I 001 14 2 0 000 02 3 IS 003 02 34 Ins Cmt Adr Cmt 4 IS 003 03 4 DRILL I RETURNED L a Ds MACHINE l IS 6 6 HEAD 1 Ta Ts Operator Interface Station Addr 77 Timebase for Step Timer A S a Port Number for Message 3 2 Press a key to change a parameter or lt ENTER gt to accept parameters gt Program Forces Disabled Data Decimal Addr Decimal PLC 5 250 Addr 5 Station Timebas Port Documnt Modify Address IO Addr Fl F2 F3 F5 F7 4 14 Chapter 4 Configuring SDS Instructions The Ins Cmt Instruction Comment window on the I O Definition screen displays the instruction comment associated with the instruction in the ladder program The Adr Cmt Address Comment window displays the address comment for the cursored address in the I O Defines field The maximum number of possible inputs and outputs in the I O Defines field correlates with the number of I O you entered in the Number of I O field when programming the SDS instruction Important Consider carefully the order in which you assign I O points
108. mment src step where the error occurred for example Advancing Returning or Loading logical address src data type file number offset and bit number of the bit which changed to cause the message for example N10 000 2 1 020 05 or 0 001 12 10 character symbolic string entered in the PLC programming software which represents the bit which changed to cause the message for example SW103 symbolic address src short address comment src 20 character or less portion of the address comment that was delimited by asterisks when the comment was entered in the PLC programming software for example Switch 1 or AdvancedL S long address comment src description of up to 50 characters of the bit address which changed to cause the message for example Tool change required Diagnostic Message Types Chapter 7 Configuring Diagnostic Messages This Message Fragment Is the ON OFF state src For error messages the state of the source bit with a 1 represented by the word ON and a 0 represented by the word OFF For Warning and 1 valid exit messages the state of the source bit with a 1 represented by the word OFF and a 0 represented by the word ON OFF ON state src For error messages the state of the source bit with a 1 represented by the word OFF and a 0 represented by the word ON For Warning and 1 valid exit messages the state of the source bit with a 1 represented by the word OFF and a
109. mp RETURNING 9 RETURNING 10 ERROR Press a function key or enter step number STEP 1 Program edit mode Current Step 0 PLC 5 25 Addr 1 Clear Copy Copy Change Step Step Config Config Fl F2 F3 F4 You can perform the following tasks from the Extended Edit screen If you want to Press this key Remove the configuration of the cursored step F1 Clear Step Copy an existing step to the cursored location The F2 Copy Step system prompts you to enter the step number of the existing step from which you want to copy Copy the configuration of an SDS instruction to a file You may want to do this if you are using an SDS instruction as a template for other SDS instructions F 3 Copy Config Retrieve an existing SDS configuration from a file into this instruction F4 Change Config Chapter 4 Configuring SDS Instructions Copying an SDS Configuration to a File To copy an SDS configuration to a file 1 Press F3 Copy Config from the Extended Edit screen The system prompts you for a file name The file name can be up to 8 characters 2 Type in the file name The system adds a SLS extension to the file name For example if the file name is DRILL the system changes it to DRILL SLS Comments for I O are not copied as part of this file Copying an SDS Configuration File to a Disk You can copy SDS configurations to a disk to transfer to other workstations To copy an SDS config
110. nfiguring the instruction depending on which processor you are using We note these differences where applicable Examples in this chapter are for the PLC 5 processor This chapter contains the following sections Section Page Smart Directed Sequencer Overview 4 2 Programming the SDS Instruction 4 5 Documenting the SDS Instruction 4 18 Configuring the SDS Instruction 4 22 Exiting the SDS Instruction 4 31 Editing and Copying SDS Instructions 4 34 What to do Next 4 37 4 1 Chapter 4 Configuring SDS Instructions 4 2 Smart Directed Sequencer Overview The SmartDirected Sequencer SDS instruction resides in ladder logic and provides state control that can be used to characterize normal and abnormal conditions The figure below shows an SDS instruction in a ladder program An SDS Instruction Ladder Program DRILL MACHINE HEAD 1 SDS SMART DIRECTED SEQUENCER Control File N10 0 Step Desc File N11 0 Length 144 No of Steps 12 Position S tep No of I O Prog file number The SDS instruction permits the user to classify groups of input values into equation form When an equation is physically satisfied by input conditions the SDS transitions to the destination step appropriate to that equation and applies the output control related to that step The SDS instruction allows two basic types of logic equations a transitional combinatorial Transitional Equations The SDS instruction which uses transition
