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Man Al2000_eng - FF
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1. 5 22 AL 2000 User Guide 11 09 2000 Connection Example of Analog Outputs External Internal twisted pair Load mA E FF Automation Oy AL 2000 User Guide 5 3 3 AIC8 Analog Input Module The AIC8 is an analog input module with 8 x 12 bit differential or 16 x 12 bit non differential ana log inputs isolated as a group The maximum common mode voltage for the AIC8 is 40V The current consumption of AIC8 is 250 mA The ranges of the AIC8 are as follows Inputs Voltage 0 480mV 0 5V 0 10V 10V Current 0 4 20mA 50 to 150 C 200 to 730 C KTY10 50 to 150 C 200 to 730 C Cu50 200 to 200 C 0 4000 8 3 bits mV 0 4000 800 bits V 0 4000 400 bits V 0 4000 200 bits V 0 4000 200 bits mA 0 4000 0 3720 20 bits C 4 bits C 0 2000 10 bits C 0 3720 4 bits C 100 900 2 bits C A constant measuring current of 1 4mA is pro vided for each input The following LED indicators are located on the front edge of the module ACT green ERR red fault Module is in operation The operating system has discovered a in the module Status of analog inputs AIO AI6 STEADY LIGHT input not scaled FLASHING LIGHT input at upper lower limit or not connected input in use and OK 0 7 red NO LIGHT FF Automation Oy
2. gt D 00 N O gu OO TIC AC For input simulation the switches are used to turn inputs on and off LED indicators ad jacent to the switches show the status of each input Connections are as follows DSIM32 DIC32DC For input simulation the switches are used to turn inputs on and off LED indicators ad jacent to the switches show the status of each input Connections are as follows DSIM32 DIC32DC i to Ya RC 3ms Black RM Ya le FF Automation Oy AL 2000 User Guide Page 3 1 06 05 00 3 HARDWARE CONFIGURATION 3 1 Selection of Mounting Rack The number of the I O modules and CPU type must be considered when selecting the mounting rack If the process to be controlled is spread over a large area considerable savings can be achieved by using the AL2000 to implement a distributed control system utilising several remote units In this case only the central unit requires PLC program ming the remote units operate as Modbus I O units only Five different mounting racks are available MR3 mini for up to 3 I O modules CPU2000SCP for up to I O modules MR65 for up to 5 I O modules MR11 for up to 11 I O modules MR16 for up to 16 I O modules 3 2 Selection of Power Input Module s The
3. Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Page 5 23 11 09 2000 Analog input 0 Analog input 1 Analog input 2 Analog input 3 Analog input 4 Analog input 5 Analog input 6 Analog input 7 5 24 AL 2000 User Guide 11 09 2000 Temperature Measurement with Pt100 e O Jumper 1 Ptt00 twisted _ 02498 Temperature Measurement with KTY10 Differential Voltage Measurement twisted mm V air p SIGN 249R E FF Automation Oy AL 2000 User Guide Non Differential Voltage Measurement Differential Current Measurement Active Transducer Passive Transducer NOTE The transducer can also be connected between SIGN and the supply ground but the common mode voltage must not exceed 40 V Non Differential Current Measurement FF Automation Oy Page 5 25 11 09 2000 Jumper 249R Jumper 249R 5 26 11 09 2000 AL 2000 User Guide 5 3 4 MIC16
4. 5 30 AL 2000 User Guide 11 09 2000 Examples for connecting mA outputs from MOC16 board Internal External Milliamper output Internal External Voltage output E FF Automation Oy AL 2000 User Guide 5 4 Central Processor Units Page 5 31 11 09 2000 There are several types of CPU module available for the AL2000 These are the CPU2000S CPU2000P and CPU2000L Module CPU20008 has three serial interfaces two RS 232C and one RS 485 IC interface for a display keypad unit and the follow ing LED indicators located on the front edge of all CPU2000S module RUN green RES red CTS1 red RTS1 red TX1 yellow RX1 yellow CTS2 red RTS2 red TX2 yellow RX2 yellow TX3 yellow RX3 yellow BAT red VS3 red Run LED Steady light or no light Slow blinking 0 5 Hz Pulse width 5096 Combined slow quick blinking Quick blinking Pulse width 9096 Quick blinking 5 Hz Pulse width 50 Very quick blinking Pulse width 2096 see table below Fault condition SER serial interface CTS handshake SER serial Interface RTS handshake SER serial interface transmitting SER1 serial Interface receiving SER serial interface CTS handshake SER2 serial Interface RTS handshake SER serial interface transmitting SER serial Interface receiving SERS serial interface transmitting SER3 serial Interface receiving Battery low indicator Fault in SER 3 interface voltage Program
5. 10 6 AL 2000 User Guide 06 05 00 10 4 2 PCON230 There is one fuse holder on the front panel of the module housing a T2 5A 5 x 20mm slow blow fuse to IEC 127 111 standard 1 Turn the fuse holder cap anti clockwise about a quarter of a turn 2 Remove the cap and replace the blown fuse with a new one 3 Replace the cap Push and turn the cap clockwise until locked 10 4 3 PWR3 There are three fuse holders on the front panel of the module which house a T315mA and 2 x T1A 5 x 20mm slow blow fuses to IEC 127 111 standard 1 Turn the fuse holder cap anti clockwise about a quarter of a turn 2 Remove the cap and replace the blown fuse with a new one 3 Replace the cap Push and turn the cap clockwise until locked 10 4 4 DOC32FP This module has two 5 x 20mm slow blow fuses to IEC 127 111 standard one for each group These are located behind the top edge of their respective connectors 1 Remove the blown fuse by unplugging it 2 Replace the blown fuse with a new one 10 4 5 ROC16K In this module there are 16 x T2 5A slow blow fuses located behind their respective output terminals and one spare fuse located behind the LED indicators When the spare fuse is on place and working the SP F LED on the front edge of the module is on Thus the spare fuse holder provides a simple way to check fuses 1 Remove the blown fuse by unplugging it 2 Replace the blown fuse with the spare fuse 3 Remember to order
6. T JJ Start function insert new values by inserting to 242 value 5 Now system program updates the RTC and resets R O 242 to zero which starts normal clock reading to R O variables E FF Automation Oy AL 2000 User Guide Page 8 1 11 09 2000 TECHNICAL DESCRIPTIONS 8 1 CPU2000S Series Modules Memories FLASH Operating system FLASH PLC program amp configuration RAM battery backed up PLC program variables RAM buffers operating system variables PLC program when executed PLC program space 8192 instruction lines Commands Approximately 260 Auxiliary memories 50 kBytes of memory reserved for auxiliary memories and variables Timers 4 x 0 01 2 55s addressable from PLC program 68 x 0 1 25 5s addressable from PLC program 8 x 1 255s addressable from PLC program Counters 16 x 0 255 addressable from PLC program Step registers 32 x 0 255 step The first 8 are reset during power failure All others can maintain their position during power failure by setting a DIP switch Controllers 32 x 16 bit PID controller functions with programmable parameters 8 x 8 bit PID controller functions with programmable parameters Loop time 5ms 20us instruction line average Serial Interfaces 3 isolated 500 VDC SER1 RS 232C 300 115200 bit s 9 pin D type connector Used for programming oper
7. 11 36 AutoLog 2000 Instruction Manual 12 12 2000 PRT R M On Operation If the bit accumulator is 1 the value of the variable n is output with two digits assuming it to be a BCD number If the bit accumulator is 0 it will be O after the instruction If the variable is not a BCD number indeterminate characters will BA RA WA Variable Affected No No No Example Outputs the content of register memory 1 once per second READ Fn Operation Read the current number of elements in FIFO store n 0 7 into the register accumu lator If there are elements in the FIFO set the bit accumulator to 1 if not clear the bit accumulator to 0 RA WA Variable Affected Yes No No Example At the rising edge of input 0 D M P C F C F C F F enter the number 12 into FIFO 0 the number 4 into FIFO 0 the number 24 into FIFO 0 number into register acc READ R T Cn Operation The register accumulator is loaded with the remaining count in timer counter n If the timer counter has counted out the register accumulator will be 0 RA WA Variable Affected No No Example Register output 0 will show the remaining time READ Sn Operation Selects sequence register n as the current sequence register BA RA WA Variable Affected No No No No Example READ Subsequent sequence register jinstructions apply to sequence register 2 FF Automation Oy READ Op
8. I O slot number gt lt output number on I O module Example 12 4 digital input number 4 on the module in slot number 2 O 6 28 digital output number 28 on the module in slot number 6 All I O modules are fitted with LED s to indicate the status of each input output and the operational status of the module These LED s are colour coded as follows Input Yellow The input is ON Output Red The output is ON ACT green yellow The module is in operation ERR Red The operating system has discovered one of the following faults Incorrect configuration module has not been configured for this slot Fault in the module SP F green The spare fuse is available and working located on the card FF Automation Oy E 5 8 AL 2000 User Guide 06 05 00 5 2 2 DIC32DC Input Module The DIC32DC is a digital input module with 32 isolated inputs in two groups of 16 inputs each The current consumption of DIC32DC is 250 mA Input wiring is connected to two detach able screw terminals on the front edge of the module The common ground for each of the two groups is connected to the bottom screw in each of the two screw terminals The logic range of the DIC32DC module is logic 0 30 to 5VDC 0 1 1mA logic 1 13 to 36VDC 4 11mA Sensor must be PNP output type or voltage supplying The following LED indicators are located on the front edge of the module ACT green Module in operation ERR red The
9. Program STR STR parameters R M 10 gt FCN Write R R R R Example 2 Read keypad Parameters 40h AL1093 keypad address 11 keypad data parameters M 020 gt read R R R R Program FF Automation Oy 11 20 AutoLog 2000 Instruction Manual 12 12 2000 Example 3 Read Clock 8583 Parameters 010 AO0h Base address 011 byte count 012 data address 013 Base address 014 byte count 015 clock data hundredth of a second 016 clock data seconds 017 clock data minutes 018 clock data hours 019 clock data year date 020 clock data weekday month 001 010 parameters from R M 010 gt FCN 030 sinitialize read address STR 013 parameters for read fcn FCN 031 read only if FCN 30 was successful Program STR STR I I DIVIIVIIIIIIAD OVEEEEEEEEEEE FCN 32 Read Ibutton serialcode This command is used to read serial code from IButton device connected into Autolog PLC s l C channel Command is executed only if Bit accu equals 1 before instruction Function parameter is defined in register accu Register accu must hold the address of the 1 byte save location Execution time is 1 4 ms If iButton is not connected to PLC command retuns BA 0 and RA 0 If iButton is connected but CRC does not match BA 0 and RA lt gt 0 If iButton is connected and it was successfully read BA 1 and RA 0 Example 1 Read iButton once in a se
10. 240 2 This mode is available for all models In this mode the contents of R O 245 and R O 246 are sent to the display In this mode it is not neccessary use the D key to change the display mode as with mode 0 each time after power up Example 1000 connects the display control program and the contents of R O 245 and R O 246 are immediately displayed When 1001 is truned off it disconnects the control program and the display will again show the time Normal display mode chosen for display set input on ON the control code for mode 1 is transferred to register output R O 240 When writing the value to R O 240 ends returns the to normal mode two first instruction lines 7 8 8 7 Segment mode mode 2 R 240 4 This display mode is available only for the AL1094 with 7 segment display In this mode R O 245 controls the right hand side of the 7 segment display so that seven of the eight bits controls a segment each and the eighth bit controls the minus sign as shown in the diagram below R O 245 bit segment Segment Segment For example to display segments e c and d the sum of corresponding num bers 16 8 4 28 should be written into register output R O 245 STR R 028 EQ R 245 Display segments e c and d 7 8 4 Text Display Mode 4 R O 240 16 This mode is available only for the AL1094R AL1093 AL1094AF and AL 1095 with al phanumeric displays The
11. Serial line mines the manner in which the mo lected by R O 214 Used for dule operates The possible settings pinong programming modbus slave for these switches are shown in the programming device table below Rate determined by R O 213 ON ON Contents of data mem Contents of data ory erased on power memory saved in the case of a power supply failure CPU2000S series module layout C2 IC1 Processor C2 IC3 System program FLASH C2 IC4 Application program FLASH C2 IC5 Data RAM IC1 ALBus FPGA IC2 Memory decoder FPGA IC3 SERS3 Uart IC4 SER2 Uart IC5 SER1 Uart SW1 DIP switch BATTERY Lithium Battery LED unit operational information LED unit SER1 LED unit SER2 LED unit SER3 SER1 RS 232C serial interface 1 SER2 RS 232C serial interface 2 SERS RS 485 serial Interface Internal bus connector Display unit connector E FF Automation Oy AL 2000 User Guide Page 5 33 11
12. memory goes from 0 to 65535 invert output 0 Example DIV R Cd Operation Divide the register accumulator by the constant d The quotient remains in the register accumulator and the remainder is stored in register output RM 244 BA RA WA Variable Affected Yes No No Example RM 10 15 2 RM 244 FF Automation Oy AutoLog 2000 Instruction Manual Page 11 11 12 12 2000 DIV R M On Operation Divide the register accumulator by the variable n The quotient remains in the register accumulator and the remainder is stored in register output RM 244 BA RA WA Variable Affected No Yes No No M 100 000 STR R DIV R DIV W I M O Operation Divide the word accumulator by the variable n The quotient remains in the word accumulator and the remainder is stored in register outputs RO 230 231 MSB LSB BA RA WA Variable Affected No No Yes No Example STR DIV EQ STR EQ STR EQ STR EQ result is in word accumulator zZ zyuxxuxnxzzz zzzozozx x the remainder is in W M 011 DIV W Cd Operation Divide the word accumulator by the constant d The quotient remains in the word accumulator and the remainder is stored in register outputs RO 230 231 MSB LSB BA RA WA Variable Affected Yes No Example END Operation Last instruction of the fast program loop CAUTION The END instruction must not be written while the program is being executed The program ex
13. 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 8 8 8 8 8 8 8 ri M S x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time x cmmt 1 ms slave loop time total output set message 18 ms 1 ms slave loop time S SH 5 ee M total The calculated time is THE GREATEST POSSIBLE TIME that the modbus message loop can take In practice this time is shorter because the slave does not always run its entire whole program loop before the slave can examine the received message The Total Responce Time When RIO channel is used the number of Modbus master messages x RIO master program loop time X a When Modbus channel protocol is used the number of Modbus master messages x slave program loop time responce message time X ms Additionally in both cases the PC control software loop time must be included in the time calculations how soon the control software is able to send the new message number of messages RIO 178500 E FF Automation Oy AL 2000 User Guide 14 3 The Commands of
14. Each I O Module has one byte reserved for status information The status bytes for the Modules in each slot are held in register outputs R O 0 31 representing slot numbers 0 31 respectively The status bytes contain possible error information as follows For All Modules No error Module does not match configuration table Data transfer error between CPU and module Module is not configured For Analog Modules Only 103 109 Error in write operation due to module being in incorrect state e2prom not responding This indicates an error in either the e2prom or the I2C serial link This is a serious error condition because without calibration information from the e2prom all input values from that module are incorrect Error in module s data bus Data transfer error between CPU and module Error occurred during module initialisation Error writing to module s RAM memory 114 116 Error in write operation due to module being in incorrect state 10 2 4 The CPU Status Table Register outputs R O 32 36 contain the following information about the CPU status 32 Watchdog test If value is 255 then Watchdog is present R O33 Display keypad version No display keypad connected AL1094R AL1093 AL1094 AL1092 AL1095 AL1094AF Operating system version number The version number is obtained by adding 200 to the contents of this register output Status of DIP switches Status of battery Battery good Battery low Battery flat faulty or missi
15. Example If variable n is equal to the number in the register accumulator the bit accumulator is set to 1 if unequal the bit accumulator is reset to 0 BA RA WA Variable Yes No No No STR EQU EQ M 001 memories 1 and 2 M 002 are equal 1 00 output 0 is 1 R R EQU R TXn Operation Affected Example Compares if the content of text string TX n n is found in given FIFO n If an iden tical text string is found the bit accumulator is set to 1 Into register accumulator is transferred BCD number which is formed from the next two characters after the string found If the characters don t represent a BCD number the register accumulator becomes zero Into the word accumulator is transferred the ASCII codes of the former characters The FIFO number to be compared is given in register accumulator BA RA WA Variable Yes Yes No Bit accumulator to 1 reset W M 12 reset W M 12 Compare if FIFO 5 ser 1 includes the text srting TX 24 Save the result to bit memory the BCD number into R M 24 and characters ASCII codes into W M 25 R M 50 51 EQU W I M O Operation Affected Example EQU Operation Affected Example If variable n is equal to the number in the word accumulator the bit accumulator is set to 1 if unequal the bit accumulator is reset to 0 BA RA WA Variable Yes No No No STR W C 03000 EQU W M 037 EQ 0 08 If word memory 37 equals 30
16. P controller Pl controller PID controller The P controller has constant gain and the result is unsatisfactory especially if the gain is low The PI controller changes the apparent gain and correscts the error in time The PID controller exaggerates variations of error in order to abtain rapid error correc tion The step responce becomes faster FF Automation Oy ls 6 4 AL 2000 User Guide 06 05 00 6 2 12 Bit Controllers The AL2000 has 32 x 12 bit controllers with PID characteristics The shortest possible update interval for one controller is 100ms The controller parameters are held in W GM memories The controllers are divided into four groups of eight controllers Within these groups the user can select different update intervals The number of controllers to be used in a particular group is given in the register outputs R O 128 to R O 131 This number also determines the group update interval depending on the number of controllers used If one controller in a group is updated the update time is 100ms Similarly if three controllers in a group are updated the update time is 300ms etc The group update interval can be reduced by reducing the number of controllers used within that particular group If the number of controllers is given as 0 no controllers will be used The system software runs the group so that there are 20 PID controllers with 500ms up date intervals 128 to 131 5 au