111. nts address in the PLC 5 4 21 Configuring DFA instruction messages 5 16 diagnostic messages fragment options 7 2 7 3 overview 7 1 procedure for 7 8 SDS instructions 4 22 steps 4 25 Configuring Editing steps in SDS 4 23 Control File Address entering for the DFA instruction 5 7 entering for the SDS instruction 4 11 Control File Layout for an SDS instruction A 6 Control File Size Requirements for a DFA instruction A 8 for the SDS instruction A 2 Copying an SDS Configuration From a File 4 36 Copying an SDS Configuration to Disk 4 35 D Data Highway Plus 1 12 Data Highway Plus Node 5 10 Data Table Memory determining amount needed for an SDS instruction A 3 Dataliner Message Displays 1 12 DDMC a typical system drawing 1 2 debugging your system 8 1 hardware configurations 2 1 how the system works 1 1 operator interface software 1 9 system components 1 8 hardware 2 1 DDMC32 configuration and operation Configuration 9 1 operator interface software installation of 3 2 system components installation 2 3 software 3 1 Menu Options 7 5 Debugging DDMC system 8 1 DFA instruction exiting the instruction 5 18 Diagnostic Fault Annunciator DFA CAR File program file memory needed A 9 Diagnostic Fault Annunciator DFA Instruction configuring messages 5 16 control file size requirements A 8 documenting 5 12 entering 5 5 entering input information 5 9 entering instruction informa
112. o annunciator panels in the plant such as a Dataliner Message Display bulletin number 2706 series DL10 7 1 Chapter 7 Configuring Diagnostic Messages 7 2 Diagnostic Message Fragments To create a diagnostic message you can select from several different fragments and string them together with connector words you define to form a sentence In other words you tell the software how to configure the message by selecting message fragments and linking them with your own words Because you enter the fragments to form the diagnostic sentence when you configure the SDS and DFA instructions it is very important that you assign clear names to steps inputs and outputs for example RETURNING ADVANCING so that your message makes sense An example of a clear statement constructed from fragments shown in italics and linking text might be Procl was Advancing when Sta3 ADVANCE Request turned off Important Fragment options for the SDS and DFA instruction messages are different The options for each type of instruction are listed below Items accompanied by src refer to source steps items accompanied by dest refer to destination steps SDS Message Fragment Options This Message Fragment Is the processor eight character name of the processor where the SDS instruction resides for example Proc or xferline instruction comment name of the SDS instruction for example Drill Station 1 Station 32R or ProbeSta step co
113. o select an alternate destination for the program installation or click on Next to accept the default destination and continue with the setup Once you have verified your destination location the Select Program Folder screen appears Select Program Folder Screen y2 Setup Select Program Folder x Setup will add program icons to the Program Folder listed below You may type a new folder name or select one from the existing Folders list Click Next to continue Program Folders Rockwell Automation Existing Folders Documents QuickTime for Windows Shareware from Dataware lt Back 3 4 Chapter 3 Installing DDMC32 Software The Select Program Folder screen allows you to select a Program Folder into which the DDMC32 program icon will be placed The default folder is named Rockwell Automation You may use this folder select one from the Existing Folders window or create a new folder by typing in your folder name 8 Click on the Next button The Select DDMC32 Option s screen appears Select DDMC32 Option s Screen Setup DDMC32 Select DDMC32 Option s Which option s do you wish to install M DFA Option lt lt Back Cancel 9 Select one or both of the options you want to use with the DDMC32 software Important At this point if any changes need to be made to previous entries click on the Back button until the appropriate screen has been reached Make any corre
114. of I O that you control in the SDS We recommend that you use a separate integer file for the step description file Use the following table to determine the starting address of the Step Description File if you want the file to start at the address immediately following the control file Step Description File Address If you have this number Then you must allow this number of words for Then you must allow for this number of words of I O your Control File in the PLC 5 for your Control File in the PLC 5 250 8 58 16 58 32 58 For example in the PLC S if your control file address is N10 0 and you are putting your step description file for an SDS with 8 I O at the end of the control file your step description file must start at N10 69 Similarly in the PLC 5 250 if your control file address is 1N10 0 and you are putting your step description file for an SDS with 8 I O at the end of the control file your step description file must start at 1N10 59 4 12 Chapter 4 Configuring SDS Instructions 3 Type your Step Description File address and press ENTER The system prompts you for the number of steps The table below lists the number of steps you can enter per SDS instruction depending on the number of I O you have Number of Steps Per SDS Instruction If you p aoe number Then you can enter this number of ee per Then you can enter this number of m per ee instruction in the PLC 5 m instruction in the PLC 5 250