17. 0 3 into the register accumulator WA Variable Affected No Example STR R Move the value of element 5 STR of shift register 0 into the register accumulator STR W I M O Operation Read the value of variable n into the word accumulator BA RA WA Variable Affected No Yes No Example Read value of input 1 0 4095 into word acc W Cd Operation Read the constant d 0 65535 into the word accumulator BA RA WA Variable Affected No No Yes No Example STR W C 00455 Initialize word accumulator to 455 XOR I M O NI NM NO DP DN BM GM NB NG P n Operation Sets the bit accumulator equal to the exclusive or function of its old value and Variable Affected No Example Output 0 is inverted once per second XOR Sd Operation If the current sequence register is at step d and the bit accumulator is O or if the sequence register is not at step d and the bit accumulator is 1 the bit accumulator is set to 1 otherwise it is reset to 0 Variable Affected No Example only one of sequence registers 0 and 1 is at step 10 memory 10 is set to 10 E FF Automation Oy AutoLog 2000 Instruction Manual Page 11 43 12 12 2000 XOR R M O NM NO n Operation Sets the register accumulator equal to the exclusive or function of its old value and the variable Variable Affected No Example sR MO 01111011B R M 1210000011 B RM2 11111000 B XOR R Cd Operation Sets the registe
18. scaling parameters start address STR Set bit accumulator to 1 STR variable to be scaled FCN call scaling function EQ save the result to WM 101 RET STOP FF Automation Oy AL 2000 User Guide TABLES 12 1 ASCII codes character Hex decimal character decimal ASCII ASCII code code 0 1 2 3 4 5 6 7 8 9 CANDOVOZET gt FF Automation 12 1 06 05 00 character decimal ASCII code lt xs lt gt TN ZOD E c7 07 7 000243 5 7 c3o7 0ocoom W A 12 2 AL 2000 User Guide 06 05 00 12 2 Decimal Octal conversions dec octal dec octal dec octal code code code code code code dec octal dec octal dec octal code code code code code code le FF Automation Oy AL 2000 User Guide Page 13 1 06 05 00 AL2000 PRODUCT LIST 13 1 Mounting Racks Code Model No Description 902158 ini Mounting Rack for I O modules no PSU 902159 ini Mounting Rack for 3 I O modules no PSU with covers 902151 Mounting Rack for I O modules 115 VAC 902152 Mounting Rack for I O modules 220 VAC 902153 Mounting Rack for I O modules 24 VDC 902150 Mounting Rack for 5 I O modules 902154 Mounting Rack for 11 I O modules 902156 Mounting Rack 16 I O modules 902100 FC50 Flat cable 0 5 m 902110 FC100 Flat ca
19. 0 02 jis greater than 500 EQ 1 33 output 33 is on e IFT Operation If the bit accumulator is 0 subsequent instructions up to the CONT instruction are skipped if the bit accumulator is 1 the instructions are executed Further IF instructions can be placed between the IF and CONT instructions The effect of all IF instructions ceases at the first CONT instruction encountered BA RA WA Variable Affected No No No No Example TR IF If input 10 0 STR these instructions will EQ not be executed CONT IF I M O NINM NO DP DN BM GM NB NG P n Operation If the variable is 0 subsequent instructions up to the CONT instruction are skipped if the variable is 1 the instructions are executed Further IF instructions can be placed between the IF and CONT instructions The effect of all IF instructions ceases at the first CONT instruction encountered BA RA WA Variable Affected No No No Example DP 077 When memory 77 changes 0 00 0 to 1 these instructions 1 01 are executed E FF Automation Oy AutoLog 2000 Instruction Manual Page 11 23 12 12 2000 IF Sd Operation If the current sequence register is at step d subsequent instructions are executed otherwise execution continues from the next CONT instruction Further IF instructions can be placed between the IF and CONT instructions The effect of all IF instructions ceases at the first CONT instruction encountered BA RA WA Variable Affec
20. 192 and RM 193 and off when the clock time reaches the value written into RM 194 and RM 195 CONT Operation Terminates the skipping of instructions The STOP instruction also has this effect The first CONT instruction encountered stops the effect of all nested IF instructions BA RA WA Variable Affected No No No Example If Input 000 1 then if Input 000 1 and Input 002 1 then Continue here in any case E FF Automation Oy AutoLog 2000 Instruction Manual Page 11 9 12 12 2000 e CSR n Operation The PLC executes the subprogram n if the bit accumulator is true BA RA WA Variable Affected No No No The states of the accumulators remain unchanged so subroutine can use the accumulator states See page 11 40 DCD R M On Operation Decodes the value of the variable n into the register accumulator If the variable is between 0 and 7 the corresponding bit is set to 1 and the remaining bits are reset to 0 If the variable is greater than 7 the register accumulator is reset to 0 The value 0 corresponds to the least significant bit and 7 to the most significant bit BA RA WA Variable Affected No No Example H C 006 000 000 Acc 01000000B Value of variable Register accumulator after DCD instruction Cn Operation If the bit accumulator is 1 decrement counter n by 1 This instruction does not perform differentiation for example when counting pulses the program must e
21. 2 Effect of the gain P P is a value 0 255 corresponding to gains of 0 1 128 corresponds to a gain of 0 5 Fig 1 Fig 2 Figure 1 P 100 20 D 2 Figure 2 P 100 2 D m s Set point Output Figure 1 shows how increasing Figure 2 shows how reducing the gain yields faster control the gain stabilises the action oscillation caused by short integration time The sum of the proportional derivative and integral terms is multiplied by the gain P Thus the gain P strengthens or weakens the effects of these coefficients 6 1 3 Effect of the integration time constant 1 Fig 1 Fig 2 Figure 1 Set point Output The figures show the behaviour of the same process for two different values of gain P and varying integration time I It can be seen that using high gain will result in overshoot even with longer integration times If the integration time is too short an oscillation of the type shown in the right hand figure will occur ls FF Automation Oy AL 2000 User Guide Page 6 3 06 05 00 6 1 4 Effect of the differentiation time constant D The effect of the differentiation time is critical as illustrated in the figures below Deriva tive control is unsuitable for many types of systems and is often not necessary at all Set point Output 6 1 5 Controller types The figure below shows the step response of the three basic controller types
22. 20mA 4 x Analog Outputs 4 20mA The following modules are required 1 x CPU2000S 1 x MR5 1x MR16 2 x POWAC 2 x PCON230 8 x DIC32DC 3 x DOC32EP 4 x ROC16 2 x AIC8 1x AIO74 1 x Flat cable O zOcv O zZzOocv opooomwmcuo JOro lt 402 lt 402 lt 402 JOro lt 402 OOoNZOOTU OONZOOTO FF Automation Oy AL 2000 User Guide Page 3 5 06 05 00 3 5 1 Configuring the Modules The required I O modules and their respective slot positions must be configured in the ALPro software This is done by selecting Hardware Configuration from the View menu The Configuration screen is shown below eS EM 151 THEE Type Pew W I 000 015 Wo 000 015 IGNORE 090 015 si The required I O modules be configured as follows 1 Select the desired slot using the up and down arrow keys 2 Select the desired type of card from the Card menu 3 Select On Error from the menu 4 Select the action to be taken in the event of an error in the card FF Automation Oy E 3 6 AL 2000 User Guide 06 05 00 3 5 2 Setting the Range of Analog Inputs The range of analog inputs can be set by selecting Range from the menu The following screen is then
23. AL 2000 User Guide 06 05 00 3 4 Hardware Configuration Set up The hardware is configured using the ALPro software The software gives directions about where to place the I O modules required by the application in the rack s Each I O module has an internal address which the AL2000 operating system detects on power up No DIP switches have to be set to determine the address of an I O module The system program checks the configuration on every program cycle this makes it impossible to accidentally replace an I O module with one of the wrong type e g during maintenance and also ensures that no mistakes can be made in the hardware configura tion Select Configure from the ALPro main menu Select the desired slot and make the following definitions Type of I O module Address of variables in the I O map On Error action to be taken in the event that the hardware configuration is not the same as that defined in the ALPro Software The options are STOP and RESET execution of PLC program stops All outputs are given the value 0 STOP execution of PLC program stops All outputs maintain their status IGNORE execution of PLC program continues 4 Type and measurement range of analog inputs for analog I O modules only 3 5 Example of Hardware Configuration In a certain application the following number of I O s must be handled 232 x Digital Inputs 24VDC 78 x Digital Outputs 24VDC 58 x Digital Outputs 230VAC 20 x Analog Inputs 4
24. AL2000 power supply is made up of two separate parts the power connecting mod ule and the power supply module All mounting racks except the MR3 and MR3 mini must be fitted with both of these units A different single unit power supply is included with the MR3 and the MR3 mini requires no power supply the CPU2000SCP has its own power supply There are two types of power connecting module available the PCON230 and the PCON24 These must be used in conjunction with the POWAC and POWDC power sup ply modules respectively PCON230 and POWAC Input voltage 230VAC Suitable for MR5 MR11 MR16 PCON24 and POWDC Input voltage 24VAC DC Suitable for MR5 PWR3 Input voltage 230VAC or 24VAC DC Suitable for only FF Automation Oy E 3 2 AL 2000 User Guide 06 05 00 3 3 Modules Required for Each Unit 3 3 1 MR5 MR11 MR16 Basic Unit The following modules must be installed in the basic mounting rack 1 PCON power connection module 2 POW power supply module 3 CPU central processing unit 4 Additionally the required I O modules 3 3 2 MR5 MR11 MR16 Expansion Unit The following modules must be installed in the expansion mounting rack PCON power connection module POW power supply module Additionally the required I O modules 3 3 3 MR5 MR11 MR16 Remote Unit The following modules must be installed in the remote mounting rack 1 PCON power connection module 2 POW power supply module 3 CPU wit
25. Analog Input Module The MIC16 is an analog input module with 16 x 13 bit individually isolated analog inputs The maximum voltage between input channels is 500VDC The current consumption of MIC16 is 600 mA The input ranges of the MIC16 are 4 20 mA and the 13 bit raw values are presented in numbers 1600 8000 By deviding the raw value with 2 the raw value limits are equal with other AL2000 analog input boards 800 4000 On the board the mA current is converted to fre quency and led to the counter chip The CPU on MIC16 board reads the frequencys every 0 5 sec ond and calculates the value for analog input based on former value and the change during the last 0 5 second The calculated value is after that corrected based on individual calibration values for that input The following LED indicators are located on the front edge of the module There are 32 indicator LEDs for inputs and 2 LEDs indicating the state of MIC 16 board The LEDs for MIC16 state are ACT green Steady light Module is in normal operation Blink light communication to AL2000 CPU doesn t operate correctly Steady light AL2000 CPU doesn t get con nection to MIC16 board or the Albus is in reset state ERR red For every input there are two leds L and H and they indicate the following states LED L LED H Steady light Input is not cali Input is not con brated nected Blinks Input value is near low limit Input value is nea
26. AutoLo English AND BCD BIN BIT BYT CLO CONT CSR DCD DCR DEC DIV END EQ EQU ERROR FCN FIN FOU GRT IF INC INV LES LOAD MID MIN MUL NEXT OR PLD PLU PRI PRT READ RES RET SBR SHL SHR Finnish JA BCD BIN BIT BYT CLO JTK CSR DCD VH DEC JAK END ON ONI EQU VIRHE FCN FIN FOU GRT JOS INC INV LES AS MID MIN KER SEUR TAI PLD PLU PRI PRT LUE RES RET SBR SHL SHR FF Automation Oy English STEP STI STOP STP STR XOR Variables NI O NO SO RO M NM SM RM DP DN BM NB SB RB GM NG SG RG P T TX C S F Q Page 14 3 06 05 00 Finnish STEP STI STOP STP STR ETAI Variable types R W R W 14 4 AL 2000 User Guide 06 05 00 E FF Automation Oy AL 2000 User Guide Page A 1 06 05 00 Appendix A PHYSICAL INSTALLATION Mounting the AL2000 in an enclosure is a rapid process due to key hole mounting The Mounting Racks are fastened with 4 M6 screws A 1 Mounting dimensions MOUNTING SPACE REQUIREMENTS DRILLING DISTANCES Width W1 Height Depth Width W2 Height mm mm mm mm mm mini MR3 MR5 MR11 MR16 NOTE At least 36 mm space should be left below the AL2000 for cabling FF Automation Oy 2 AL 2000 User Guide 06 05 00 Figure A 2 Dimensions of display keypad unit AL10
27. Automation Oy l 6 AL 2000 User Guide 06 05 00 Input 220VAC 50Hz Output 24VDC 3 5A M4mm dia Figure A 12 Dimensions of AL9624 3 5 power supply 165 Figure A 12 Dimensions of AL9624 8 power supply li FF Automation Oy
28. In 1 NIn O Auxiliary memory 0 255 One s complement of auxiliary memory M Additional auxiliary memory 0 255 One s complement of additional auxiliary memory GM Additional auxiliary memory 0 255 One s complement of additional auxiliary memory BM Output 0 255 One s complement of output SM SG SB SO Conditional setting of memory M GM BM output 0 255 Used with EQ instruction RM RB RO Conditional resetting of memory M GM BM output 0 255 Used with EQ instruction DP Change auxiliary memory from 0 to 1 numbered from 0 127 Compares memory state to that at beginning of cycle Change auxiliary memory from 1 to 0 numbered from 0 127 Compares memory state to that at beginning of cycle Pulse variable The variable is 1 for the duration of one program cycle P000 ten times per second P001 once per second and P002 once per minute Sequence register or a step of a sequence register There are 64 sequence registers number configurable from 8 64 default 32 These registers have 256 steps each One s complement of sequence register S Timer 0 79 Timer resolutions are as follows Timer Resolution Time Span 0 3 10 ms 0 02 2 55s T4 7 100 ms 0 2 25 5s T8 15 1s 2 255s T16 79 100ms 0 2 25 5s In the IF and STEP instructions T refers to the bit accumulator In the PRT instruction T refers to TEXT Counter 0 15 count down from 255 to 0 In the PRT instruction C refers to a numerical value le FF
29. Internal 10 0 4 T e ov RC 230 ms 20 36 VAC Q Y Layout of the DIC32AC IC1 Interrupt register IC2 Module address detection IC3 Internal data bus buffer IC14 Code register for module IC15 Test register LD1 LED Unit ACT ERR indicator LED Unit input status 10 131 Internal data bus connector Terminals for inputs 10 115 Terminals for inputs 116 131 FF Automation Oy Page 5 9 06 05 00 5 10 AL 2000 User Guide 06 05 00 5 2 4 DIF16 Fault Checking Digital Input Module The DIF16 is a digital input module with 16 fault checking inputs isolated as a group The following LED indicators located the front edge of the module ACT green Module in operation ERR red The operating system has discovered a fault in the module 0 15 yellow Inputs 10 115 are ON F0 15 red Fault in inputs 10 115 q a a 2 a a 2 a 723323538 The DIF16 can detect short and open circuit faults in the cable The status of each input can be determined from the LED indicators and can be
30. R O 081 R O 082 R O 083 R O 084 R O 085 R O 086 R O 087 R O 088 R O 089 R O 090 R O 091 Status information for I O modules in slots 0 31 Watchdog status information Keypad Display unit type System program version DIP switch SW1 status Battery and SER3 fault status File transfer error counter Processor Type 0 80C32 1 80C320 CPU type 0 S 1 SCP Error code on program save FPGA IC1 version FPGA IC2 version Flash manufacturer code Flash device code Number of non answered Modbus slave address for SER1 Type number of detected Modbus error for SER1 MODBUS error information for SER1 MODBUS counter abandoned messages on SER1 MODBUS counter accepted messages on SEH1 MODBUS message transmission delay for SER1 MODBUS response timeout for SER1 MODBUS response timeout for SER2 CTS RTS control memory forSER1 CTS bit 7 RTS bit 1 CTS RTS control memory forSER2 CTS bit 7 RTS bit 1 MODBUS error information for SER2 MODBUS response timeout for SER3 MODBUS error information for SER3 MODBUS counter abandoned messages on SER2 MODBUS counter accepted messages on SER2 MODBUS message list completed for SER2 MODBUS message transmission delay for SER2 MODBUS counter abandoned messages on SER3 MODBUS counter accepted messages on SER3 MODBUS message list completed for SER3 MODBUS message transmission delay for SER3 Number of non answered Modbus slave address for SER2 Type number of detected Modbu
31. The programming software issues error messages when it encounters error conditions during programming ERROR 010 ERROR 020 ERROR 021 ERROR 022 ERROR 025 ERROR 030 ERROR 031 ERROR 032 ERROR 033 ERROR 040 ERROR 044 ERROR 050 ERROR 060 ERROR 080 ERROR 085 ERROR 090 ERROR 091 ERROR 092 ERROR 093 No AutoLog instruction on program line Instruction write to memory failed Instruction write to memory failed Instruction write to memory failed The instruction entered is not valid Variable number too large Decimal number too large Decimal number setting too high Invalid octal number Instruction not found in program by FIND Not an AutoLog 16 instruction Transfer exceeds program space Hex file read error Invalid variable DISP Insertion pushes program beyond 2047 4095 Unidentified instruction in program at start Address of END instruction is 62 76 oct A second END instruction in the program No STOP instruction in the program FF Automation Oy AutoLog 2000 Instruction Manual Page 11 5 12 12 2000 11 4 AL2000S Instructions BA Bit Accumulator RA Register Accumulator WA Word Accumulator n variable number d constant AND M O NI NM NO BM GM NB NG DP DN P n Operation Sets the bit accumulator equal to the logical product of its old value and the variable BA RA WA Variable Affected Yes No No No Example STR 0 1 If input I 1 from card 0 is ON and 0 2 input 2 from card 0 is OFF AND Sd Operati
32. Variable Affected No No Example 1 5 4 MUL Operation Multiply the word accumulator by the constant d The least significant word of the product remains in the word accumulator and the MSB LSB eight bit variables are stored in register outputs R O 230 231 RA WA Variable Affected No Yes No Example Contents of word memory 30 10 WM 10 WM10 11 W M Ww C W M R R M R R M W M W M MUL W I M O Operation Multiply the word accumulator by the variable n The least significant word of the product remains in the word accumulator and the MSB LSB eight bit variables are stored in register outputs R O 230 231 RA WA Variable Affected No Yes No Example WM 1 WM 2 WM 10 11 zZ zyuxxxnxzzz lt lt lt lt lt lt lt FF Automation Oy 11 30 AutoLog 2000 Instruction Manual 12 12 2000 NEXT Sde Operation If the current sequence register has been at step d for e seconds it moves on to the next step BA RA WA Variable Affected No No No Example 000 010 The sequence register 001 010 moves around steps 0 1 2 002 010 at intervals of 10 seconds 003 Back to start from step 3 000 OR I M O NINM NO DP DN BM GM NB NG P n Operation Sets the bit accumulator equal to the logical sum of its old value and the variable BA RA WA Variable Affected Yes No No No Example STR OR Set bit accumulator to 1 OR Sd Operat
33. accumulator into a two digit BCD number 00 99 if the number in the accumulator is greater than 99 the result is indeterminate BA RA WA Variable Affected No No No Example STR R 0101 0000B 280DES BCD R T now 1000 0000B 80BCD WT Operation Converts the number in the word accumulator into a four digit BCD number if the number in the accumulator is greater than 9999 the result is indeterminate BA RA WA Variable Affected No No Yes No Example STR W 04396 W A before 0001 0001 0001 0001 B BCD W T W A after 0100 0011 1001 0110 B before 4396 DEC after 4896 BCD Q W M 000 17302 DEC E FF Automation Oy AutoLog 2000 Instruction Manual Page 11 7 12 12 2000 RT Operation Converts the contents of the register accumulator into binary format assuming it contained a two digit BCD number before the instruction if the accumulator does not contain a BCD number the result is indeterminate BA RA WA Variable Affected No Yes No No Example R R 1001 0100B 294 BCD T now 0101 1110B 94 DES WT Operation Converts the contents of the word accumulator into binary format assuming it contained a four digit BCD number before the instruction if the accumulator does not contain BCD number the result is indeterminate BA RA WA Variable Affected No No No Example SIR 00512 A before 0000 0010 0000 0000 B BIN W T A after 0000 0
34. and rise time of the step response of the process are determined and the controller settings are determined on that basis TtUO P controller UP C TSYO PI controller UP 1 25c Tl 3Tt PID controller Up 0 85c TI 2Tt TD 0 42Tt 6 4 2 Oscillation Method The gain and oscillation cycle time at the point of oscillation are determined and the controller settings are determined on that basis P controller KP 0 5KPcr KP 1 UP gain PI controller KP 0 455KPcr Where TI 0 85Tcr Integration time constant PID controller KP 0 6KPcr Differentiation time constant KPcr TI 0 5 Critical gain at which the process oscillates TD 0 12Tcr Cycle time of process oscillation The above two methods yield reasonable starting points for the controller parameters which can be further refined during operation The ALPro software can be used for moni toring controller variables building trend data and producing documentation le FF Automation Oy AL 2000 User Guide Page 7 1 06 05 00 7 DISPLAY KEYPAD UNITS There are several display keypad units available for the AL2000 most of which can be connected to the CPU board via interface 7 1 AL1096 Display Keypad Units AL 1096PS PE front panel mounted enclosure RS232 connection 320x240 pixel STN graphic LCD display backlit touch screen max 40 x 30 touch keys Clock and calendar battery backup AL 1096S front panel mounted enclosu
35. and the bit accumulator to the register accumulator assuming that both are BCD numbers If the result is greater than 99 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 If the numbers are not BCD numbers the result is indeterminate NOTE The constant d which is a BCD number is written in the program as a decimal number Example constant 16 0001 0000 bit format 1 0 BCD format BA RA WA Variable Affected No No Example 0001 0001B 11 BCD 0001 1001B 19 BCD 0011 0000B 30 BCD FF Automation Oy 11 32 12 12 2000 AutoLog 2000 Instruction Manual PLD R M On Operation Affected Example Adds the variable n and the bit accumulator to the register accumulator assuming that each contains a BCD number If the result is greater than 99 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 If the addend and augend are not BCD numbers the result is indeterminate BA WA Variable Yes No Register memory 1 9 OR bit accumulator 1 STR acc 0001 0000B 10 BCD 0000 1001B 9 BCD 1B bit acc 0010 0000B 20 BCD W Cd Operation Affected Example Convert the constant d 0 9999 to BCD format and add it and the bit accumulator to the word accumulator assuming that both are BCD numbers If the result is greater than 9999 the bit accumulator is set to 1 otherwise the bit accumulator
36. be accounted for when tuning the controller using the step response method Example Temperature control of circulating water by 3 point control Desired value W I 2 02 Actual value WI 2 01 Mixing valve Logic program for water heating STR W C Integration time 50 0 15 0 65535 EQ GM greater value gives slower action STR C Differentiation time 2 0 1s 0 255 EQ GM greater value gives bigger steps STR C P 100 110 EQ GM gretaer value gives slower action STR Set point e g from potentiometer EQ GM STR Actual value from temperature sensor EQ STR EQ STR EQ STR BIT STR EQ OQ Controller in automatic mode Q Pulse interval 1s 222 2 2 2 2 Read open bits Convert to bits controllers O 7 Use bit for controller 1 to open valve Read close bits Convert to bits Use bit for controller 1 to close valve BIT 00 5000 FF Automation 6 8 AL 2000 User Guide 06 05 00 6 4 Controller Tuning In a control system suitable values must be found for the control parameters P and D Suitable parameters can be determined using mathematics or a Bode diagram however these methods can be time consuming Controllers are usually tuned on the basis of ex perimental data from the control system Two simple and effective methods for this are described below 6 4 1 Step Response Method The delay
37. digital output module with 16 fault checking FET type outputs isolated as a group The electronically protected outputs can withstand a load of 1A each and may be connected in parallel load output must not exceed 0 84 The following LED indicators are located on the front edge of the module ACT green Module in operation ERR red The operating system has discovered a fault in the module 0 15 red Outputs O0 O15 are ON F0 15 red Fault in outputs O0 O15 The statuts of each output can be determined as follows Status 0 15 Fault F0 15 Input OFF Input ON Open short circuit Short circuit to GND Vcc These status conditions can be used in the PLC program The outputs are connected to as shown in the diagram below FEEDBACK INFO FF Automation Oy Page 5 13 06 05 00 3 I IF RITI I TT 5 14 AL 2000 User Guide 06 05 00 5 2 8 OOC16 Relay Output Module The OOC16 is a digital output module with 16 solid state re lay outputs The current consumption of OOC16 is 250 mA The voltage range of the module is 20 280VAC with a maxi mum continuous load of 0 6A The following LED indicators are located on the front edge of the module ACT yellow green Module is in operation ERR red The operating system has discovered a fault in the
38. is reset to 0 If the numbers are not BCD numbers the result is indeterminate BA RA WA Variable Yes No Yes No STR 00313 0000 0001 0011 1001 B 139 BCD PLD W C 00400 const 0000 0001 1001 0000 B 190 BCD 0000 0011 0010 1001 329 BCD PLD W M On Operation Affected Example Add variable n and the bit accumulator to the word accumulator assuming that each contains a BCD number If the result is greater than 9999 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 If the addend and augend are not BCD numbers the result is indeterminate BA Variable Yes No memory 003 4900 at the beginning OR set bit accumulator to 1 0000 1001 1001 0010 992 BCD WM 0001 0011 0010 0100 B 1324 BCD BA 0000 0000 0000 0001 B 1 BCD 0010 0011 0001 0111 B 2317 BCD FF Automation Oy AutoLog 2000 Instruction Manual Page 11 33 12 12 2000 PLU R Cd Operation Adds the constant d and the bit accumulator to the register accumulator If the result is greater than 255 the bit accumulator is set to 1 otherwise the bit accumulator is reset to O RA WA Variable Affected No No Example 1 to register memory 123 per second PLU Operation Adds the variable n and the bit accumulator to the register accumulator If the result is greater than 255 the bit accumulator is set to 1 otherwise the bit accumu
39. module SP F yellow green The spare fuse is available and working 0 15 red Outputs O0 O15 are ON Each output is protected by a separate F1 6A quick blow fuse The fuses are mounted in sockets located directly be hind the output screw terminals and are easily replaceable In the event of a fuse blowing a spare fuse is located in a socket directly behind the LED indicators The SP F LED on the front edge of the module indicates if the spare fuse is working and mounted in its socket This provides a simple way to check fuses A spare fuse should always be installed in the module s spare fuse socket The output wires are connected to the screw terminals as shown below External Internal A 0 B A 1 B A 2 B A 3 B A 4 B A 5 B A 6 B A 7 B Cc N A Fuse 24 VAC A E 220 VAC O 1 A E Uo WED UO UMP WP UO UOP UO OOOO OAO O O O OAS OAO O OAO O OAO OA O O O O O O O OOO z li FF Automation Oy AL 2000 User Guide 5 2 9 ROC16K Relay Output Module The ROC16K is a digital output module with 16 relay outputs The current consumption of ROC16K is 500 mA The outputs are potential free N O gold plated relay contacts with a maximum continuous load of 2A making this module ideal for low current signalling applications The following LED indica tors are located on the front edge of the module ACT yellow green Module is in
40. not in use 1 Controller in automatic mode 3 Controller in manual mode Writing 1 to register memory R GM 8 mode would activate controller 1 in automatic mode The contents of register memory R GM 14 output will then be generated in ac cordance with the control algorithm and parameters Three point control outputs are also written to register outputs R O 192 and R O 196 The required pulse interval can be writ ten to register output R O 200 Writing 3 to register memory R GM 8 mode would activate controller 1 in manual mode In this mode the controller program computes the control algorithm once and then leaves the controller in manual mode This allows the user to use greater control intervals The controller program continuously monitors the output so returning to automatic mode does not cause steps or spikes in the controller output If a controller is deactivated by writing O to its mode register memory the remaining reg ister memories for that controller become available for other purposes For example de activating controller 2 by writing 0 to R GM 16 would leave register memories GM 17 23 available for other purposes FF Automation Oy ls 6 2 AL 2000 User Guide 06 05 00 6 1 1 Control Algorithm The following control algorithm is used DYzP e ti e ti 1 D e ti 2e ti 1 e ti 2 e ti I Where P gain 0 1 D differentiation time constant e error integration time constant 6 1
41. operation ERR red The operating system has discovered a fault in the module SP F green The spare fuse is available and working 0 15 red Outputs O0 O15 are ON Each output is protected by a separate T2 5A slow blow fuse The fuses are mounted in sockets located directly behind the output screw terminals and are easily replaceable In the event of a fuse blowing a spare fuse is located in a socket directly behind the LED indicators The SP F LED on the front edge of the module indicates if the spare fuse is working and mounted in its socket This provides a simple way to check fuses A spare fuse should always be installed in the module s spare fuse socket The output wires are connected to the screw terminals as shown below External Internal MH 220VAC OQ CI OO o TDN FF Automation Oy Page 5 15 A 0 B A 1 B A 2 B A 3 B A 4 B A 5 B A 6 B A 7 B E Em A E Gi UO U UO WNP gt WOY UOP Uo z VSP SP SGPSASSPDSA SSDS SSAA O O OSO O O O OAO O O MENSEN 06 05 00 5 16 AL 2000 User Guide 06 05 00 5 2 10 ROC16Z Relay Output Module The ROC16Z is a digital output module with 16 relay out puts These are potential free N O relay contacts with a max imum continuous load of 4A The following LED indicators are located on the fron
42. queue and returns with bit accu set to 1 If either parameter is not good FCN will return with bit accu set to O If message already exists in message queue the previous message request will be re moved from message list If current transfer in progress is the same message as requested message request is ignored Function will however return 1 Example 1 Send message every time input goes actice Parameters W M 010 3 Serial channel W M 011 10 message number Program STR 0 0 EQ M 000 STR DP 000 On positive derivation STR R C 010 Get parameters from W M 10 gt FCN 024 INV EQ SM ERROR STOP FCN 32 Read Ibutton serialcode This command is used to read serial code from IButton device connected into Autolog PLC s 12C channel Command is executed only if Bit accu equals 1 before instruction Function parameter is defined in register accu Register accu must hold the address of the 1 byte save location Execution time is 1 4 ms If there is no ibutton connected to PLC command retuns bit accu 0 and register accu 0 If there is iButton connected but CRC does not match bit accu 0 and register accu lt gt 0 If there is Ibutton connected and it was successfully read bit accu 1 and register accu 0 Example 1 Check for iButton every 1 second Program STR STR R FCN IF serial code saved into R M 0 gt check for ibutton if ibutton was attached to PLC and data was succesfully read
43. register accumulator into element d 0 255 of shift register n 0 3 BA RA WA Variable No No Yes C 000 Clear the register accumulator 0 00 At the rising edge of input 0 M 000 000 Q 000 002 clear element 2 of shift register 0 Subtracts the constant d and the bit accumulator from the register accumulator assuming that both are two digit BCD numbers If the result is less than 0 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 If the numbers are not BCD numbers the result is indeterminate BA RA WA Variable No No MO 1 0 Subtract 16 0001 0000B BCD 216 DES from the 16 bit number register memories 14 15 MID R M On Operation Affected Example Subtracts the variable n and the bit accumulator from the register accumulator assuming that they are two digit BCD numbers If the result is less than O the bit accumulator is set to 1 otherwise the bit accumulator is reset to O If the numbers are not BCD numbers the result is indeterminate RA WA Variable No No Reset bit accumulator FF Automation Oy AutoLog 2000 Instruction Manual Page 11 27 12 12 2000 MID W Cd Operation Convert the constant d 0 9999 to BCD format and subtract it and the bit acc from the word accumulator assuming that the word accumulator contains a BCD number If the result is less than 0 the bit accumulator is set to 1 otherwise the bit accumulato
44. state Execution of the pro gram has stopped The status of the out puts remain Reason The program was stopped using the pro gramming tool Measure to be taken Start execution of the program with the START command The program is Normal operation running The program is running The execution of the program has stopped The status of all out puts is 0 The execution of the program has stopped The status of all out puts is 0 The execution of the program has stopped The status of all out puts is 0 Disturbances in supply voltage After 4 min the blinking returns to nor mal Too low supply voltage It has dropped below 17 VDC 180 VAC and has not exceeded 20 VDC 195 VAC There are faults in the program Hardware fault or the STOP command has been erased or the END command was moved during the exe cution of the program FF Automation Oy Check the supply volt age Check the supply volt age Correct the program and re start execution Switch off the supply voltage and switch on again Correct the pro gram and re start execution 5 32 AL 2000 User Guide 11 09 2000 All CPU2000S series modules are equipped with DIP switches located directly beneath the LED indicators on Enable writing to Disable writing to the front panel of the module The FLASH memory FLASH memory position of these DIP switches deter Serial line Mode se
45. the bit accumulator is reset to O BA RA WA Variable Affected No No No Example When register output 1 sis between 146 and 154 output 2 is 1 LES Operation If variable n is less than the register accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to O BA RA WA Variable Affected No No Example When register memory 2 sis less than register output 1 output O is 1 Operation If the constant d is less than the number in the word accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 BA RA WA Variable Affected Yes No No No Example STR W 0 001 When analog input 01 LES W 06000 sis less than 6000 EQ 1 30 output 30 is 1 LES W Operation If variable n is less than the number in the word accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 BA RA WA Variable Affected Yes No No No Example STR W When word memory 4 LES W M sis less than analog input 01 EQ output 30 is 1 FF Automation Oy AutoLog 2000 Instruction Manual Page 11 25 12 12 2000 LOAD Cnd Operation If the bit accumulator is 1 counter n is loaded with the initial setting d After the instruction the bit accumulator contains the status of the counter 1 2 counted out 0 running A setting can be defined for the counter with the programming device If itis non zero it will be used if it is zero the
46. used in the PLC program Status indication is as follows Status 0 15 Fault F0 15 Input OFF Input ON Open circuit Short circuit Connection diagram for a switch IK gt logic 0 0 13 1 4 mA logic 1 1 9 6 7 mA 1 j 112 Connections for DIN19234 or NAMUR transducer I 113 C7 2 114 a STATE 115 24 V IN liE FF Automation Oy AL 2000 User Guide 5 2 5 DOC32EP Digital Output Module The DOC32EP is a digital output module with 32 x 24VDC PNP type outputs in two groups of 16 outputs each The current consumption of DOC32EP is 250 mA The DOC32EP has electronic overload and short circuit protection The outputs can withstand a load current of 1A each and can be connected in parallel If connected in parallel the load on each output must not exceed 0 8A The following LED indica tors are located on the front edge of the module ACT green Module in operation ERR red The operating system has discovered a fault in the module 0 31 yellow Inputs 10 131 are ON Output wires are connected to the screw terminals as shown below External Internal e od f S Pd U1 L FF Automation 5 11 06 05 00 O
47. 0 10 EQ W M 020 Read contents of WM 10 STI W M 020 sinto the word accumulator FF Automation Oy 11 40 AutoLog 2000 Instruction Manual 12 12 2000 STOP Operation Last instruction of the program the first program line will be executed next Terminates the range of the IF instruction BA RA WA Variable Affected No No No No STP Operation The PLC s main program ends with this command and all subroutine programs must be written after the STP command STR I M O NINM NO BM GM NB NG P n Operation Reads the state of variable n into the bit accumulator The variable is not affected BA RA WA Variable Affected Yes No No No Example STR i Read state of input 0 into acc STR DPn Operation If auxiliary memory n is 1 and was 0 at the start of the program cycle the bit accumulator is set to 1 If the auxiliary memory is 0 or was already 1 at the start of the program cycle the bit accumulator is reset to 0 RA WA Variable Affected No No Example Read state of input 0 into memory Rising edge jinverts output 5 STR DNn Operation If auxiliary memory n is 0 and was 1 at the start of the program cycle the bit accumulator is set to 1 If the auxiliary memory is 1 or was already at the start of the program cycle the bit accumulator is reset to 0 BA RA WA Variable Affected No No No Example At falling edge of input 1 decrement counter 3 by 1 E FF Automation O
48. 00 output 8 is on W Cd If the constant d is equal to the number in the word accumulator the bit accumulator is set to 1 if unequal the bit accumulator is reset to 0 BA RA WA Variable No No There may be several successive comparisons FF Automation Oy 11 16 AutoLog 2000 Instruction Manual 12 12 2000 FCN Operation If the bit accumulator is true the FCN instruction executes one of the following functions After successful execution of the instruction the bit accumulator is true An undefined function call or illegal calculation parameter s may cause bit accumulator to reset CAUTION The FCN instruction must not be used in the fast program loop Affected n selects the function for execution calculationtime 0 logarithm a 13 ms 1 natural logarithm a 12 ms 2 sqrt square 7 ms 8 percent 10 scaling of word variable a 7 ms 11 scaling of word variable a 8 ms output sign integer and decimal part 24 Send modbus message 30 write to C channel 31 read from 2 channel 32 read serial number from Ibutton Before calling the FCN instruction the variables content which is to be scaled must be written to word accumulator After execution of FCN instruction the result of calculation is in word accumulator The resolution of the result depends on the used function 0 log 65535 4 8164 in word acc is 48164 In 65535 11 090 in word acc is 11090 1 2 s
49. 000 1100 1000 B before W A 200 BCD after 200 DEC BIT M O BM GM n Operation Moves the content of the register accumulator into 8 successive bit variables such that the least significant bit goes to address n the next to address n 1 etc and the most significant bit to address n 7 Register accumulator Variable bit 0 n bit 1 n 1 bit 2 n 2 bit 3 n 3 bit 4 n 4 bit 5 n 5 bit 6 n 6 bit 7 BA Variable Affected No Yes Example 10000010B Turn on outputs 2 15 and 2 09 FF Automation Oy 11 8 AutoLog 2000 Instruction Manual 12 12 2000 e BYT I M O BM GM Operation Converts 8 successive variables to a byte in the register accumulator Variable n becomes the least significant bit and variable n 7 the most significant bit Variable Register accumulator bit 0 bit 1 bit 2 bit 3 bit 4 bit 5 bit 6 bit 7 Variable Affected No Example The time setting for stimer 6 is read from inputs for example a thumbwheel switch CLO Operation Compares the 16 bit value in register memories RO 250 and RO 251 RO 250 high byte with the variable given as the instruction parameter The bit accumulator is reset to 0 when RO 250 RO 251 R M O n R M O n 1 CAUTION The 16 bit values compared must be in the same format i e both binary or both BCD BA RA WA Variable Affected No No Example Output 012 is turned on when the clock time reaches the value written into RM