115. ogram Directory online PLC 5 PROGRAM DIRECTORY FOR PROCESSOR SDSC5 ONLINE File Name Type Size words PEE AEE E E E E S E oes eee ie EE EEE 0 system 10 1 undefined 0 2 ladder 67 a DFA5 custom routine 223 fessssssssssssssssssssssSs sss SSS SSS SSS SS SSS 5555S 55555555555 55555555555 5555555554 Press a function key or enter file number or name gt Program PLC 5 25 Series A Revision H 5 25 Addr 1 SDSC5 Proc Save Return Change Who Memory Monitor Functns Restore to Menu Station Active Map File Fl F2 F3 F4 FS F6 F8 5 3 Chapter 5 Configuring DFA Instructions 5 4 If you are configuring a new program you need to download the DFA CAR file If not go to Entering or Modifying a DFA Instruction on page 5 5 Download the DFA CAR file Important To download the DFA CAR file you must be in online Program mode To download the DFA CAR file into your program do the following steps 1 Press F2 Save Restore The system displays the Save Restore function keys 2 Press F4 Restore Program The system displays a window containing a file directory of a specific type see the figure below File Directory Window PLC 5 PROGRAM DIRECTORY FOR PROCESSOR D IPDS ARCH PLC5 CAR File Name Name Size Date Time l TSR RR a SRS SS SRR Raa SS SSR SH SSSR saras rsa a Ss anne eter nSase se see ls 0 DFAS 936 9 06 91 10 lla I
116. on a a distributed configuration to control I O from several remote locations All PLC 5 processors can be linked using the Data Highway Plus to a common operator interface terminal where programming monitoring and troubleshooting are performed Chapter 1 Understanding How a DDMC32 System Works All PLC 5 processors can still be programmed with familiar ladder logic in addition to using the diagnostic instructions In DDMC32 PLC 5 processors utilize the instructions that can automatically detect machine faults and abnormal conditions Using 6200 Series software you can program PLC 5 processors with industrial computers the plant floor terminals or any IBM AT compatible computer If you want to know more about the PLC 5 processor refer to PLC 5 Family Programmable Controllers Installation Manual publication 1785 10 4 or the Pyramid Integrator Design Manual publication 5000 6 2 1 1771 I O With DDMC32 you can select from more than 80 types of I O modules to create a configuration perfect for your manufacturing needs I O modules can be discrete analog or intelligent Refer to the Automation Systems Product Catalog 6180 Industrial Computer The 6180 Industrial Computer provides an industrially hardened expandable hardware platform This computer is versatile and modular and lets you design a configuration suitable for your individual application The 6180 computer is the common operator interface for your DDMC32 sys
117. or 7 9 Edit Templates 7 7 Creating a new Template 7 7 Deleting Templates 7 7 Editing templates 7 9 Templates new 7 7 terms and conventions P 3 Transitional Equations in the SDS instruction 4 2 Transitional equations configuring editing 4 25 Troubleshooting operator interface problems 8 12 Type Selection Menu bar 7 7 U Using Multiple PLC s A 5 W Warning 4 26 warning timeout messages 7 4 I 5 ALLEN BRADLEY WU 394 ROCKWELL INTERNATIONAL COMPANY With offices in major cities worldwide WORLD EUROPE MIDDLE HEADQUARTERS EAST AFRICA Allen Bradley HEADQUARTERS 1201 South Second Street Allen Bradley Europe B V Milwaukee WI 53204 USA Amsterdamseweg 15 Tel 1 414 382 2000 1422 AC Uithoorn Telex 43 11 016 The Netherlands FAX 1 414 382 4444 Tel 31 2975 43500 Telex 844 18042 FAX 31 2975 60222 Publication 6404 6 5 1 January 1998 As a subsidiary of Rockwell International one of the world s largest technology companies Allen Bradley meets today s challenges of industrial automation with over 85 years of practical plant floor experience More than 11 000 employees throughout the world design manufacture and apply a wide range of control and automation products and supporting services to help our customers continuously improve quality productivity and time to market These products and services not only control individual machines but integrate the manufacturing process whil
118. ords of program file memory PLC 5 250 Processor To determine the amount of program memory used per DFA instruction in the PLC 5 250 processor use the formula from Table A L depending on your number of I O Table A L Formulas for Determining Amount of Program File Memory for DFA Instructions in the PLC 5 250 Number of I O Formula 8 194 words number of I O points defined x 20 16 224 words number of I O points defined x 20 32 288 words number of I O points defined x 20 A 9 Appendix A Reference Information For example consider that we have 2 DFA instructions with 8 I O 4 inputs defined 2 DEA instructions 194 words 4 inputs 20 2 194 80 2 274 548 words of program file memory The control status bits are Bit Definition EN Rung Enable ER Error true if runtime error detected ME Message Enable true is message is to be sent You can obtain information about the control file from the Extended Status screen in the DFA instruction The Extended Status screen provides the status of specific bits in the control file in user friendly terms Numbers 1771 T O 1 11 1784 KT Addressing for the 6180 Industrial Computer 3 2 A Address Comment 4 15 5 9 editing 4 20 5 13 Attention Notes P 3 C CAR Utility downloading into program DFA CAR 5 4 SDS CAR 4 6 Combinatorial Equations in the SDS instruction 4 3 Combinatorial equations configuring editing 4 27 comme
119. r the tasks associated with each selection File Menu Option If you want to Choose File and Select an existing database Database Create a new report format New Format Modify the report format Modify Format Generate a report Generate Report Open a report for viewing Open Report Save a specific report Save Report Print a report Print Set printer options Print Setup Exit the Report Generator and return to the Exit DDMC32 main screen Edit Menu Option If you want to Choose Edit and Copy selected text from the report to the Windows Copy clipboard View Menu Option If you want to Choose View and Show or hide the toolbar Note the Toolbar contains the same options as the menu Icons are used for recognition purposes Toolbar See detailed information on the current report line Extended Info of the Weekly Default or Monday Tuesday Sunday reports Schedule Menu Option If you want to Choose Schedule and Add a scheduled report time such as a daily Add weekly or hourly Modify a scheduled report generation time Modify Supply the Report Generator with a username and Login password for an existing account with administrative privileges Chapter 10 Using the Report Generator Software Help Menu Option If you want to Choose Schedule and See the Report Generator version information About Toolbar The Toolbar is a shortcut to options that are used on a regular basis
120. ransition true for one PLC scan if step transition occurred ME Message Enable true if message is to be sent TE Timer Enable true if timer is used in current step RS Reset Sequencer a status bit if true sequencer is in normal run mode if false Sequencer is in step zero mode DV Future use PC Precheck if 0 precheck is enabled and the SDS at state transition will check if the destination step expected inputs match the mapped inputs if 1 precheck is disabled and the SDS instruction at state transition will not check the destination step expected inputs MR Mismatch Reset a control bit if the SDS instruction is in a mismatch condition setting this bit to 1 will release the mismatch check and the SDS instruction will start from step 0 to find a step to enter TB Time base the instruction entry allows the programmer to select either 01 or 1 0 second time base for the timer You can obtain information about the control file from the Extended Status screen in the SDS instruction The Extended Status screen provides the status of specific bits in the control file in user friendly terms Reference Information for Read this section to learn about reference information for the DFA the DFA Instruction instruction Execution Times Tables A I and A J show the execution times per program scan for a DFA instruction in the PLC 5 or the PLC 5 250 with 8 16 and 32 I O Appendix A Reference Information Table A I E
121. rator fault logs Software Smart Directed Sequencer execution times control file Appendix A Reference Information requirements step description file requirements maximum steps and step description file layout Diagnostic Fault Annunciator execution times control file requirements Data Highway P lus message block layout and communication delay P 2 ATTENTION and Important Notes Terms and Conventions Preface Using this Manual Information that is especially important is identified with an ATTENTION or Important note circumstances that can lead to personal injury or death property A ATTENTION identifies information about practices or damage or economic loss Important provides you with information that is critical for the successful application and understanding of this product In this manual we use the following terms DDMC32 Distributed Diagnostics and Machine Control 32 bit Industrial automation system containing hardware and software components that help you configure a control and diagnostics system for your equipment SDS Smart Directed Sequencer An instruction that resides in ladder logic providing state machine control and up to date diagnostics for your machine DFA Diagnostic Fault Annunciator A monitoring only instruction which resides in ladder logic used to generate messages when a fault occurs programmable controller A solid state control device that is programmed
122. rns to the Program Directory Enter or Modify a DFA Instruction To enter or modify DFA instruction in your ladder program 1 Cursor to the file you want to edit in the Program Directory and press F8 Monitor File Chapter 5 Configuring DFA Instructions The system displays your ladder program and the Ladder Editor main menu 2 Cursor to the rung where you want to position the DFA instruction If you are modifying an existing rung cursor to the DFA rung 3 Press F10 Edit The system displays the Ladder Editing screen 4 If you are editing an existing rung press F5 Modify Rung entering a new rung press F4 Insert Rung The system displays the Edit Rung screen 5 Ifyou are a changing an existing instruction press F5 Modify Instruction entering a new instruction press F4 Insert Instruction The system prompts you for the instruction you want to add 6 Type pra and press ENTER If you are modifying an existing instruction DFA already appears at the prompt Important As an alternate method of entering the instruction you may Press F10 Others a Press F9 Seqncer from the Instruction Classes function keys a Press F5 DFA from the Sequencer function keys 5 6 For the PLC 5 PLC 5 250 Chapter 5 Configuring DFA Instructions The system displays the DFA instruction see the figure below DFA Instruction SSS SS SS Se DIAGNOSTIC FAULT ANNUNC