50. 000 User Guide 06 05 00 In the following table the calibration points are calculated for the two different standard Pt100 measurement ranges available for AL2000 PT100 Temp range 200 730 OFFSET point 10 30 0 OFFSET point 20 C Resistor value 88 22 98 04 Calibration constant dv 400 800 GAIN point 8096 544 0 GAIN point 90 130 0 Resistor value Q 149 82 295 43 Calibration constant high 3600 3200 On the PC you should see the following values when the adjustment is correct OFFSET GAIN 10 90 3600 E FF Automation Oy AutoLog 2000 Instruction Manual Page 11 1 12 12 2000 11 PROGRAMMING Paragraph 11 1 discusses the available alternative programming methods Since separate docu mentation is provided for the programming programs they are only briefly outlined below 11 1 Programming methods The programming device can be any IBM compatible PC computer The program is transferred through the programming cable to the PLC When programming with a PC the AlPro programming software is used With the programming software the PLC program can be written either in OFF LINE mode without a PLC for subsequent transfer or in ON LINE mode the program is immediately transferred to the PLC The AL 2000 series Programmable Logic Controller incorporates a programming port Seri information on the operation of instructions and commands and a RS 232C interface Accordingly t
51. 09 2000 Precautions Against Data Loss When handling CPU modules care should be taken not to touch the metallic parts of the PCL rack this could cause damage to data stored in the RAM If the AL2000 s working environment is especially noisy or susceptible to violent electrical storms DIP1 should be set to the OFF position after programming this protects the con tents of the FLASH memory FF Automation Oy l 5 34 AL 2000 User Guide 11 09 2000 5 4 1 CPU2000S Module The CPU2000S is the basic CPU module The ACT ERR RS 485 serial interface uses detachable screw terminals for ease of connection The RS 232 CTS1 RTS1 TXL and RS 485 serial ports are isolated in two CTS2 RTS2 RC groups to 500VDC The current consumption of CPU2000S is 700 mA at 5 VDC voltage level E FF Automation Oy AL 2000 User Guide Page 5 35 11 09 2000 5 4 2 CPU2000P Module ACT ERR The CPU2000P is a CPU module with two fast CPU counter inputs and a built in power supply The NUN counter inputs and the RS 485 serial interface use detachable screw terminals for ease of con nection The RS 232 and RS 485 serial ports are isolated in two groups to 500VDC They are also isolated as a group to 500VDC The current consumption of CPU2000P is 600 VS3 RXG TX3 mA This CPU is designed for use with the MR3 mini mount
52. 0P depending on number of I O modules With no external supply 2 years with max ambient temperature 60 Normal use up to 10 years Natural 6HE 4 233 3 mm x 160 mm x25 mm 0 35 kg CPU2000S 902200 CPU2000P 902205 FF Automation Oy AL 2000 User Guide Page 8 3 11 09 2000 8 2 CPU2000L Module CPU Ethernet or CPU Ethernet Flash memory RAM memory Bus Operating system QNX Software Serial Interfaces LED Indicators Power Consumption Cooling Operating temperature 486DX4 DX5 5x86 AMD 10 Base2 5 AUI 10 Base T RJ 45 Pentium 233 MHz AMD 10 100 Base2 5 AUI 10 100 Base T RJ 45 16 48 MB FLASH 16 32 MB Optional PC 104 extensions HDD FDD etc FCS control system software 1 isolated SER1 RS 232C 300 115200 bits s 9 pin D type connector SER2 RS 422 485 232 300 115200 bits s 11 LED indicators 4 A 5VDC Natural 0 50 Available also for higher ambient temperatures For testing PC in installation phase following devices can be connected to CPU2000L Option Display driver Option Display unit Option Keyboard PC 104 VGA SVGA 256 colour grey scale maximum resolution 1024 x 768 VGA SVGA video monitor with 15 pin D type connector Connector for Mouse amp Standard IBM AT keyboard FF Automation Oy 8 4 AL 2000 User Guide 11 09 2000 8 3 AL2000S P Variables 8 3 1 Single Bit Variables Input 0 255 One s complement of input When
53. 1 high limit of measured input 0 4095 102 low range scaled output eg 10 C 103 high range scaled output eg 115 C 104 Offset to 0 value input data 105 decimal count 0 4 input data 106 Sign 0 1 negative output data 107 interger part output data 108 decimal part output data WM WM WM WM WM WM WM WM WM 00000 low limit of input Pt100 50 150 C 100 wanted output 50 0 150 0 tenths of percent 04000 high limit of input 101 00000 low limit of output 102 00200 high limit of output 103 01000 offset 1000 0 C 104 00001 decimals 105 00100 Intialize pointer 2 099 points to W M 100 099 Initial pointer 1 points to W M 099 0 01 word input to be scaled into WA 001 set bit accumulator to 1 011 call scaling function Example i 555 OL NZQZONZONZOZOZOZO FF Automation Oy 11 18 AutoLog 2000 Instruction Manual 12 12 2000 Launch modbus message to serial channel Command is executed only if Bit accu equals 1 before instruction Function parameters are defined in word memories Register accu must hold the address of the first parameter before FON instruction Parameters 1 parameter Serial Channel 12 Ser1 2 Ser2 3 Ser3 2 parameter Message number 0 511 Execution time is about 0 03 ms FNC 24 checks the parameter values and if parameters are OK it will add the mes sage number to the first place in message
54. 13 902219 Model No POWDC 100W POWDC 25W PCON24 POWAC115 PCON115 POWAC230 PCON230 PCON24 100 13 9 Special Units Code 902400 Model No DSIM 32 13 10 Accessories Code 900860 901017 901017 901023 901019 900870 900850 900855 902172 902174 902178 902180 Model No AL1093F AL1093D AL1093DC AL1094 AL1094R AL1094F AL1095A AL1095B AL1096 S AL1096 T AL1096PS AL1096PE Description Digital Input Output Module 16 DI 24 V DC 16 DO 20 40 VDC 1A Description Analog Input Module 8 16 Al Thermocouple Input Module 8 TI Analog Input Output Module 7 14 Al 4 AO Analog Input Module 16 galvanic isolated Analog Output Module 16 AO 4 20 mA Frequency Input Module maximum 10 kHz 16 Channels Description Power Supply Module Supply Voltage 24 VDC Power Supply Module Supply Voltage 24 VDC Power Connection Module with POWDC module Power Supply Module Supply Voltage 90 132 VAC Power Connection Module with POWAC115 module Power Supply Module Supply Voltage 180 265 VAC Power Connection Module with POWAC230 module Power connection module with POWDC 100W module Description Digital Inputs Output Simulator Description Clock and Calendar Display Keypad 2x16 Characters 16 Function Keys Clock and Calendar Display Keypad With Surface Mounting Plate 2x16 Characters 16 Function Keys Clock and Calendar Display Keypad for Customers front Plate 2x16 Characters 16
55. 2 D or F 3 xx day two digits 01 31 Dor F 4 XX hour two digits 01 24 D or F 5 minute two digits 01 59 Dor F 6 x day of week one digit 01 07 Dor F 1 mon 2 tue 7 sun B Enter Parameters into Register variable Key display continue RM000 address octal number DorBorF WMO00 continue with B browsing variables Dor Bor F ROO000 address of variable continue with D Dor F XXX enter parameters value Dor F XX001 address 001 or new address Dor F XXX enter parameters value D or F and or quit by F key C Display register memory output or word memory The value of register variable is updated continuously into the display Update rate is one second Key display continue RM000 address octal number CorDorF WMO000 continue with C browsing variables CorDor F RLOOO address of variable D gt update Dor E or F D gt next variable Dor F RLOOO E display varaible s address CorDorF escape by F key D Next Display Mode In the normal display mode 0 the display information may changed by pressing the D key This is performed as follows display continue 15 30 hours minutes Dor F 17 05 date month Dor F 00 01 date of week Dor F models AL1093 AL1094AF AL1095 FF FF R O 245 and R O 246 in hex Dor F 15 30 hours minutes etc FF Automation Oy l 7 6 AL 2000 User Guide 06 05 00 7 8 2 Data Display Mode 1 R
56. 2 2000 STEP Sd Operation If the bit accumulator is 1 the current sequence register moves to step d If the bit accumulator is 0 do nothing RA Variable Affected No No Example at step 139 move to step 0 STEP T Operation If the bit accumulator is 1 the current sequence register moves on to the next step If the previous step is 255 the new step is O Variable Affected No Example STR Select sequence register 0 STR valid until the next selection STEP Sequence register moves to next step 10 times per second STI I M O BM GM n Operation Reads the state of binary input output memory to bit accumulator Register accumulator is pointing to the bit variable to be read BA RA WA Variable Affected Yes No No No Example STR R C 012 The state of input 12 is the bit accumulators STI state read address is 12 decimal STI R M On Operation Loads the register accumulator with the variable whose address is the value of the variable given as the instruction parameter WA Variable Affected No Example STR R C 00 001 010B 10 dec EQ R M Read contents of RM 10 STI R M into the register accumulator STI W n Operation Load the word accumulator with the variable whose address is the value of the variable given as the instruction parameter For accessible addresses see the tables of the variables BA RA WA Variable Affected No No No Example SIR W C 010 0 000 000 000 001 01
57. 2 LEDs indicating the state of MOC16 board The LEDs for MOC16 state are ACT green Steady light Module is in normal operation Blink light communication to AL2000 CPU doesn t operate correctly Steady light AL2000 CPU doesn t get con nection to MOC16 board or the Albus is in reset state ERR red For every input there are two leds L and H and they indicate the following states FF Automation Oy QO S OQ OFC VIS VIC I CHOICES SES Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Page 5 29 11 09 2000 Analog output 0 Analog output 1 Analog output 2 Analog output 3 Analog output 4 Analog output 5 Analog output 6 Analog output 7 Analog output 8 Analog output 9 Analog output 10 Analog output 11 Analog output 12 Analog output 13 Analog output 14 Analog output 15
58. 2 bit differential or 14 x 12 bit non differential analog inputs 500 VDC group isolation is pro vided by opto isolators and DC DC converters The maximum common mode voltage for the AIO74 is 5V The current consumption of AIO74 is 600 mA The ranges of the AlO74 are as follows Inputs Voltage 0 480mV 0 5V 0 10V 10V Current 0 4 20mA 50 to 150 C 200 to 730 C KTY10 50 to 150 C 200 to 730 C Cu50 200 to 200 C 8 3 bits mV 800 bits V 400 bits V 200 bits V 200 bits mA 20 bits C 4 bits C 10 bits C 4 bits C 100 900 2 bits C Outputs 0 4 20 mA 0 4000 200 bits mA A constant measuring current of 1 4mA is pro vided for each input The following LED indicators are located on the front edge of the module ACT green ERR red fault Module is in operation The operating system has discovered a in the module Status of analog inputs Al0 AI6 STEADY LIGHT input not scaled FLASHING LIGHT input at upper lower limit or not connected input in use and OK 0 6 red NO LIGHT FF Automation Oy O O O OOO 24 V Analog output 0 Analog output 1 Analog output 2 Analog output 3 ov Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog s
59. 20AN AL32 AL16 AL14 and or a computer via serial interface The AL2000 can function as MODBUS Master or MODBUS Slave to other units Several MODBUS masters can be used in the same AL2000 system One AL2000 can operate as a master to another AL2000 which in turn can operate as master to a third AL2000 This allows large distributed control systems to be realised Using MODBUS to connect the AL2000 to a computer running software such as PARAGON opens up unlimited opportunities for SCADA Supervisory Control And Data Acquisition applications 4 1 1 Error Checking All MODBUS communication is subject to the following error checks by both Master and Slave units CRC16 Checksum Command Validity Check Address Validity Check Message Length Check Framing Check Message Integrity Check Messages may be transmitted at rates of 300 115kbaud The composition of the mes sage frames is shown below SLAVE FUNC MEMORY DA TA CRC16 CHECK ADDRESS ADDRESS SUM START DATA STOP 1 bit 8 bits 2 bits Modbus messages are launched from master either based on pollrate defined in the message or if user has defined conditional messages these are launched from PLC program with FCN instruction The Slave unit ignores all invalid messages If after trans mitting a message the Master does not receive a valid response from a slave it will time out after 500 ms and re send the message If the Master still does not receive a vali
60. 6 save the value into display variable FF Automation Oy l 7 8 AL 2000 User Guide 06 05 00 7 9 4 Display Control Characters STR W 0 01 read word input 001 into word accumulator BDC W convert to BCD EQ W 000 save into word memory STR 001 print on 1 second period PRT lt 1 gt lt 01 gt lt 04 gt to line 1 column 4 PRT R 000 the value of W T 1 first high byte PRT R 001 and then low byte STOP 7 9 5 Setting the Time and Date Using Register variables STR STR EQ STR AND 000 Step register 0 in use 0 00 Clock synchronising input 065 065 000 001 activate clock time setting 000 step registers step to register accumulator 000 program is executed only if current step is greater than 0 000 019 2 seconds delay made by STEP register 0 000 005 242 transfer time to real time clock 001 if in step 001 242 disable reading of real time clock 001 check if reading of real time clock 242 is disabled pulse interval 0 1 second go to next step 96 set year JJOO mm DI set month Sequencies in setting clock time set day 1 of month Stop system program RTC clock read function by inserting to R O 242 value 1 set hour part of time Set new values to clock variables from R O 247 to R O 255 in BCD format S M P S S S C T S C S C O C O C T C T T T T
61. 8 016 O24 O9 017 O25 O10 O18 O26 O11 O19 O27 012 O20 028 013 021 029 014 022 030 015 023 031 O0 O1 02 O4 05 O6 O7 O8 O9 5 12 AL 2000 User Guide 06 05 00 5 2 6 DOC32FP Digital Output Module The DOC32FP is a digital output module with 32 x 24VDC PNP type outputs in two groups of 16 outputs each The cur rent consumption of DOC32FP is 250 mA The DOC32FP has group overload and short circuit protection two groups using 2 x F4A quick blow fuses located behind the top edge of their respective connectors The outputs can withstand a load current of 0 5A each however the maximum total cur rent for each group must not exceed 4A The following LED indicators are located on the front edge of the module O8 016 024 O9 017 025 010 018 026 011 019 027 012 020 028 013 021 029 014 022 030 7 015 O23 031 ACT green Module in operation ERR red The operating system has discovered a fault in the module O0 0 31 yellow Inputs 10 131 are ON O1 02 03 O4 O5 O6 External Internal 07 O8 O9 Output wires are connected to the screw terminals as shown below li FF Automation Oy AL 2000 User Guide 5 2 7 DOF16 Fault Checking Digital Output Module The DOF16 is a
62. 93D min the key is the tallest 17 component on the board O ug allel 84 the key is the tallest component on the board Figure A 4 Dimensions of display keypad unit 1094R FF Automation Oy AL 2000 User Guide Page A 3 06 05 00 79 996 Figure A 5 Dimensions of display keypad unit AL 1094AF 0 1 2 3 4 5 6 7 10 11121314 15617 8 9 C DJEJFJ B CIDIEIF Display Cutout Figure A 6 Dimensions of display keypad unit AL1093F FF Automation Oy l 4 AL 2000 User Guide 06 05 00 Display Figure A 7 Dimensions of display keypad unit AL1095A OOOOOOOO OOOOOOOO 145 Display Cutout Figure A 8 Dimensions of display keypad unit AL1095B FF Automation AL 2000 User Guide Page A 5 06 05 00 1e 5mm Adjustment 144t 0 5 Figure A 9 Dimensions of graphic display keypad touchscreen unit AL1096S T 191 0 5 203 0 3 149 8 0 5 Figure A 10 Dimensions of graphic display touchscreen unit AL1096PS PE FF
63. 9600 bit s 4 2 Setting Up A MODBUS Master A MODBUS master be set up on SER1 and or SER2 and or SER3 by following the steps below Example Set The Serial Port 2 to Modbus MASTER baud rate 9600 N 8 1 5 215 set SER2 to MASTER mode 4 229 set SER2 baud rate to 9600 0 219 set SER 2 data configuration to 8 N 1 See chapter 9 3 Register Output Configuration for available baud rates communication modes and data configuration modes FF Automation Oy E 4 4 AL 2000 User Guide 06 05 00 4 2 1 Configure the MODBUS Master Messages In one transmission several input or output values can be transferred between master and slave This is called a message A separate definition must be made for each master slave message max 63 per serial port stating what information is to be sent MODBUS Master message definitions should be made using the Modbus Configuration program in the ALPro software The serial interface to be configured should be selected first SER2 SER3 MODBUS after which message definitions can be made as follows rg Alprowin Editor lol File Compile View Transfer PLC Tools Debug Help sung www 00 Plc Type Project Name Major version Minor version 120005 esmazzo0 fi fi Com 1 9600 onnected to AL2000sc File Message Protocol Transfer s Wa mxp SYE Comi Com Com3 Com4 Com5 Ho Master D
64. Automation Oy AL 2000 User Guide Page 8 5 11 09 2000 8 3 2 Register 8 bit Variables RM R NM R GM RNG RO RNO R SM R SG R SO R RM R RG R RO RT RC Q F Register memory 0 255 These are 8 bit registers One s complement of register memory Register general memory 0 255 These are 8 bit registers some of which are reserved for 8 bit PID controllers One s complement of register general memory Register output 0 255 all of which are reserved for special purposes Register outputs defines the operational parameters of CPU One s complement of register output Conditional setting of register memory general memory output Used with EQ instruction Conditional resetting of register memory general memory output Used with EQ instruction Register timer This is identical to the timers listed above T or R T is used as the variable according to the instruction Also refers to the register accumulator in some instructions Register constant 0 255 except register counter with the READ and LOAD instructions C or R C is used as the variable according to the instruction Queue 0 3 Each queue has 256 x 8 bit locations First In First Out store 0 7 Each FIFO has 256 x 8 bit locations 8 3 3 Word Variables or 16 bit variables WI WM W GM WO W SM W SO W RM W RO WT WC Word input 0 255 Word memory 0 255 indirectly addressable up to 16363 These are 16 bit memories Word m
65. Function Keys Display Keypad Display Keypad Clock and Calendar Display Keypad for Customers front Plate Clock and Calendar Display Keypad 16 keys Clock and Calendar Display Keypad 4 keys Graphic Display 240 x 128 5 function keys Graphic Display 240 x 128 touch screen 10 x 8 STN Graphic Display Touch Panel 320 x 240 40x30 Switches STN Graphic Display Touch Panel 320 x 240 40x30 Switches Centronic printer port Delivery Time and Technical Data by Request FF Automation Oy AL 2000 User Guide Page 13 3 06 05 00 13 11 Converters for Serial Communication Code Model No Description 901225 AL6442 CNV 1 full duplex Serial Interface Conversion Unit RS232 422 485 901462 AL 6405 Power Supply CNV 1 903190 CNV 2 Half duplex Signal Converter RS232 RS485 13 12 Power Supplies Code Model No Description 901383 AL9624 3 5 Power Supply Unit 24VDC 3 5A 901380 AL9624 8 Power Supply Unit 2 VDC 8A 902218 AL UPS AL UPS Module for Use with Accumulator 901374 AL9624 2 1 5 Power Supply Unit 24VDC 2A 20VAC 1 5A 13 13 Programming Cables Code Model No Description 901172 ALC2 Programming Cable PC AL2000 Length 2 m 901173 ALC5 Programming Cable PC AL2000 Length 5 m 901175 Cable AL1096 PC Length 5 m 901176 Cable AL1096 Autolog Length 5 m 901510 AL9042 Cable AutoLog D9P CNV1 2 5m 901177 Cable Modem D9P AutoLog D9P Length 2 5m 901178 Cable PC D9S Modem D9P Length 2 5m 901179 Ca