123. rquee 2 Activate Type DLO Y Type DL10 v Vv l T Logger Port COM2 f Pott c 0M2 Printer Audible Message Indication Baud 3600 M Baud 9600 m 4 m 4 Parity NON Parity NON Data Length BIT Data Length 8 BIT Stop Bits BIT M Stop Bits 1 BIT 7 2 For each marquee enter the following information Type Port Baud a Parity a Data Length a Stop Bits 3 Click on OK A message box appears notifying you that your changes will take effect the next time the DDMC32 software is restarted Activating the Banner Logger Printer and Audible Message Options From the Configure Output Devices screen you can activate the Banner Logger Printer and Audible Message options by clicking on their corresponding checkboxes Once you have chosen the appropriate options click on OK to close the Configure Output Devices screen 9 2 Chapter 9 Configuration and Operation of the DDMC32 System Configuring the Clock Creep The DDMC32 system enables you to configure the timing on your Option marquee output You can enable Clock or Creep output Enable the Clock Creep Functions 1 From the Configure menu choose Clock Creep The Configure Clock Creep screen appears Configure Clock Creep screen Configure Clock Creep r Creep Banne I Manueel IE Merquee2 Goch reer fe SingleDron E Single Drop Guidon MutteDrop r Clock Column f 4 Background Charac
124. rrors within the SDS configuration utility use the other for running the DDMC32 software This chapter contains the following sections Section Page Correcting Step Configuration Errors 8 1 Locating Sequencing and Timing Errors 8 5 Troubleshooting Problems in your Operator Interface 8 12 What to do Next 8 13 If you have errors in your step configuration when completing SDS instruction entry the system displays an error list see next page This error list may be accessed by pressing F9 Display Err Lst from the Step Directory until errors are corrected 8 1 Chapter 8 Debugging Your DDMC32 System Sample Error List Screen a ERRORS IN STATION 7R CONFIGURATION ERROR 1 Step 1 Input O transition condition results in an input state mismatch for specified destination step ERROR 2 Step 15 timer specified destination step is not configured Press a key for desired function or lt ESC gt to return to directory w monitor mode C rrent Step 0 PLC 5 12 Addr F The error list displays configuration errors in different formats depending on the type of error that occurs The errors that could occur are a input state mismatch timer destination step not configured a timer destination step out of range a destination step not configured a destination step out of range a invalid configuration a marked exit a warning timeout These errors are described in the following sections Input State Mism
125. rs Chapter 1 Understanding How a DDMC32 System Works a 1771 1 0 a 6180 Industrial Computer with the following minimum configuration Cat 6180 AB C BDBACACZA 100 MHZ Pentium Processor Series 10 4 TFT No Software PCI 2Mg DRAM Video Board Windows NT 4 0 16Mg RAM 120V Power Card 1 3G Hard Drive 1784 KTX 3 5 Floppy Drive a Data Highway Plus a Dataliner message displays DDMC32 Software DDMC32 software contains several tools to help you monitor generate annunciate and store information about faults When a fault is detected by a PLC diagnostic instruction a message packet with the appropriate coded data is sent to the operator interface terminal The DDMC32 software assembles the data used during programming to form the text of the fault message If configured by the user the terminal automatically displays the message in a window reserved for alarm messages Because the software automatically assembles the message you do not have to create and store separate and unique diagnostic messages You have to configure the message templates using the Template Editor in the DDMC32 software The Template Editor permits you to design templates to reflect individual types of DFA and SDS faults per each Processor Control File combination for these instructions When a DFA or SDS instruction generates a fault the corresponding template is used by the DDMC32 software to build the appropriate message
126. ruction in the PLC 5 or the PLC 5 250 with 8 16 and 32 I O Combinatorial SDS OR and AND transitions have been averaged in these are typical times Appendix A Reference Information Table A A Execution Times for an SDS Instruction in the PLC 5 Number of I O Step 0 Initialization Typical Step Transition No MSG Step Transition with MSG 0 350 ms base 8 0 050 ms step 0 433 ms 0 633 ms 0 720 ms 16 0 050 ms step 0 633 ms 0 720 ms t32 0 050 ms step 0 633 ms 0 720 ms Table A B Execution Times for an SDS Instruction in the PLC 5 250 Number of I O Step 0 Initialization Typical Step Transition No MSG Step Transition with MSG 0 200 ms base 8 0 013 ms step 0 200 ms 0 270 ms 16 0 013 ms step 0 200 ms 0 245 ms 0 270 ms 32 0 013 ms step 0 200 ms 0 245 ms 0 270 ms Control File Size Requirements Tables A C and A D list the control file size requirements in the PLC 5 processor and the PLC 5 250 for an SDS instruction with 8 16 and 32 TO Table A C Control File Size Requirements for an SDS Instruction in the PLC 5 Number of I O Number of Words Needed for Control File 8 68 16 68 32 68 Table A D Control File Size Requirements for an SDS Instruction in the PLC 5 250 Number of I O Number of Words Needed for Control File 8 58 16 58 32 58 Appendix A Reference Information Step Description File Size Requirements Table A E lists the number of words needed for each step in th
127. s 0 0 0 c eee eee eee eee 10 12 What to Do N Xt sceri cose cnet eeneeee dirs to roes been cas 10 12 Appendix A Appendix Overview 0 eee eee ee eee A 1 Reference Information for the SDS Instruction A 1 Reference Information for the DFA Instruction A 7 iii Manual Objectives Audience Preface Using this Manual This manual shows you how to implement and use a Distributed Diagnostics and Machine Control DDMC32 system This system provides diagnostic machine fault detection and automatic messaging capabilities Diagnostic messages provided by DDMC32 help reduce the downtime associated with troubleshooting your equipment In this manual we provide procedures for installing DDMC32 system components configuring DDMC32 software monitoring a system using DDMC32 We assume that if you are using this manual you know or are familiar with PLC 5 hardware 6200 Series software 1771 VO Allen Bradley operator interface and programming terminals the line or machine for which you are developing the program P 1 Preface Using this Manual What this Manual Contains Table P A lists the chapters of this manual and the contents of each chapter Table P A Sections of this Manual If you want to read about Refer to chapter Overview of DDMC32 components and how they fit into the 1 Understanding How a DDMC 32 system System Works Procedures for installing DDMC32 hardware
128. t 3 Press F2 I O Edit The system displays the Step Directory Step Directory PLC 5 aa Step Directory for DRILL MACHINE HEAD 1 a Control File N10 0 Step Description File N10 102 Step Step Name Step Step Name 0 INITIALIZATION 2 LOADING 2 3 4 5 6 7 8 9 10 PeSS SSS SSS SS SSS SSS SSS SS SS SSS SS SSS SS SSS SS SS SSS SSS SSS SSS SSS SSS SSS SSS SSS SS SSS SSS S Press a function key or enter step number STEP 10 Program edit mode Current Step 0 PLC 5 25 Addr 1 Proc Name Change Update Exit Edit Extnded 1 0 Accept Mode Msg DB Step Edit Monitor Edits F1 F2 F3 F5 F6 F8 F10 Chapter 4 Configuring SDS Instructions You can perform the following functions from the Step Directory If you want to Press this key Change between remote run program mode F1 Change Mode and test mode Update the internal SDS data base F2 Update Msg DB documentation for diagnostic messages Exit the configuration utility This key is F3 Exit active only when the Step Directory is your point of entry into the SDS instruction Configure or edit your combinatorial or F5 Edit Step transitional equations Display the Extended Edit screen F6 Extnded Edit Display the I O Monitor screen Refer to F8 I O Monitor Chapter 8 Debugging Your DDMC32 System for information on the I O Monitor screen Accept all entries edits The system prompts F10 Accept Edits you to confirm
129. t and click on OK Setup will begin Follow the instructions as they appear on the screen Chapter 3 Installing DDMC32 Software The DDMC32 Welcome Setup screen appears DDMC32 Welcome screen 4 Setup DDMC32 Welcome to the DDMC32 Setup program This program will install DDMC32 on your computer It is strongly recommended that you exit all Windows programs before running this Setup program Click Cancel to quit Setup and then close any programs you have running Click Next to continue with the Setup program WARNING This program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law Cancel 5 Click on the Next button to continue or Cancel to quit the setup program The Software License Agreement screen appears Software License Agreement DDMC32 Please read the following License Agreement Press the PAGE DOWN key to see the rest of the agreement GRANT OF LICENSE Rockwell Automation and its third party licensors grant to you a non exclusive license to install and use the software programs in this package collectively referred to as the S oftware on either a a single computer or b a network server for access by one user by way of terminal or computer attached to the network server S