66. GND IBM PC XT AL 2000 Cannon DB25S Cannon DE9P TxD 2 gt 2 RxD RxD 3e o 9 TxD CTS 5 o 4 DTR GND 7 o 5 GND IBM AT TOSHIBA 1000 AL 2000 Cannon DE9S Cannon DE9P TxD 3e o 2 RxD RxD 2e o 3 TxD CTS 8 o 4 DTR GND 5 o 5 GND AL1091 Terminal AL 2000 Cannon DB25S Cannon DE9P TD 2 2 RxD RD 3 e 3 TxD GND 7 gt 5 GND CTS 5 gt 4 DTR RTS 3 8 CTS 24V 12 5 _ NOTE Supply voltage shall be connected or 5V 9 toeither of these two not to both GND 8 e MODEM AL 2000 Cannon DB25P Cannon DE9P RxD3 e o2 RxD TxD2 gt 3 TxD GND 7 o o5 GND DTR 20 o7 This way when used on DCD 8 o8 CTS dialled phone lines RTS4 gt 2 7 RTS This way when used on CTS5 58 CTS fixed lines FF Automation Oy 14 2 AL 2000 User Guide 06 05 00 14 2 Data Communication Time Calculation Sheet Communication speeds cmmt 1200 bit s 9 2 ms 9600 bit s 1 2 ms 19200 bit s 0 57 ms 28800 bit s 0 38 ms umber of bytes message message message message message message message message message message message message message message message message message message 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt 1 ms slave loop time 8 x cmmt
67. Log FCS Control Software 14 CABLES AND COMMUNICATION TIME SHEET 14 1 14 2 Data Communication Time Calculation Sheet 14 3 The Commands of AutoLog Appendix A PHYSICAL INSTALLATION A 1 Mounting Dimensions FF Automation Oy l 12 12 2000 AL 2000 User Guide FF AUTOMATION OY HEAD OFFICE SERVICE CENTER Erakuja 2 Meijerikuja 01600 VANTAA 37650 Valkeakoski Tel 358 9 5306310 Tel 358 3 5846390 Fax 358 9 53063130 Fax 358 3 5846711 http www ff automation com e mail info ff automation com FF Automation Oy AL 2000 User Guide Page 1 1 14 11 2000 GENERAL DESCRIPTION 1 1 Introduction The AL2000 is a new modular PLC from FF Automation Finland Due to it s modular design different hardware configurations can easily be made for specific automation and data acquisition requirements The AL2000 is designed to be used in medium and large scale applications The AL2000 can be easily programmed using an ordinary PC and the ALProWin programming software ALPro has an extensive instruction language for PLC program ming with over 260 instructions available Programming difficult procedures is made easy by the many instructions which have been developed for specific applications The ALPro EIL Extensive Instruction Language is a highly efficient programming tool which is both easy to learn and simple to use For programmers who are familiar with ladder logic programming ALProWin introdu
68. ManAL2000S P eng121200 AL 2000S P User Guide AL2000S V9941 System Program v 3 07 FF AUTOMATION OY HEAD OFFICE SERVICE CENTER Erakuja 2 Meijerikuja 01600 VANTAA 37650 Valkeakoski Tel 358 9 5306310 Tel 358 3 5846390 Fax 358 9 53063130 Fax 358 3 5846711 http www ff automation com e mail info ff automation com U Manuals English AL2000UM 12 12 2000 PV AL 2000 User Guide 12 12 2000 AL 2000S P User Guide AL2000S V9941 System program V 3 07 FF AUTOMATION OY HEAD OFFICE SERVICE CENTER Erakuja 2 Meijerikuja 01600 VANTAA 37650 Valkeakoski Tel 358 9 5306310 Tel 358 3 5846390 Fax 358 9 53063130 Fax 358 3 5846711 http www ff automation com e mail info ff automation com FF Automation Oy AL 2000 User Guide 12 12 2000 TABLE OF CONTENT GENERAL DESCRIPTION 1 1 Introduction 1 2 Basic Design PROGRAMMING 2 1 Programming the AL2000 2 2 DSIMM32 Digital I O Simulator HARDWARE CONFIGURATION 3 1 Selection of Mounting Rack 3 2 Selection of Power Input Module s Modules Required for Each Unit Hardware Configuration Set up Example of Hardware Configuration DISTRIBUTED CONTROL SYSTEM 4 1 The Modbus RTU Protocol 4 2 Setting up a MODBUS Master 4 3 Setting up a MODBUS Slave 4 4 Using Modems with MODBUS OPERATIONAL TECHNICAL DATA 5 1 Power Supply 5 2 Digital I O Modules 5 3 Analog I O Modul
69. No No Example Reset bit accumulator R M 12 13 16 bit number R M 12 13 R O 1 underflow occurs subtract 1 from R M 12 Operation Subtract the constant d and the bit accumulator from the word accumulator If the result is less than 0 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 BA RA WA Variable Affected Yes No Yes No Example STR C 000 Reset bit accumulator STR W M 60 Subtract the constant 3500 MIN W 03500 word memory 60 MIN W Operation Subtract variable n and the bit accumulator from the word accumulator If the result is less than 0 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 BA RA WA Variable Affected No Yes No Example STR 000 Reset bit accumulator STR W M 60 Subtract value of word memory 106 MIN W M 106 value of word memory 60 MUL R Cd Operation Multiply the register acc by the constant d The least significant byte remains in the register acc and the most significant byte is stored in register output RM 244 BA RA WA Variable Affected No Yes No No Example STR R M 000 MUL R C 002 E FF Automation Oy AutoLog 2000 Instruction Manual Page 11 29 12 12 2000 MUL R M On Operation Multiply the register accumulator by the variable n The least significant byte remains in the register accumulator and the most significant byte is stored in register output R O 244 WA
70. O 215 O 219 O 001 O 229 S 000 000 S 001 S 001 DDADDAADA select English instruction set select MODEM on SER2 select terminal mode SER2 data configuration select baud rate 1200 Bd establish connection dial number ATEOVODP844992 CR S 002 RO 232 RO 233 S 002 S 003 S 004 S 001 O 232 C 013 S 002 S 010 O 233 C 049 S 010 S 011 S 011 speed character length and parity dial phone number pulse dialing 030 time out tone dialing 060 disable echo digit responses check that connection is established data transfer AL2000 is sending some data CR S 055 S 055 S 056 S 012 S 012 S 013 S 014 S 014 5 015 060 003 sterminate connection hang up 003 ATHO lt CR gt S 16 RO 232 RO 233 S 016 O 232 C 013 S 017 S 019 S 019 S 000 S 017 S 018 S 012 PLC waits for next connection attempt if hang up is unsuccessful then hang up again FF Automation Oy AL 2000 User Guide Page 5 1 06 05 00 OPERATIONAL TECHNICAL DATA All AL2000 components are furnished with identification labels which state the code se rial number and name of the quality control inspector On most components these stick ers can be found on the bus connectors A sample identification label is shown below 902203 FF AUTOMATION OY code E Made In Finland Serial 01 0593001 64 DCL 5 1 Power Supply Each mounting rack e
71. SSZ ON H O H H OS 010 10 0 998 990 SSc 0 Wd WS Wd OH WS OS WIN ON Automation Oy FF 11 09 2000 8 7 AL 2000 User Guide e E c AA gt AA e e e N lt lt lt 2 gt H LM l 1 S8cC O0INH M SS2 82L IN M SL ejels enye 2 esn ul81s s 10 ponueseH 4amMod Aq payoajje JOU 9S anez 4amod Joy 19S919q IM 4amod Buunpsnieis UNEO AA jenjoe L LL INS H NH OHH OSH ONY OH EF6LF F6E EGL Wa WS OH INS OS INN ON N Automation Oy FF 9 1 11 09 2000 AL 2000 User Guide 9 REGISTER MEMORIES OUTPUTS amp VARIABLES 9 1 Reserved Memories and Outputs R O 000 081 R O 032 R O 033 R O 034 R O 035 R O 036 R O 037 R O 038 R O 039 R O 040 R O 043 R O 044 R O 045 R O 046 R O 048 R O 049 R O 050 R O 051 R O 052 R O 054 R O 055 R O 056 R O 057 R O 058 R O 059 R O 060 R O 063 R O 080
72. al reset of register memory or output Used in conjunction with EQ instruction Register timer Identical with the timers listed above T or R T is used as the variable according to the instruction Also refers to register accumulator in some instructions Register constant 000 255 decimal except register counter with the READ and LOAD instructions C or R C is used as the variable according the instruction Queue 4 off Numbered from 0 to 3 The queue length can be 1 256 FIFO store 8 off Numbered from 0 to 7 The FIFO store has 256 locations FF Automation Oy 11 4 12 12 2000 AutoLog 2000 Instruction Manual 11 2 3 Word variables or 16 bit variables WI Word input 0 255 off Numbering depends on configuration Word memory 16384 off Directly addressable numbered from 000 to 256 Indirectly addressable from 000 to 16384 EQI and STI instructions Word memories 0 to 127 overlaps with register memories 0 255 Word output 4096 off Directly addressable numbered from 000 to 256 Indirectly addressable from 000 to 4096 EQI and STI instructions Conditional set of directly addressable word memory or output Conditional reset of directly addressable word memory or output Word accumulator Word constant 0 9999 decimal NOTE Refer to chapter 15 at the end part of this manual AL2000 series PLC s memory and I O maps AL2000 series PLC s data retention during power failure 11 3 Error messages
73. algorithm is as follows DY 100 gain e t e t 1 P term e t integration time constant term diff time constant e t 2e t 1 e t 2 D term The D term controls how strongly the control process reacts to rapid changes in the input signal The differentiation time constant is an 8 bit parameter and is given in hundreds of milliseconds 0 1 25 5s The larger the time the greater the changes to the output sig nal If the differentiation time constant is given as 0 the D term is not used The term controls how quickly the process reacts to stabilise offset error The integra tion time constant is a 16 bit parameter and is given in hundreds of milliseconds 0 1 6553 5s The larger the integration time constant the slower the process reacts to offset errors If the integration time constant is given as 0 the term is not used The P term controls the gain such that P 100 gain where gain can be from 0 01 100 Therefore if gain 0 P TERM NOT USED if gain 5 P 20 if gain 0 5 P 200 if gain 0 02 P 5000 if gain 0 01 P 10000 FF Automation Oy 6 6 AL 2000 User Guide 06 05 00 Example 1 If Pterm 100 D term 0 I term 0 Then a 1 change in input signal would produce a 1 change in output signal Example 2 If P term 50 D term 0 I term 0 Then a 1 change in input signal would produce 2 change in output signal The P term can also be used where the input and outpu
74. alue Step 4 Set the upper adjustment value for the input Before going to step 5 the upper calibration value must be inserted Step 5 Read the upper adjustment value AS the result of succesful unsuccesful adjustment of input PLC s system program writes into register output R O 220 the result value 0 adjustment was succesful no error code NOTE When calibrating at the upper and lower calibration points be sure to allow enough time for the sensor to stabilise e g allow sensor enough time to heat up of the boiling water FF Automation Oy l 10 8 AL 2000 User Guide 06 05 00 The result of adjustment is that the zero point value from the PLC s analog input corresponds the minimum value of input and high value in PLC corresponds the high value of input The value can be seen in the PLC as a number from 0 to 4095 as a raw value 10 5 1 What is needed for adjustment You need the ALPro or AlproWin software a PC an accurate mA meter an accurate V meter an adjustable resistance reference and when calibrating current inputs millam per source For making the readings of the analog inputs you have to use the PC and the ALPro software For the adjustment of the analog inputs of AL2000 CPU only one instruction has to be downloaded to the PLC the STOP instruction Through the AlproWin watch table you can see the values of all AL2000 s analog inputs How to read the input values using the PC and AlproWin 1 C
75. am cycle 2 analog inputs per program cycle of which one input 0 will be updated every cycle 1 analog input per program cycle default FF Automation Oy AL 2000 User Guide Page 10 1 06 05 00 10 In the design of the AL2000 special attention has been paid to ease of service rapid fault finding and correction Special procedures have been built into the operation system which continuously supervise the AL2000 s operation A good selection of spare modules especially power supplies and CPUs as well as cables and fuses is highly recommended This will reduce expensive down time in the event of a fault occurring 10 1 Checking the Hardware Configuration On power up the AL2000 checks that the hardware configuration is the same as the one defined with the ALPro software The hardware configuration table defines the following items Slot number of the module The address and number of the I O s in the module Type code of the module Action to be taken in the event that the hardware configuration is not the same as that defined in the ALPro Software After a warm start with the START instruction the following operations are performed Status of memories and outputs remain unchanged PLC program is moved from RAM memory into the EEPROM PLC program is checked and executed if no errors found After the second program cycle parameters are read from the register memori
76. and models D and F can be fitted with client designed face plate AL1093C D AL1093F S ig DIS1 0 1 2 3 4 5 6 7 819 AJBJ DJEJFJ 7 4 AL1094 R AF Display keypad Units The AL1094 display keypad unit without clock and calendar functions It has a 4 digit 7 segment display four LED indica tors and a 4 key keypad The unit can be fitted with client designed face plate The AL1094R display keypad unit without clock and calendar functions It has 2 x 16 character alphanumeric display two LED indicators and a 4 key keypad In addition to displaying the values and time date information the AL1094R unit can also display text using the PRT instruction The unit can be fitted with client designed face plate FF Automation AL 2000 User Guide Page 7 3 06 05 00 The AL1094AF display keypad unit has 2x20 character alphanumeric display clock cal endar 8 keys 4 indicating leds summer and one 24VDC 300 mA output for external in dicating ligth The AL1904AF can display text using the PRT instruction The unit can be fitted with client designed front plate Output 4 buzzer output 5 control output for external indicating ligth AL1094AF OO 0000 OOOO 7 5 Reading The Keypad R O 209 The ASCII code of the last character from keypad is stored in the regis ter output R O 209 when the keypad is connec
77. arity in terminal mode SER2 data length and parity in terminal mode Calibration of analog input Slot number of module to be calibrated Input number on module to be calibrated Input type to be calibrated Lower calibration value 4 MSB Lower calibration value 8 LSB Higher calibration value 4 MSB Higher calibration value 8 LSB Number of step registers configurable from 8 to 64 default 32 SER2 communication speed Word variable multiplication division MSB Word variable multiplication division LSB SER1 last character received from terminal SER2 last character received from terminal SERS last character received from terminal CPU counter input status AL2000SCP Analog input update rate 1 2 4 8 inputs per program cycle Value of CPU analog output 0 AL2000SAA SAC Value of CPU analog output 1 AL2000SAA SAC Value of CPU analog output 2 AL2000SAA SAC FF Automation Oy 9 3 AL 2000 User Guide 11 09 2000 Selection the display information Number of power fail interruptions Setting the time Slave address of AL2000 High byte of multiplication division remainder Left side of numerical display for AL1092 Right side of numerical display for AL2092 Date and time information month Date and time information date Date and time information day of the week Date and time information hour Date and time information minute Date and time information second Clock amp Calendar number o
78. ata Function Slave Data Adr Poll Rate Sati Sat2 1 lt 03 WM Continuous 000 000 00233 00244 16 gt M 00233 00244 006 Continuous ooo 000 ER info 4 info Messages 2 Total messages 2 GSMAL2000TST MBB Com 1 9600 Connected to AL2000scp Modify Modbus Message Master Data Direction Slave Data Jw gt 0200 ozoo J lt 03 200 2255 Slave No Poll Rate Satel 1 2 006 continuous 000 OK Master data Variable type and address range in the Master where data is to be written to or read from Direction Arrow defines whether operation is read from slave 03 or write to slave 16 7 Slave data Variable type and start address in the Slave where data is to be written to or read from Slave No Address of slave where data is to be written to or read from Address 0 is used for broadcast messages Broadcast messages are received by all slaves but the slaves do not respond to these messages Poll rate Defines the update rate for this message Possible poll rates are Continuous X update message as fast as possible 1 second 10 seconds 30 seconds 60 seconds Conditional launch message from PLC program with FCN instruction Satel1 Satel2Satel codes are used when Satel radio modems are used as repeaters not added yet In the above example message 1 would read outputs 0 15 from slave 1 and place them in the masters mem
79. ator s terminal bar code reader MODBUS slave master communication with supervising PC modem handshakes SER2 RS 232C 300 115200 bit s 9 pin D type connector Used for operator s terminal bar code reader MODBUS slave master communication with supervising PC modem handshakes SER3 RS 485 300 115200 bit s screw terminals Used for operator s terminal bar code reader MODBUS slave master communication with supervising PC PC interface For display keyboard unit Isolation Serial interfaces SER1 and SER2 are isolated as a group Serial interface SERG is isolated separately Isolation is between groups 500VDC metal frame and the internal data bus FF Automation Oy ls 8 2 11 09 2000 LED indicators Watchdog Clock Power consumption Battery life Cooling Dimensions Weight Product Codes AL 2000 User Guide RES fault red RUN PLC functioning green TX1 TX2 TX3 serial interfaces transmitting yellow RX1 RX2 RX3 serial interfaces receiving yellow CTS1 CTS2 serial interfaces CTS handshaking red RTS1 RTS2 serial interfaces RTS handshaking red BAT battery low red VS3 fault in SER3 interface red Separate watchdog circuit with excess voltage protection and low voltage detection Year month week day hour minute second and number of six minute periods from the beginning of the day Battery backed up 600mA 5V for CPU2000S 0 2 1 2A 24V for CPU200
80. ble 1 0 m 13 2 Central Processing Units Code Model No Description 902200 CPU2000S Central Processing Unit 902205 CPU2000P Central Processing Unit 902204 CPU2000L Central Processing Unit 902207 PC104 adapter with CPU2000L reserves 2 I O Board Places 902132 Mother Board for CPU2000L 13 3 Serial Communication and Router Boards Code Model No Description 902195 AL2000SER Serial Communication Unit for use with AL2000 902197 AL Router Modbus Router 13 4 Input Modules Code Model No Description 902220 DIC32DC Digital Input Module 32 DI 24 V DC 902224 DIC32AC Digital Input Module 32 DI 24 V AC DC 902228 DIF16 Digital Input Module 16 Error checking DI 24 VDC 13 5 Output Modules Code Model No Description 902240 DOC32EP Digital Output Module 32 DO 20 40 V DC 1A 902244 DOC32FP Digital Output Module 32 DO 20 40 V DC 0 5 A 902248 DOF16 Digital Output Module 16 Error checking DO 24 VDC 1 902260 ROC16K Relay Output Module 20 280 V AC 2 A RO 902264 OOC16 Solid State Relay Output Module 20 280 V AC 0 6 A Delivery Time and Technical Data by Request FF Automation Oy ls 13 2 06 05 00 AL 2000 User Guide 13 6 Input Output Modules Code 902266 Model No DIO32 13 7 Analog Modules Code 902273 902274 902270 902272 902277 902310 Model No AIC8 TIC8 AIO74 MIC16 MOC16 FIC16 13 8 Power Units Code 902209 902210 902211 902214 902215 902212 9022
81. ble AutoLog D9P Radiomodem 15P Length 2m 901180 Cable AutoLog D9P Radiomodem 15P Length 8m 901181 Cable PC FCS D9S CNV1 Length 8m 901187 Cable GSM modem AL2000S 901193 Cable PC CNV2 Length 2 5 m 901194 Cable CNV2 AL RJ45 Length 2 5 m 13 14 Programming Software Code Model No Description 941006 ALPro3 x ALPro3 x Programming Software DOS version 941010 Update from AL AX ALGT ALEDIT ALPro dos to ALProwin 1 xx 941011 Update from ALPro1 2 x dos to ALPro3 x dos 941020 ALProwin 1 xx 13 15 Other Programs Code Model No Description 941060 MODBUS RTU Development Kit for PC 90661 1 Modbus Analyser 906603 Modbus Test Program for PC Dos FF Automation Oy 13 4 AL 2000 User Guide 06 05 00 13 16 AutoLog FCS Control Software Code Model No Description 941024 Autolog 2000 FCS Development Licence 941025 Autolog 2000 FCS Run Time Interface Licence 941027 Autolog 2000 FCS Run Time Licence for AL2000 CPU 941026 AutoLog 2000 FCS Communication Programs Modbus RTU TCP IP Siemens Allen Bradley etc le FF Automation Oy AL 2000 User Guide Page 14 1 06 05 00 1 4 CABLES AND COMMUNICATION TIME SHEET 14 1 Cables Cables required for connecting a PC to the AL2000 and for SER1 and SER2 interfaces 4V max 20 mA DCD selectable RXD data to the AL2000 TXD data from the AL2000 12V from AL2000