130. talling DDMC32 components varies depending on the operator interface terminal you use We describe procedures for 6180 Industrial Computer on the following pages Using a 6180 Industrial Computer The table below lists the general procedure for installing your DDMC32 hardware components when using a 6180 Industrial Computer Refer to the manuals listed for more detail 2 3 Chapter 2 Installing DDMC32 Hardware Components Installing DDMC32 Hardware Components when using a 6180 Industrial Computer To perform this task Refer to this manual Publication or Cat Number 1 Install PLC 5 or PLC 5 250 and 1771 1 0 PLC 5 Family Processor Installation 1785 10 4 nstructions Pyramid Integrator 5110 ISET Design Installation S tartup and ntegration Manual 2 Install communications link Communication Interface Module 1784 2 31 nstallation Data a Set the 6 switch assembly switches as follows 12345 6 OPEN X XX CLOSED XX X Based on the factory s setting only switches 2 and 3 must be modified Important When installing and configuring your 6200 series software the switch setting for on will correspond to a 1 and the switch setting for off will correspond to a 0 b Install Data Highway Plus Interface Module cat no 6180 Industrial Computer User s Manual 6160 6 5 1 1784 KT into an ISA slot c Connect the 1784 CP cable from the 6180 to the PLC 5 Family Programmable Controllers 1786 6 5 12
131. tem You can use the 6180 computer to a develop ladder logic rungs and SDS instructions using 6200 Series Software and the SDS Configuration Utility a display diagnostic messages using Monitoring Software a define graphic displays of your equipment that can be used to monitor the operation For more information about the 6180 Industrial Computer refer to the 6180 Industrial computer brochure publication 6180 1 0 Chapter 1 Understanding How a DDMC32 System Works What to Do Next Data Highway Plus Data Highway Plus DH is the network that links the PLC 5 programmable controllers and the operator interface terminal so that they can communicate with one another The Data Highway Plus lets you a download ladder logic with SDS instructions into multiple PLC 5s a receive diagnostic messages from multiple PLC 5s a implement a centralized common operator interface for all control elements of the DDMC32 system If you want to know more about Data Highway Plus refer to Data Highway Data Highway Plus Protocol and Command Set Manual publication 1770 6 5 16 Dataliner Message Displays Dataliner message displays bul no 2706 series DL10 are highly visible message display devices used for diagnostics operator prompts and status messages These displays can be used with your system as annunciator panels for the messages sent by the DDMC32 software This chapter gave you an overview of how the DDMC32 system works to
132. ter iz F Banner F Merquee I Marquee 2 SingleUrop E Single Drop Move eve 4 seconds Display Width f kuiro Mutor Column f 4 Message N Refresh every f Z seconds Direction Left to Right r Marquee Drops Clock Marquee 1 0 0 ry ry rSrSr3rarara wl w araara rara Creep Marquee 1 2 To use the Clock or Creep functions check the Enable Clock Creep checkbox and then click on either Clock or Creep If you check Clock the Clock section of the screen is enabled if you check Creep the Creep section of the screen is enabled 9 3 Chapter 9 Configuration and Operation of the DDMC32 System Configure the Clock Function If you enable the Clock function you must configure the following parameters a Define the output device s on which you want the clock to appear Specify Banner Marqueel and or Marquee2 a Enter the column in which you want to start the clock time enter 1 through 80 a Enter the rate in seconds at which you want the clock to refresh Configure the Creep Function If you enable the Creep function you must configure the following parameters a Define the output device s on which you want the clock to appear Specify Banner Marqueel and or Marquee2 a Enter the column from which you want the creep to start enter 1 through 80 a Enter a background character This character will be used to separate your message from its next oc
133. tion 5 7 entering number of I O 5 8 I 1 entering the control file address 5 7 entering the message control block address 5 8 entering the program file number 5 8 execution times A 7 importing 6 1 modifying an instruction 5 5 modifying instruction information 5 7 overview 1 7 5 2 programming 5 2 reference information A 7 Diagnostic Message Configurator error messages 7 4 mismatched step messages 7 4 one valid exit timeout messages 7 4 status messages 7 4 step timeout messages 7 4 warning timeout messages 7 4 Diagnostic Messages configuring 7 8 fragment options for the DFA instruction 7 3 for the SDS instruction 7 2 types of DFA 7 5 error 7 4 INIT error 7 4 mismatched step 7 4 one valid exit timeout 7 4 status 7 4 step timeout 7 4 warning timeout 7 4 zero step 7 4 Directory structure DDMC B 1 Displaying fault log 10 11 Documenting the DFA instruction 5 12 the SDS instruction 4 18 E Edit Selection Menu bar 7 6 Editing address comments 4 20 5 13 instruction comments 4 20 5 13 Message Template Editor 7 3 entering SDS instruction in the PLC 5 4 9 Entering a DFA Instruction 5 5 Entering I O Addresses for the SDS instruction 4 17 Entering I O Information for the SDS instruction 4 14 Equation Editor screen 4 29 Equation List screen 4 28 Error List description of 8 1 error types 8 2 8 4 error messages 7 4 Errors correcting sequencin