82. ces a new and efficient way to write PLC programs However for programmers who prefer to work with ladder logic an additional module is available for this purpose The AL2000L provides versatile communication capabilities via serial interface or Ethernet LAN AL2000 has been designed giving special attention to ease of use and rapid service A thorough Self Diagnostics Function SDF continuously supervises the AL2000 s operation In the event that a fault in the system is discovered by the SDF the user is immediately informed A fault condition is displayed on the module by means of an LED and sent via serial interface or Ethernet LAN to a supervising PC if the user so chooses This makes servicing the AL2000 both easy and rapid Basic Mounting Rack Expansion Mounting Rack AL 2000 AL 2000 MM ll U 4 M N Analog I O s Communication max 512 max 256 Line The AL2000 is versatile enough for the most demanding of applications FF Automation Oy ls 1 2 AL 2000 User Guide 14 11 2000 The AL2000 can be used to realise a fully distributed control system Remote units can be connected to a central AL2000 unit via a fast serial interface It is only necessary to program the central AL2000 unit with all remote units operating as simple I O units however for more demanding situations local programs can be written to the remote units Typical applications for the AL2000 are T
83. ch can house a maximum of 32 I O modules This basic unit can consist of one basic mounting rack and one expansion mounting rack All CPU modules are equipped with three serial interface ports and an I C interface port for connection of a keypad display unit The CPU2000P is equipped with own power supply unit 1 2 5 The CPU2000L Module The CPU2000L is a powerful CPU based on the pentium 586 and is entirely PC compatible The CPU2000L is equipped with two serial interfaces an I C interface port for connection of a keypad display unit parallel printer port Ethernet LAN and connec tors for standard IBM AT keyboard 1 2 6 The I O Modules There are several modules available for both digital and analog inputs and outputs These modules are slot in cards which can be installed in any of the mounting racks and controlled by any of the slot in CPU modules All I O modules are equipped with LED indicators which indicate the status of inputs and or outputs and any error condition le FF Automation Oy AL 2000 User Guide Page 2 1 14 11 2000 PROGRAMMING 2 1 Programming the AL2000 The AL2000 can be programmed using an normal PC running Windows 9x or NT and the AlproWin programming software The AL Extensive Instruction Language ALEIL com prising over 260 commands is used for programming the AL2000 Due to the AL2000 s versatility pure ladder logic programming would not make eff
84. cond Program STR STR FCN IF 001 000 serial code saved into R M 0 gt 032 check for ibutton if ibutton was attached to PLC and data was succesfully read 000 make comparison 100 device code 000 result to memory 0 001 1 data byte 101 000 000 STR EQU EQ STR EQ AND EQ Etc CONT lt lt lt lt lt lt lt H OV Example 2Check for iButton every 1 second Program STR R C 000 parameters from R M 000 gt STR P 001 every second IF T parametrit alkaen R M 10 gt FCN 032 Read possible Ibutton EQ 005 set output 5 active CONT FF Automation Oy AutoLog 2000 Instruction Manual Page 11 21 12 12 2000 Operation If the bit accumulator is 1 move the contents of the register accumulator into FIFO store n 0 7 If there was room in the FIFO set the bit accumulator to 1 if not clear the bit accumulator to 0 BA RA WA Variable Affected Yes No No Yes Example STR At the rising edge of input 0 EQ STR STR enter the number 12 FIN sinto FIFO 0 FOU Fn Operation If the bit accumulator is 1 move the oldest number in FIFO store n 0 7 into the register accumulator If a number was available in the FIFO set the bit accumulator to 1 if not clear the bit accumulator to 0 BA RA WA Variable Affected Yes Yes No Yes Example STR EQ STR STR FIN STR FIN FOU At the rising edge of input 0 0 amp _ enter t
85. d response it will ignore all further messages destined for that slave for 10 seconds On the next run through the message list the Master will attempt to send messages to that slave again The PC s MODBUS COM port may be initialised from DOS using MODE COM1 9600 8 2 N P liE FF Automation Oy AL 2000 User Guide Page 4 3 06 05 00 4 1 2 Addresses of Inputs and Outputs All I O points have addresses these are used by MODBUS The address assignment be seen on the ALPro configuration screen s I O map I O addresses are assigned in blocks of 16 therefore there will be unused addresses if an I O module requires less then 16 addresses For an AlO74 module the used unused addresses are AlO74 Inputs 0 1 AIO74 Outputs 0 1 4 5 6 14 2 3 2 3 Unused addresses are represented by the symbol 4 1 3 Serial Port Configuration The AL2000 has 3 serial interfaces of which all can be configured to function as MODBUS Slave and MODBUS Master independently of one another These are SER 1 SER2 RS 232 SER RS 485 The serial ports must be configured for the required baud rate and MODBUS master slave mode This is done by initialising the following register outputs MODBUS modes SER 1 SER 2 SER MODBUS Slave MODBUS Master Baud Rates SER 1 SER 2 SER 0 3 1 2 2 4 4 8 9 6 19 2 kbit s 28 8 38 4 57 6 115 2 kbit s Maximum cable length for RS 232 is 15m for 9600 bit s Maximum cable length for RS 485 is 1200m for
86. displayed GSMA f sman200 qmm ER Flex Select Input Range 5 V Differential p 10 V Differential 0 20 m Differential Ptl00 alpha 0 00385 50 150 c Ptl00 alpha 0 00385 200 730 C Pt100 alpha 0 00391 200 770 C wire Pt100 alpha 0 00385 50 3 wire Pt100 alpha 0 00385 200 730 c 3 wire 100 alpha 0 00391 200 770 C 10 50 150 Cu50 200 200 c 3 wire Cu50 200 200 c 0 480 mV Single Ended 0 5 V Single Ended 0 10 V Single Ended 10 10 V Single Ended li FF Automation Oy AL 2000 User Guide Page 4 1 06 05 00 4 DISTRIBUTED CONTROL SYSTEM All CPU modules are capable of controlling AL2000 remote units in addition to the basic unit each having a maximum of 32 I O modules Each remote unit may consist of one basic mounting rack and one expansion mounting rack The MODBUS RTU protocol is also supported all CPU modules enabling the AL2000 to be connected to other PLCs and computers via serial interface Using MODBUS remote units a fully distributed con trol system can be realised Basic Unit Expansion Unit Modbus RS 485 300 11520 bit s Modbus or 2 FF Automation Oy E 4 2 AL 2000 User Guide 06 05 00 4 1 The MODBUS RTU Protocol Using the MODBUS RTU protocol the AL2000 can be connected to other PLCs AL2000 AL100 AL
87. e elec tronic overload and short circuit protection and can withstand a load current of 1A each Outputs may be connected in parallel but the current on each output must not exceed 0 8A The total sum current is thus for 4 parallel connected output I 4 0 8 A 32A The input logic range of the DIO32 module is logic 0 30 to 5VDC 0 1 1mA logic 1 13 to 36VDC 4 11mA The sensor must be of PNP output type or voltage supply ing The following LED indicators are located on the front edge of the module ACT green Module is in operation ERR red The operating system has discovered a fault in the module 0 15 red Outputs O0 O15 ON 0 15 yellow Inputs 10 115 are ON Output Connections External Internal 20 40 V Input Connections External Internal Switch PNP sensor T FF Automation Oy Page 5 17 06 05 00 O8 116 124 O9 H7 125 010 118 126 011 119 127 012 120 128 013 121 129 014 122 130 015 123 131 O0 O1 02 O4 05 O6 O7 O8 O9 5 18 AL 2000 User Guide 11 09 2000 5 3 Analog I O Modules All analog I O modules have multiple range input outputs and are fitted with detachable screw terminals for I O wiring These terminals ca
88. e memory to its state at the beginning of the program cycle Pulse variable The variable is one for the duration of one program cycle P000 ten times per second P001 once per second and P002 once per minute Sequence register or a step of a sequence register There are 32 sequence registers with 256 step each String constant 0 255 These are text strings with a maximum length of 16 ASCII characters each Used in conjunction with the PRT or EQU R TX instructions Timer 80 off Numbered 000 79 The resolution and range of the timers varies as follows resolution T 000 003 10 ms T 004 007 100 ms T 008 015 1 s 2 255 5 T 016 079 100 ms 0 2 25 5s In the IF and STEP instructions T refers to the bit accumulator In the PRT instruction T refers to TEXT Counter 16 off Numbered from 000 to 015 The counters count down their range is 255 0 In the PRT instruction C refers to to a numerical value range 0 02 2 55 s 0 2 25 5 11 1 2 Register variables or 8 bit variables R M GM R NM NG RO R NO R SM SG SL R RM RG RL RT RC Q F Register memory 256 off Numbered from 000 to 255 One s complement of register memory Register output Register outputs are reserved for PLC s system program Register outputs 0 and 1 are the analogue outputs from PLC One s complement of register output Conditional set of register memory or output Used in conjunction with EQ instruction Condition
89. ecution must always be suspended if any of the instructions preceding the END instruction are removed added or altered BA RA WA Variable Affected No No No No Example STR NO 000 100 Hz oscillator EQ 000 This loop runs every 5 ms END STR m The regular program starts here FF Automation Oy 11 12 AutoLog 2000 Instruction Manual 12 12 2000 EQ M O BM GM n Operation Sets the variable equal to the contents of the bit accumulator BA RA WA Variable Affected No No No Yes Example STR Output 0 EQ follows input 0 EQ SM SO SB SG n Operation If the bit accumulator is 1 set the variable to 1 if the bit accumulator is 0 do nothing BA RA WA Variable Affected No No No Yes Example STR Input 0 sets EQ SO 0 00 output 10 to 1 EQ RM RO RB RG n Operation If the bit accumulator is 1 reset the variable to 0 if the bit accumulator is 0 do nothing BA RA WA Variable Affected No No No Yes Example STR Input 0 00 resets EQ output 1 00 EQ R M On Operation Sets the variable equal to the contents of the register accumulator BA RA WA Variable Affected No No No Yes Example STR EQ C 085 Constant 85 loaded into M 211 register memory 211 R R EQ R RM ROn Operation If the bit accumulator is 1 reset the variable to 0 if the bit accumulator is 0 do nothing BA RA WA Variable Affected No No Yes Example If input 10 1 register
90. emories 0 127 overlap register memories 0 255 Additional word memory 0 255 These are 16 bit memories some of which are reserved for 16 bit PID controllers Word output 0 255 indirectly addressable up to 4096 These can be used as auxiliary memories Conditional setting of word memory output Conditional resetting of word memory output Word accumulator Word constant 0 65535 bin 0 9999 bcd 8 3 4 Special Variables TX String constant 0 255 These are text strings with a maximum length of 16 characters each Used in conjunction with the PRT instruction FF Automation Oy ls AL 2000 User Guide Page 8 6 11 09 2000 2 A O N SY 1 lt S gt D gt O3 pue LS 9607 000 sindino piom pue 49 L 8E9 1 000 pesseuppe pS 99 voc GSS2 OWH ZON M SSz 92LIN M S60v OH M OS M O M sn 5 5 0 5 20 WH H INS H WN HN H SL enje ejels eoe 62 en e S enoe eseui ose s s NA pue dd SGc
91. entire display will be reserved for text produced by the PRT instruction E FF Automation Oy AL 2000 User Guide Page 7 7 06 05 00 7 8 5 Normal Mode with Key B Function Disabled Mode 5 R 240 32 This mode is available only for the AL1094R AL1093C D F and AL1095A models with alphanumeric displays The unit functions otherwise normally but the changes of content of variables are disabled 7 8 6 Display Lock Mode 6 R 240 128 This mode is available only for the AL1094F R AL1093C D F and AL 1095A B with al phanumeric displays Current display information will be retained and no changes will be allowed 7 9 Program examples 7 9 1 Printing Date Information STR EQ STR PRT 0 01 000 000 print 248 date point 247 month 190 point and hundreds of year 255 year 0 99 T T 7 9 2 Real Time Control with R 253 6 minutes from midnight STR 253 read number of six minute periods from beginning of day LES 174 every day starting from 17 30 EQ 000 17 5 60 6 175 210 until 21 00 000 0 01 output on 7 9 3 Display Step Registers 0 and 1 0 99 002 set register outputs R O 245 and 246 240 display mode 1 value 000 read step register s 0 step into register accumulator convert to BCD form 245 save the value into display variable 001 read step register s 1 step into register accumulator convert to BCD form 24
92. eration Affected Example AutoLog 2000 Instruction Manual Page 11 37 12 12 2000 The status of the timer counter 1 counted out O running is loaded into the bit accumulator RA WA Variable No No Output 0 changes state a moment at intervals of 5 seconds 005 Fifo operates in data areas FO WM1024 1151 F1 WM1152 1279 F7 WM1920 2047 Operation Affected Example Qn Operation Affected Example RET Operation Affected SBR n Operation If the bit accumulator is 1 clear FIFO store n 0 7 delete contents BA RA WA No No No STR STR RES Variable Yes At the rising edge of input 0 000 000 000 clear FIFO 0 If the bit accumulator is 1 reset all elements of shift register n 0 3 to zero BA RA WA Variable Yes No No No STR RES When input 0 is 1 reset all elements of shift register 2 The subroutine ends here execution is then returned to main program BA RA WA Yes Yes Variable Yes Yes The states of the accumulators remain unchanged so main program can use the accumulator states after executing the subroutine This is the starting instrucion of a subroutine See page 12 44 FF Automation Oy 11 38 AutoLog 2000 Instruction Manual 12 12 2000 e SHL Q n ddd Operation If the bit accumulator is 1 shift the elements of shift register n 0 3 one step to the left The number in t
93. ers were output there was room in the output buffer BA RA WA Variable Affected Yes No No No Example STR P 001 Set bit accumulator to 1 PRT TX STROOS3 Print the text string name STRO0O3 to active output port R Cd Operation If the bit accumulator is 1 the constant d given as the instruction parameter is output with two digits The constant d is assumed to be between 00 and 99 If the constant d is greater than 99 indeterminate characters will be output If there was room for the characters in the print buffer the bit accumulator is 1 after the instruction The number 0 99 must be coverted to BCD format before printing RA WA Variable Affected No No No Example 020 century R C d convert to BCD format 000 save to auxuliary memory 255 year convert to BCD format 001 save to auxuliary memory 000 Put output to display unit DP 001 Print once per second lt ESC gt Y lt 00 gt lt 00 gt place the cursor up left R M 000 century 20 R M 001 amp tens amp ones PRT RT Operation If the bit accumulator is 1 the character in the register accumulator is output If there was room for the character in the output buffer the bit accumulator is 1 after the instruction BA RA WA Variable Affected No No No Example Put output to display unit a character has been received from the serial line echo it and clear the character buffer FF Automation Oy
94. es If the configuration for a particular I O module is correct the green ACT LED on that module should be on and the red ERR LED should be off In the event of an incorrect hardware configuration for a particular module the red ERR LED on that module will be on Information about the configuration error is simultaneously sent to a supervising PC via serial interface provided that this function is enabled After a hardware configuration error has been detected the CPU will react in the manner specified during configuration with the ALPro software The following alternatives are available STOP and RESET Suspends execution of the PLC program and sends a reset signal to all the I O modules returning all outputs to 0 STOP Suspends execution of the PLC program maintaining all outputs in their current state IGNORE Continues execution of the PLC program If the faulty module is replaced with a correct and working one the CPU will resume using of that module The above checking procedure is performed on all defined I O modules Any modules not defined using the ALPro software are completely ignored by the CPU This checking procedure supervises the address and data busses in the motherboard and I O modules FF Automation Oy 10 2 AL 2000 User Guide 06 05 00 10 2 Tracing Faults and Solving Problems AL2000 informs the user of any faults and malfunctions by the following means Operating system LED indicators
95. es 5 4 Central Processor Units CONTROLLERS 6 1 8 Bit Controllers 6 2 12 Bit Controllers 6 3 Three Point Controllers 6 4 Controller Tuning DISPLAY KEYPAD UNITS AL1096 Display Keypad Units AL1095 B Display Keypad Units AL1093 Display Keypad Units AL1094R F AF Display Keypad Units Reading the Keypad Control of LED Indicators Display Control Characters Display Modes Program Examples 8 TECHNICAL DESCRIPTIONS 8 1 CPU2000S Series Modules 8 2 CPU2000L Module 8 3 AL2000S P Variables IE FF Automation Oy AL 2000 User Guide 12 12 2000 9 REGISTER MEMORIES OUTPUTS amp VARIABLES 9 1 Reserved Memories and Outputs 9 2 Modbus Error Information Register Outputs 9 3 Control variables for AL1095 graphical symbols 9 3 Register Outputs which must be set 10 TROUBLE SHOOTING AND SERVICE Checking the Hardware Configuration Tracing Faults and Solving Problems The CPU Battery Fuse Replacement Adjusting of Analog Inputs PROGRAMMING Programming Methods AL2000 Variables Error Messages AL20008 Instructions 12 TABLES 12 1 ASCII Codes 12 2 Decimal Octal Conversion Mounting Racks Central Processing Units Serial Communication and Router Boards Input Modules Output Modules Input Output Modules Analog Modules 8 Power Units 13 9 Special Units 13 10 Accessories 13 11 Converters for Serial Communication 13 12 Power Supplies 13 13 Programming Cables 13 14 Programming Software 13 15 Other Programs 13 16 Auto
96. eturned in the register accumulator and selects the output port for printing O I C 12 Ser1 2 Ser2 3 Ser3 If there is room for more than 80 characters the bit accumulator is set to 1 if not the bit accumulator is reset to O Variable Affected No Example C 002 Repeatedly prints the text T Still Still here T here In WinAlpro yu can write this PRT 000 PRT Still here PRT T ccccc Operation If the bit accumulator is 1 the five characters given in the instruction are output If it is not desired to output as many as five characters the output can be terminated with the character in which case a carrier return and line feed will not be added at the end or with the character in which case a carrier return and line feed will be added Any characters that can be produced with the keyboard are valid as parame ters except that CTRL B 12 hex is not acceptable as the second character The bit accumulator is 1 after the instruction if the characters were output there was room in the output buffer BA RA WA Variable Affected No No Example PRT Input 0 is on FF Automation Oy AutoLog 2000 Instruction Manual Page 11 35 12 12 2000 PRT TX n name Operation If the bit accumulator is 1 the text string number n or name is printed to the active output port The text strings can be edited with ALPro Symbol Edit Text selection The bit accumulator is 1 after the instruction if the charact
97. f six minutes from the beginning of the day Date and time information year Controller 0 Controller 1 Controller 2 Controller 3 Controller 4 Controller 5 Controller 6 Controller 7 Counter 1 control registers SAC R GM 96 112 Counter 2 control registers SAC R GM 128 191 AL1095 Graphical objects see 9 3 9 2 Modbus Error information Register Outputs SER1 SER2 SER3 Slave ID number RO 48 RO 88 R O 90 Type number of detected error RO49 89 RH O 91 Error codes First cycle second cycle 33d warning error in building master request 34d warning error on sending master request 35d warning no answer 36d warning receive timeout command 37d warning receive timeout data 38d warning CRC error 39d warning received address command different than request address command le FF Automation Oy AL 2000 User Guide Page 9 4 11 09 2000 9 3 Control variables for AL1095 graphical symbols R GM Graphic object 1 mode R GM 160 Graphic object 5 mode R GM Value R GM 161 Value R GM X start point RGM 162 X start point R GM X length R GM 163 X length R GM Y start point R GM 164 Y start point R GM Y length R GM 165 Y length R GM uppdate interval RGM 166 246 uppdate interval R GM R GM R GM Graphic object 2 mode R GM Graphic object 6 mode R GM Value R GM Value R GM X start point R GM X start point R GM X length R GM X length R GM Y start point R GM Y start point R GM Y length R GM Y length R GM uppdate