134. u on the Report Generation menu bar A list of all available report names appears Open screen Open Look in Ddme32 El c a sunday fmt x duration fmt thursday fmt a frequency fmt sa tuesday fmt E friday fmt a wednesday fmt a monday fmt wklpdflt frt Files of type 7 Cancel Highlight the report you need and click on Open The selected report will be displayed on the screen and written to the disk in the default DDMC32 directory Opening a Report To view an existing report select Open Report from the File menu Highlight the report and click on Open Save As If you have generated a report or opened an existing report and want to save it under a specific name choose Save As from the File menu Choose the directory you want the file to be saved in and type in a new file name in File name field Important Do not add rpt to the end of the file name DDMC32 will automatically add the rpt extension Chapter 10 Using the Report Generator Software Printing a Report You can print reports at any time To print a report 1 Generate or open a report 2 From the File menu choose Print 3 Set the parameters for your print scheme and click on OK The report or a portion of the report if chosen is printed to the default printer Modifying a Printer Options You can modify the way reports are printed To change printer options 1 From the File menu choose Pr
135. uration to a disk 1 Insert a disk into the disk drive 2 Exit to DOS 3 From any directory type copy hard drive IPDS ARCH PLC5 name of file SLS disk drive IPDS ARCH PLC5 name of file SLS and press ENTER For example copy C IPDS ARCH PLC5 DRILL SLS A IPDS ARCH PLC5 DRILL SLS and press ENTER If you want to copy all of the files you can replace name of file with an asterisk 4 Insert the disk into the system to which you are transferring the configuration 4 35 Chapter 4 Configuring SDS Instructions 5 Type copy disk drive IPDS ARCH PLC5 name of file SLS hard drive IPDS ARCH PLC5 name of file SLS and press ENTER For example copy A IPDS ARCH PLC5 DRILL SLS C IPDS ARCH PLC5 DRILL SLS and press ENTER The system now copies the SDS configuration file to your disk Copying an Existing SDS Configuration from a File Important To copy an existing SDS configuration from a file into another instruction the number and order of inputs in the saved configuration must match exactly the number and order of inputs in the new SDS into which it is being copied If they do not match an error is reported when you accept the edits You see a message telling you to clear the step you cannot edit invalid steps The PLC 5 250 allows 32 bits for the timer preset value the PLC 5 allows only 16 If you are copying a PLC 5 250 configuration into a PLC 5 configuration timer pres
136. xecution Times for a DFA Instruction in the PLC 5 Number of I O Typical Send a Message 8 0 224 ms 0 320 ms 16 0 224 ms 0 320 ms 32 0 224 ms 0 320 ms Table A J Execution Times for a DFA Instruction in the PLC 5 250 Number of I O Typical Send a Message 0 207 ms 0 207 ms 0 207 ms Control File Size Requirements Table A K lists the control file size requirements in the PLC 5 and PLC 5 250 for a DFA instruction Table A K Control File Size Requirements for a DFA Instruction in the PLC 5 and PLC 5 250 Controller Number of I 0 Number of Words Needed for Control File PLC 5 8 16 or 32 69 PLC 5 250 8 16 or 32 58 Appendix A Reference Information Amount of Program File Memory Needed for DFA CAR File A DFA instruction uses program memory for the contents of the CAR file The DFA CAR uses 223 words of program memory in the PLC 5 processor and 210 words of program memory in the PLC 5 250 processor Therefore the total amount of program memory used is different depending on if you are using a PLC 5 processor or a PLC 5 250 processor PLC 5 Processor To determine the amount of program memory used per DFA instruction in the PLC 5 processor use the following formula 17 words 4 words per I O programmed or 17 words 4 of inputs defined For example consider that we have 2 DFA instructions with 4 inputs each 2 DFA instructions 17 words 4 4 2 17 16 2 33 66 w
137. your equation a Press F1 Select Input again to select your second input Using this method the AND is automatically placed between your inputs Continue selecting inputs and operands until your equation is complete The following conditions apply to every equation you enter If you want to use a single input in more than one equation within a single step you need to duplicate it in the I O Defines on the I O Definition screen a Inputs do not have to be contiguous The order in which each input occurs or goes true is not significant as long as the Boolean expression is fulfilled a More than one expression can be entered and mixed with transitions to create logical OR functions a Up to four logical AND combinations can be defined in an 8 input SDS which would be the equivalent Boolean of A B or C D or E F or X Y Up to eight AND conditions can be defined for a 16 or 32 I O SDS When you have finished entering your equation press F10 Accept Equation Chapter 4 Configuring SDS Instructions Important After you have accepted an equation the label EQx where x is equal to the number of the equation within the step appears on the Step Edit screen 7 Press tesc to return to the Equation List screen On the Equation List screen it is possible to view your equation in two different forms a Abbreviated form shows the input numbers and operands For example 06162 a Expanded form uses input ad

User Manual - Rockwell Automation

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