98. h DIP switch set to remote mode 4 Additionally the required I O modules Remote units are connected to the basic unit via serial interface SER3 li FF Automation Oy AL 2000 User Guide 3 3 4 Mounting Rack This unit is intended for use as a remote unit or a stand alone unit for small applications This unit can not be expanded by adding other mounting racks neither can it be used as an expansion mounting rack The following modules must be installed in the for use as a basic unit PWRS power supply module CPU central processing unit Additionally the required I O modules Note If this mounting rack is used as a remote unit the CPU DIP switch must be set to remote mode 3 3 5 MR3 mini Mounting Rack This unit is intended for use as a remote unit or a stand alone unit for small applications This unit can not be expanded by adding other mounting racks neither can it be used as an expansion mounting rack The following modules must be installed in the MR3 mini for use as a basic unit 1 CPU2000P central processing unit 2 Additionally the required I O modules The MR3 mini is powered by the CPU2000P module and therefore requires no seperate power supply The CPU2000P however requires an input voltage of 24V Note If this mounting rack is used as a remote unit the CPU DIP switch must be set to remote mode FF Automation Oy Page 3 3 06 05 00 3 4
99. he Pulp and Paper Industry Remote Control Systems The Steel Industry Water Treatment Plants Waste Water Treatment Plants Machine Manufacturing Pumping Stations The Chemical Industry Saw Mills Building Automation Regional Control Systems Machine Control The AL2000 together with control software such as PARAGON or FCS opens up unlimited opportunities for SCADA Supervisory Control And Data Acquisition applications for every industrial control situation The following is a summary of the advantages offered by the AL2000 system Savings in mounting space due to the construction Flexibility of hardware configuration You only buy what you need Robustness the binary outputs are overload and short circuit protected Reliability natural cooling requires no fan Versatile communication using RS 232C RS 422 485 serial interfaces and Ethernet LAN Powerful PID control capabilities Rapid key hole installation Easy service efficient self diagnostics and detachable screw terminals cables connect directly to each I O module Setting up the AL2000 system for a particular application is a simple and methodical procedure as outlined below 1 Determine the type of CPU module power supply units and the number and type of I O modules required Select the number and size of mounting racks allowing for possible future expansion Select the length of flat cable required to connect the expansion mou
100. he following alternative programming methods are available the ALProWin programming software the ALPro programming software a PROM programmer A complete program for the PLC can be produced using the programming software ALProWin or ALPro which run on a personal computer The programming software also allows for off line programming and versatile program documentation etc Memories of the PLC and programs When a program is transferred from a programming device to the PLC the program first goes to RAM and after completion of the START command to FLASH memory When logic program is transferred from the PLC to a programming device the program is first stored from RAM to FLASH and then transferred to the programming device The logic program is stored in a FLASH memory When power is applied to the Programmable Logic Controller the program is read into RAM for execution 11 1 1 Programming with a PROM programmer When a number of PLCs with identical functions are required programming is easiest to do by duplication First program one FLASH using one of the program ming programs or a terminal and then copy the finished program into the program memories of the remaining PLCs with a FLASH programmer FF Automation Oy 11 2 AutoLog 2000 Instruction Manual 12 12 2000 11 1 2 Programming with ALProWin ALPro The program with comments is first written in plain text form using the text editor of ALProW
101. he maximum permissible length of the fast loop is 62 instructions but it is advisable to keep it as short as possible in order to avoid slowing down the main program more than necessary No instructions are allowed in the fast loop CAUTION The END instruction must not be written while program execution is in progress The program must always be halted when instructions preceding the END in struction are deleted added or changed FF Automation Oy 11 3 12 12 2000 AutoLog 2000 Instruction Manual 11 2 AL2000 variables 11 2 1 One bit variables BM GM NM NB NG SM SB SG SL RM RB RG RL DP Input 0 7 off Numbered 000 007 One s complement of input When I n 1 NI n 0 Auxiliary memory 256 off Numbered 000 255 Auxiliary memory 256 off Numbered 000 255 One s complement of auxiliary memory Output 0 7 off Numbered 000 007 The unused ouputs and ouputs 008 255 can also be used as one bit auxiliary memory One s complement of output Conditional set of memory or output 256 off Used in conjunction with EQ instruction Conditional reset of memory or output 256 off Used in conjunction with EQ instruction Change of auxiliary memory from 0 to 1 128 off Numbered 000 127 Compares the state of the memory to its state at the beginning of the program cycle Change of auxiliary memory from 1 to 0 128 off Numbered 000 127 Compares the state of th
102. he number 24 into FIFO 0 enter the number 34 sinto FIFO 0 move the number 324 from FIFO 0 into the register acc GRT R Cd Operation If the constant d is greater than the register accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 Variable Affected Example STR When register output 1 GRT sis less than 100 EQ output 1 is on GRT When HI 1 is less than 200 EQ output 2 is on GRT R M On Operation If variable n is greater than the register accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 Variable Affected No Example STR R C 100 When register memory 0 GRT R M 000 sis greater than 100 EQ 0 00 output 0 is 1 FF Automation Oy 11 22 AutoLog 2000 Instruction Manual 12 12 2000 W Cd Operation If the constant d is greater than the number in the word accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 BA RA WA Variable Affected Yes No No No Example STR W When word memory 1 GRT W sis less than 4009 EQ output 002 is on GRT W when WM 1 is less than 1050 EQ output 003 is on GRT W I M O Operation If variable n is greater than the number in the word accumulator the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 BA RA WA Variable Affected Yes No No No Example STR W C 00500 When analog input 002 GRT W
103. he register accumulator is shifted into the vacated position right end of the shift register The element shifted out of the shift register goes into the register accumulator d 0 255 is the length of the shift register 1 BA RA WA Variable Affected No Yes Example The falling edge of input 0 moves a 560 step conveyor one step to the left 002 060 SHR SHR instruction uses word outputs QO uses WO 512 639 Q1 uses WO 640 767 etc and these word outputs can be used for other purposes only if SHR instruction is not used Operation If the bit accumulator is 1 shift the byte sized elements of shift register n 0 3 one step to the right The number in the register accumulator is shifted into the vacated position left end of the shift register The element shifted out of the shift register goes into the register accumulator d 0 255 is the length of the shift register 1 BA RA WA Variable Affected No Yes Example The rising edge of input 0 000 200 moves a 300 step conveyor 001 100 one step to the right STEP RT Operation If the bit accumulator is 1 move the current sequence register to the step indicated by the contents of the register accumulator If the bit accumulator is 0 do nothing BA RA WA Variable Affected No No Example The sequence register moves to the step indicated register memory FF Automation Oy AutoLog 2000 Instruction Manual Page 11 39 12 1
104. icient use of all its features although AlproWin allows the use of ladder logic in addition to ALEIL AlproWin features both on line and off line programming graphical representation of variables and an excellent tool for documentation of PLC programs For more detailed information concerning AlproWin please consult the AlproWin User Manual 2 1 1 Programming with the AlproWin Software Before programming the AL2000 the hardware configuration must be defined This is done using the AlproWin software The PLC program can be written using the text editor in AlproWin or using any other word processor or editor and save file in ASCII mode AlproWin compiles the PLC program for running on the AL2000 PLC programs are saved on disk for later use 2 1 2 I O Module Addresses Each slot in the mounting rack has its own unique address which is automatically recognised by the I O module installed in that specific slot Two special registers in the I O modules are provided for a test procedure done by the CPU module This permits the CPU to continuously supervise the function of the internal bus check that the correct I O modules are installed in the correct slots etc The registers in the I O modules also contain information about the type of the I O module This makes it possible for the CPU to fully check the I O configuration If an I O module is accidentally replaced with the wrong type of I O module e g during repair service the CPU discovers and rep
105. ignal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Current 1 4mA Analog signal Analog signal Signal ground Page 5 19 11 09 2000 Analog input 0 Analog input 1 Analog input 2 Analog input 3 Analog input 4 Analog input 5 Analog input 6 5 20 AL 2000 User Guide 11 09 2000 Layout of the AIO74 IC5 Internal data bus buffer IC6 Module address detection circuit LD1 LED unit active error indication LED unit inputs status 10 16 Internal bus connector Screw terminals for outputs Screw terminals for inputs Resistors for current to voltage conversion Voltage converter Voltage converter Temperature Measurement with Pt100 e O Jumper Differential Voltage Measurement Q twisted Yet V pair SIGN 2498 E FF Automation Oy AL 2000 User Guide Non Differential Voltage Measurement Differential Current Measurement Active Transducer A E Jumper 249R A EN Passive Transducer Jumper 12498 NOTE The transducer can also be connected between SIGN and the supply ground but the common mode voltage must not exceed 40 V Non Differential Current Measurement FF Automation Oy Page 5 21 11 09 2000
106. in Any other text editor producing ASCII text will do just as well The program is then compiled with ALProWin compiler into a form that the Programmable Logic Controller understands stored on a diskette and transferred into the memory of the PLC when desired Further features of ALProWin e Macros Emphasizing the program structure Page division writing similar program sections etc Windowing Error messages easy to include in the listing file ON LINE features including display of variables history display on line editor etc For example the basic displays can be stored on disk which facilitates the clearing of fault conditions ALProWin contains HELP screens describing the functions Available in Finnish and English language versions A free version of the program ALProWin demo or ALPro demo is also available similar to ALProWin ALPro proper but the length of the program that can be written is limited as well as a manual ALProWin ALPro Programming manual 11 1 3 Fast program loop A fast program loop can be written into the Programmable Logic Controller for execution at timer interrupts at intervals of 5 ms The executable program of the loop starts as program line 0000 and ends at an END instruction When the fast program loop is in use the PLC reads inputs 0 7 and writes to outputs 0 7 every time before executing the fast loop The differentiation of auxiliary memories 0 7 is timed by the fast loop T
107. ing rack and its built in power supply is capable of driving the I O modules fitted in this rack The CPU2000P cannot be used with any other type of mounting rack The CPU2000P requires an input voltage in the range 20 32 VDC or 20 26 VAC OOOOO 26 D OM Data SER3 D Of 56 FF Automation 5 36 AL 2000 User Guide 11 09 2000 5 4 3 CPU2000L Modules 486 DX4 DX5 version irm RES RUN XACT IRQ The CPU2000L is the most powerful CPU mod ae ule in the AL2000 range The CPU2000L is 66 Fpow Fen based on the 486 DX4 DX5 running up to 133MHz The module is PC compatible running Fpow FlashVppON QNX The CPU2000L is equipped with connec ten FlashWREnable tors for an IBM AT keyboard RS232C port RS232 422 485 port and Ethernet LAN AUI 10BaseT The board can be equipped with PC104 extension board to connect additional PC104 devices The FLASH disks are available in 16 MB 24 MB and 48 MB sizes and are ideal for use in poor environmental conditions where standard disk systems would be unreliable Pentium 586 version The CPU2000L is the most powerful CPU mod ule in the AL2000 range The CPU2000L is based on the 586 running on 233MHz The module is PC compatible running QNX The CPU2000L is equipped with connectors for an IBM AT keyboard RS232C port RS232 422 485 port and Ethe
108. interval RGM 174 256 uppdate interval R GM Graphic object 3 mode R GM Graphic object 7 mode R GM Graphic object 3 mode R GM Graphic object 7 mode R GM Value R GM Value R GM X start point R GM X start point R GM X length R GM X length R GM Y start point R GM Y start point R GM Y length R GM Y length R GM uppdate interval RGM 182 266 uppdate interval R GM X start point R GM X start point R GM Graphic object 3 mode R GM Graphic object 8 mode R GM Value R GM Value R GM X start point R GM X start point R GM X length R GM X length R GM Y start point R GM Y start point R GM Y length R GM Y length R GM uppdate interval RGM 190 276 uppdate interval R GM RGM 191 277 Graphic object update interval 1 1 sec 2 2 sec 0 256 sec FF Automation Oy ls 9 5 AL 2000 User Guide 11 09 2000 9 4 Register Outputs which must be set RH 212 Selected language 0 English 1 Finnish 210 Terminal mode SER1 data configuration 8 bit parity NONE 7 bit parity EVEN 7 bit parity ODD 8 bit parity EVEN 8 bit parity ODD R O 213 Serial interface SER1 communication speed 0 300 bit s 1200 bit s 2400 bit s 4800 bit s 9600 bit s 19200 bit s 28800 bit s 38400 bit s 57600 bit s 115 kbit s 1 2 3 4 5 6 7 8 9 RO 214 Serial interface SER1 mode Programming EVS 112 bar code camera Terminal printing Serial interface to computer MODBUS slave modem MODBUS master Note DIP switch
109. ion If the bit accumulator is 1 before the instruction or if the current sequence register is at step d the bit accumulator is set to 1 otherwise it is reset to 0 BA RA WA Variable Affected No No Example the sequence register sis at step 27 or 28 reset memory 5 OR R Cd Operation Sets the register acc equal to the logical sum of its old value and the constant d BA RA WA Variable Affected No No No Example STR R M 001 RM1 200100011B OR R C 128 10000000 R M EQ RM2 10100011 B FF Automation Oy AutoLog 2000 Instruction Manual Page 11 31 12 12 2000 OR R M O NM NO n Operation Sets the register acc equal to the logical sum of its old value and the variable BA RA WA Variable Affected No No No Example STR M 001 RM41 200001111 B OR R M 002 RM2 211110110 B EQ R M 003 RM3 11111111B OR W Cd Operation Set the word acc equal to the logical sum of its old value and the constant d BA RA WA Variable Affected No No Yes No Example STR W M 045 45 0001 1101 1111 0000 B OR W C 09006 0010 0011 0010 1110 B EQ W M 021 21 20011 1111 1111 1110 B OR W I M On Operation Set the word accumulator equal to the logical sum of its old value and variable n BA RA WA Variable Affected No Yes No Example STR W M 033 W M 33 1011 01100110 1100 B OR W M 024 W M 24 0000 0010 1111 0100 B EQ W M 012 12 1011 0110 1111 1100 B PLD R Cd Operation Adds the constant d
110. is advisable to take the lower value about 10 higher than minimum measure value When the signal value corresponding to the lower calibration value can be read on AlproWin s watch table set into R O 220 a value of three 3 Now the calibration program reads the signal value and moves to step four 4 to insertion of the upper calibration value into register outputs R O 226 and R O 227 When the signal value corresponding to the upper calibration value can be read on ALPro s debug screen set into R O 220 a value of five 5 Now the calibration program reads the signal value calculates the values of the calibration parameters and saves the values to the FLASH memory After that the calibration program informs the user if the calibration was succesful by writing into R O 220 the value zero 0 or if the result was unsuccesfull the error code From the error codes the user can check what the problem was E FF Automation Oy AL 2000 User Guide Page 10 11 06 05 00 The error codes for analogue input calibration are as follows 027 028 128 129 130 140 FLASH verification error FLASH write error input signal low input signal high adjustment value low adjustment value high input signal high gt 4000 input address too high The Pt100 sensor is nonlinear The following temperatures corresponds to the resistance values given in the table DIN 43 760 below FF Automation Oy 10 12 AL 2
111. lator is reset to 0 Using the bit accumulator in this way as a carry bit allows calculation with numbers greater than 255 RA WA Variable Affected No No Example Reset bit accumulator 22 RM 12 RM 2 PLU Operation Add the word constant d and the bit accumulator to the word accumulator If the result is greater than 65535 the bit accumulator is set to 1 otherwise it is reset to 0 BA RA WA Variable Affected Yes No Yes No Example STR Add 1 to word memory 50 STR W once per minute PLU W EQ W PLU W I M O Operation Add variable n and the bit accumulator to the word accumulator If the result is greater than 65535 the bit accumulator is set to 1 otherwise the bit accumulator is BA RA WA Variable Affected No Yes No Example STR When 1000 1 STR W M WM 003 WM 34 WM 25 1 EQ FF Automation Oy 11 34 AutoLog 2000 Instruction Manual 12 12 2000 PRI TX Operation If the bit accumulator is 1 the text string whos number is given in the register accumulator is printed to the active output port The bit accumulator is 1 after the instruction if the characters were output there was room in the output buffer WA Variable Affected No Example Set bit accumulator to 1 Set 22 to register accumulator Print with indirectly addressing the text string number 22 PRT Cd Operation The number of vacant character positions in the print buffer is r
112. lt ages to the AL2000 45V 3A 12V 0 6A QO v 12V 0 6A O 12V There are four LED indicators in the POWDC O 5V module O POW FAIL 12 V green 12V supply ON 12 V green 12V supply ON 5 V green 5V supply ON POW FAIL red Supply voltage too low The POWDC power supply module isolates the supply to AL 2000 from the external supply voltage The POWDC also provides electronic overload protection to limit the output power The high frequency interference filter is de signed to standards VDE 0806 VDE 0871 and FCC 15B li FF Automation Oy AL 2000 User Guide 5 1 4 POWAC Power Supply Module The POWAC power supply module is designed for use with the PCON230 power connection module and supplies the following voltages to the AL2000 45V 10A 12V 0 6 12V 0 6A There is one green LED indicator in the POWAC module POWER ON Supply voltage ON In addition the POWAC is furnished with two potentiometers for voltage adjustments 5V Adjustment for the 5V supply At12V Adjustment for the 12V supplies There is one glas tube fuse inside power unit size 5 x 20 mm ratings 3 15 A 250 VAC slow blow FF Automation Oy Page 5 5 06 05 00 AL 2000 POWAC POWER ON Qa 5v 12v 5 6 AL 2000 User Guide 06 05 00 5 1 5 PWR3 Power Supply Module The PWR3 is a complete power supply module for use with the mounting rack Input vol
113. make comparison device code result to memory 0 1 data byte STR EQU EQ STR EQ AND EQ Etc CONT Ezzzzzz H OV FF Automation Oy AutoLog 2000 Instruction Manual Page 11 19 12 12 2000 Example 2 Read iButton once in a second Program STR R C 000 parameters from M 000 gt STR P 001 every second IF T parametrit alkaen R M 10 gt FCN 032 Read possible Ibutton EQ 005 set output 5 active CONT FCN 30 and FCN 31 Write FCN30 amp read FCN31 functions These commands are used to communicate with external lC devices connected into Autolog PLC s channel Command is executed only if Bit accu equals 1 before instruction Function parameters are defined in word memories Register accu must hold the address of the first parameter before FCN instruction Parameters 1 parameter Slave address 2 parameter Byte count 3 parameter Data 0 parameter Data n Execution time is about 0 1 ms byte For read function FCN 31 last byte is always read without ACK Read bytes are stored right after parameter byte count When you wish to connect I2C devices to PLC refer always to specification provided by the device manufacturer device address READ WRITE operations etc Also make shore that there are no duplicated device addresses in l C channel Example 1 Write Outputs every 1 second 4Ch lI2C l O board address 11 byte count OFh output data Parameters
114. memory 100 is set to 0 otherwise 123 FF Automation Oy AutoLog 2000 Instruction Manual Page 11 13 12 12 2000 EQ R SM SOn Operation Affected Example If the bit accumulator is 1 set the variable equal to the contents of the register accumulator if the bit accumulator is 0 do nothing BA RA WA Variable No No Yes STR EQ If input 11 1 STR register memory 100 200 STR otherwise register EQ memory 100 123 EQ W M On Operation Affected Example Set the variable equal to the contents of the word accumulator BA RA WA Variable No No No Yes STR W 2 00 memory 3 EQ W M 003 follows analog input 0 EQ W RM RO n Operation Affected Example If the bit accumulator is 1 reset the variable to 0 if the bit accumulator is 0 do nothing BA RA WA Variable No Yes 03000 If input 1004 1 130 memory 130 0 04 sis set to 0 W RM 130 otherwise 3000 EQ W SM SOn Operation Affected Example If the bit accumulator is 1 set variable n equal to the contents of the word accumulator if the bit accumulator is 0 do nothing BA RA WA Variable No No No Yes STR 04500 EQ W M 130 If input 1004 1 STR W C 05000 memory 130 5000 STR 0 04 otherwise word EQ SM 130 memory 130 4500 FF Automation Oy 11 14 AutoLog 2000 Instruction Manual 12 12 2000 EQI M O BM GM Operation W
115. more spare fuses 10 4 6 ROC16Z The procedure is exactly the same as for the ROC16K module except that ROC16Z uses 16 x T5A slow blow fuses 10 4 7 OOC16 The procedure is exactly the same as for the ROC16K module except that the OOC16 uses 16 x F1 6A quick blow fuses BUSS PC Tron WICKMANN WERKE TR5 SCHURTER MSF Microfuse FF Automation AL 2000 User Guide Page 10 7 06 05 00 10 5 Adjusting of Analog Inputs AL2000 s analog inputs are pre calibrated prior to delivery and should require no further adjustment The non linearity of temperature measuring elements are compensated on analog boards system program The resolution of the analog input is 12 bits However for extremely accurate results inputs can be re calibrated in the following way On the table below the calibration variables and their functions are showed output variable 8 bit 16 bit for adjustment variables emen os _ o0 f RO 222 Input number on analog board The initialization of adjustment step is controlled through register ouput R O 220 The permitted adjustment steps are Before step 1 Slot number Input number on analog board and both calibration variable values into R O s 224 225 226 227 should be inserted Step 1 Start adjustment Step 2 Set the lower adjustment value for the input Before going to step 3 the lower calibration value must be inserted Step 3 Read the lower adjustment v
116. n WARNING battery weak and should be replaced FAIL battery exhausted faulty or missing erial connection 3 power supply ok 4 5 6 S The AL2000 checks the battery on power up If the voltage is sufficient the battery condition indicated in 36 is OK If the voltage is close to minimum the condition indicated is WARNING The system program continues to check the battery condition and if it does not improve shortly after power up the condition indicated will be FAIL The system program continuously monitors the battery condition during operation If the battery becomes exhausted develops a fault or is removed this information is imme diately sent to R O 36 E FF Automation Oy e NZ AL 2000 User Guide Page 10 5 06 05 00 10 3 1 Battery Replacement The battery is mounted in a compartment on the CPU module immediately above the SER1 interface port The battery can be replaced in the following way Turn off power to the AL2000 Remove the CPU module from its slot Note If there is data saved in the RAM memory Remove battery compartment cover of the PLC ignore items 1 2 7 and 8 Remove old battery Insert new battery with positive pole facing e edge of the PCB Replace battery compartment cover Replace the CPU module in its slot Turn on power to the AL2000 The CPU module must have an uninterrupted power supply in order to maintain the contents of the RAM and the correct
117. n be removed from the module without disconnecting the wiring There are two labelling conventions for the screw terminals de pending on whether the terminal is an input or an output Input Black text on a white background Output White text on a black background The numbers of the inputs or outputs are shown on both the screw terminals and any LED indicators provided these being decimal numbers from 0 7 Analog I O s must be configured using the ALPro software Analog inputs and outputs are defined as follows Inputs W slot number gt lt input number Outputs W slot number gt lt output number Example W 2 4 analog input number 4 on the module in slot number 2 W O 6 3 analog output number 3 on the module in slot number 6 When an Analog Input or Output is defined the type of input or output has to be first de fined in ALPro After this definition the approriate connections should be made prefer ably using twisted pairs see diagrams on the following pages All modules are pre calibrated at the factory and should require no further adjustment for normal use However if extremely accurate measurements are required the user should re calibrate using the ALPro software ALPro also allows the user to perform calibration on line E FF Automation Oy AL 2000 User Guide 5 3 2 AIO74 Analog Input Output Module The AIO74 is a combined analog input output module with 4 x 12 bit analog outputs and 7 x 1
118. ndow 1 2 2 Power Suppl Each mounting rack except MR3 models must be fitted with a power supply module and a power connecting module The power supply cable is connected to the power connecting module The power supply module provides the AL2000 with the voltages it needs The includes a single unit power supply and does not require separate power connecting and power supply modules The MR3 mini does not require a power supply power for this mounting rack come from the CPU2000P 1 2 3 Internal Bus The internal bus handles communication between the I O modules and the CPU When an expansion mounting rack is used the internal bus is extended from the basic mounting rack to the expansion mounting rack using a flat cable The internal bus provides fast communication and is designed to IEC Standards IEC47B CO8 for electrical features and CO10 for mechanical features Each I O module is connected to the mother board using DIN41612 connectors The expansion mounting rack does not require its own CPU since the internal bus is extended to serve the expansion mounting rack via a flat cable The basic mounting rack and the expansion mounting rack if fitted are hereafter collectively referred to as the Basic Unit FF Automation Oy 1 4 AL 2000 User Guide 14 11 2000 1 2 4 The CPU2000S Series Modules The CPU2000S is the basic general purpose CPU unit for the AL2000 This CPU can control the basic unit whi
119. ng Serial connection 3 power supply ok ROS7 Reserved R 38 63 Reserved for possible future use FF Automation Oy l 10 4 AL 2000 User Guide 06 05 00 10 2 5 The Remote Unit Status Table Each remote unit has one byte reserved for status information This is held in register outputs R 64 79 representing remote unit numbers 32 47 respectively The status bytes contain possible error information as follows 0 No error 33 161 Excessive bus traffic 34 162 Remote station not responding 35 163 Remote response framing error 36 164 Remote response break up 37 165 CRC checksum error 144 159 Error in the module in remote unit slot 0 15 respectively 10 2 6 Software Faults If the ALPro software gives the message PLC not connected check the programming cable and communication speed serial port selection 10 3 The CPU Battery The CPU2000S series modules require a 3 3 6V 1 2AA lithium battery e g TADIRAN TL 5101 VARTA CR 1 2AA etc This battery is used for the RAM and the clock and calendar IC The life expectancy of the battery is over 2 years without the CPU being connected to a power supply if the operating environment temperature does not exceed 60 C However under normal use the battery has a life expectancy of over 10 years Information about the condition of the battery is stored in R O 36 There are three possible battery states R O 36 0 1 2 4 OK battery good conditio
120. nsure that the counter is decremented by one for each pulse BA RA WA Variable Affected No No Yes Example 100 Count 100 pulses Differentiate input 1 FF Automation Oy 11 10 AutoLog 2000 Instruction Manual 12 12 2000 DEC R M On Operation If the bit accumulator is 1 decrement the variable by 1 and load the value of the variable into the register accumulator Decrementing a variable whose value is 0 gives 255 If the bit accumulator is 0 the variable is not decremented but only loaded into the register accumulator If the variable was decremented the bit accu mulator was 1 and the result was 255 zero minus 1 the bit accumulator is set to 1 otherwise the bit accumulator remains at 0 RA WA Variable Affected No Yes Example Decrement memory 112 once per second Every time memory goes from 0 to 255 invert output 1 DEC W M On Operation If the bit accumulator is 1 decrement variable n by 1 and load the new value of the variable into the word accumulator If the bit accumulator is 0 the variable is not decremented but only loaded into the word accumulator Decrementing a variable whose value is 0 gives 65535 If the variable is decremented the bit accumulator was 1 and the result is 65535 the bit accumulator is set to 1 otherwise the bit accumulator is reset to O RA WA Variable Affected No Yes P Decrement memory 130 M 10 times per second Every time
121. nting rack if used Use the ALPro Win software to define the hardware configuration number and type of I O modules and their respective slot numbers Select the communication protocol e g MODBUS RTU Install the AL2000 Design and write the PLC program Transfer the PLC program from the PC to the AL2000 Testthe PLC program and correct possible errors Save the PLC program onto disk Make documentation for the PLC program ALProWin can help with this le FF Automation Oy AL 2000 User Guide Page 1 3 14 11 2000 1 2 Basic Design The AL2000 is a modern PLC designed for general purpose industrial automation and data acquisition The AL2000 s modular design allows each mounting rack to be fitted with the CPU and I O modules which best meet the specific demands of each applica tion 1 2 1 Mounting Rack Five different sizes of mounting rack are available with space for 3 5 11 or 16 I O modules All mounting racks are delivered with mother boards that connect the different I O modules to the CPU The modular design enables easy and rapid installation of different hardware configurations The I O cabling is connected to detachable screw terminals on the front edge of each I O module All I O modules can be removed or re positioned in the rack without disconnecting the I O cables The front cover of the unit hides the screw terminals but allows the LED indicators indicating the status of each I O to be seen through a wi
122. number 2 to ON position 219 Terminal mode SER2 data configuration 8 bit parity NONE 7 bit parity EVEN 7 bit parity ODD 8 bit parity EVEN 8 bit parity ODD le FF Automation Oy AL 2000 User Guide Page 9 6 11 09 2000 R 229 Serial interface SER2 communication speed 300 bit s 1200 bit s 2400 bit s 4800 bit s 9600 bit s 19200 bit s 28800 bit s 38400 bit s 57600 bit s 115 kbit s RO 215 Serial interface SER2 mode Terminal printouts modem EVS112 bar code camera Serial interface to computer MODBUS slave modem MODBUS master 218 Terminal mode SER3 data configuration 8 bit parity NONE 7 bit parity EVEN 7 bit parity ODD 8 bit parity EVEN 8 bit parity ODD R O 217 Serial interface SER3 communication speed 300 bit s 1200 bit s 2400 bit s 4800 bit s 9600 bit s 19200 bit s 28800 bit s 38400 bit s 57600 bit s 115 kbit s R O 216 Serial interface SER3 mode Terminal printouts modem EVS112 bar code camera Serial interface to computer MODBUS slave modem MODBUS master FF Automation Oy 9 7 11 09 2000 AL 2000 User Guide R O 236 Analog input update rate BON 1 analog input per program cycle default each analog board 2 analog inputs per program cycle 4 analog inputs per program cycle 8 analog inputs per progr
123. ogram The PLC now performs I O updates and the main program starts again from line 1 Therefore the main program is executed only up to the first CSR instruction the rest of the main program is not executed at all If there is a CSR call for a subroutine that does not exist the PLC interpretes the CSR instruction as a NOP instructionand continues normally STP Operation The PLC s main program ends with this command and all subroutine programs must be written after the STP command CSR n Operation The PLC executes the subprogram n if the bit accumulator is true Affected Bit accumulator Register accumulator Word accumulator Variable The states of the accumulators remain unchanged so subroutine can use the accumulator states SBR n Operation This is the starting instruction of a subroutine RET Operation The subroutine ends here execution is then returned to main program Affected Bit accumulator Register accumulator Word accumulator Variable The states of the accumulators remain unchanged so main program can use the accumulator states after executing the subroutine Example Scaling subroutine for analogue variables The scaling parameters are transferred in main program with the EQI instruction The result after the subroutine call is retrieved with the STI instruction from word accumulator or from WM 101 STR C 001 set bit accumulator to 1 CSR 001 call subroutine 1 STP main program end SBR start of subroutine 1 EQ STR
124. on If the bit accumulator is 1 before the instruction and the current sequence register is at step d the bit accumulator remains at 1 otherwise it is reset to O BA RA WA Variable Affected No No No Example STR If input is 1 and the AND sequence register is at step 19 EQ set memory 201 to 1 AND R Cd Operation Sets the register accumulator equal to the logical product of its old value and the constant d 0 255 BA RA WA Variable Affected No No Example 2 210010001 B 00001111 B RM6 200000001 B AND R M O NM NO n Operation Sets the register accumulator equal to the bit by bit logical product of its old value and the variable BA RA WA Variable Affected No No Example RM2 10010001 B RM5 200110001 B RM6 200010001 B FF Automation Oy 11 6 AutoLog 2000 Instruction Manual 12 12 2000 W Cd Operation Set the word accumulator equal to the logical product of its old value and the constant d BA RA WA Variable Affected No No Yes No Example STR W 12 3 0000 0011 0000 1101 B AND W C 0000 0111 1111 1111 B EQ WM 15 0000 0011 0000 1101 B AND W Operation Set the word accumulator equal to the logical product of its old value and variable n BA RA WA Variable Affected No No Yes Example STR W 0000 0011 0000 1101 AND W 0000 0000 0010 0110 B EQ 0000 0000 0000 0100 B RT Operation Converts the number in the register
125. on all modules Error messages sent via serial interface to a supervising PC Error messages during PLC programming with the ALPro software 10 2 1 Hardware Faults Trouble shooting table RES signal on the disturbances in Check the power supply CPU module the supply voltage cabling and the PCON and POW modules All LED signals disturbances in the Check the Power Supply are missing on supply voltage cabling and the PCON the I O module and POW modules ERR signal The I O module is not in Check the hardware on the I O the right slot configuration module The I O module is broken Replace the broken I O module The I O modules The PLC program Correct the program do not operate uses wrong I Os in the expected manner The definition of the analog Check and correct module is incorrect the definitions Incorrect resistors on the Check the resistors inputs outputs of the and replace them with analog I O module correct resistors Fuse in the relay Replace the fuse output module is blown The content Disturbances in the Check the power supply of R O 241 supply voltage is not equal to 0 E FF Automation Oy AL 2000 User Guide Page 10 3 06 05 00 10 2 2 The ALPro Diagnostic Display The ALPro programming software can be used to display diagnostic information to assist in the correction of hardware problems This display can be produced by selecting Diagnostics from the Configure menu 10 2 3 The I O Module Status Table
126. onnect the AL2000 to the PC and start the AlproWin software 2 f you want to read inputs in values from 0 to 1000 write the following program otherwise you see the values from 0 to 4000 STR W 000 This program was made for the analog input If you DIV W C 004 want to include all analogue inputs at once you can EQ W M 000 add similar instructions for all the rest of the STOP analog inputs Compile program by choosing Compile from the main menu Transfer the program to the PLC by choosing Transfer project from the Transfer submenu and start PLC program execution Choose Watch table from the View submenu insert desired variables to watch table and start updating by choosing Start loop from Loop submenu Now you can see the values of the variables on watch table Check that the PLC s Run led is blinking indicating normal operation Begin calibration procedure E FF Automation Oy AL 2000 User Guide Page 10 9 06 05 00 10 5 2 Current input You need an adjustable current source and a mA meter with enough accuracy 0 1 Connect the adjustable current source to the analogue input number 1 terminals SIGN SING and I Analog input 1 0 When calibrating analog input 1 0 insert number 1 into R O 221 1 and number 0 into R O 222 O Other inputs must be adjusted with corresponding numbers in R O 221 and in O 222 Input 0 4 R O 221 0 and current source RO 222 4 10 5 3 Voltage input You need an adjus
127. operating system has discovered a fault in the module 0 31 yellow Inputs 10 131 are ON External Internal Switch 7 i 10 ENE Ff sensor T 20 36 Layout of the DIC32DC IC1 Interrupt register IC2 Module address detection IC3 Internal data bus buffer IC14 Code register for module IC15 Test register LD1 LED Unit ACT ERR indicator LED Unit input status 10 131 Internal data bus connector Terminals for inputs 10 115 Terminals for inputs 116 131 FF Automation Oy AL 2000 User Guide 5 2 3 DIC32AC Input Module The DIC32AC is a digital input module with 32 isolated inputs in two groups of 16 inputs each The current consumption of DIC32AC is 250 mA Input wiring is connected to two detach able screw terminals on the front edge of the module The common ground for each of the two groups is connected to the bottom screw in each of the two screw terminals The logic range of the DIC32AC module is logic 0 0 to 5 VAC 0 1 1mA logic 1 19 to 36VAC 6 11mA The following LED indicators are located on the front edge of the module ACT green Module in operation ERR red The operating system has discovered a fault in the module 0 31 yellow Inputs 10 131 are ON External
128. orts the mistake immediately upon power up 2 1 3 MODBUS Using the standard MODBUS RTU protocol AL2000 units can operate as masters driving other AL2000 AL14 AL32 and AL20AN slave units thus enabling large scale and distributed control systems to be realised This is a standard feature on all AL2000 CPU modules The MODBUS software included with AlproWin can be used to define the master slave units and their respective addresses The MODBUS protocol can also be used to communicate with PLCs made by other manufacturers and all supervisory software currently available FF Automation Oy ls 2 2 AL 2000 User Guide 14 11 2000 2 2 DSIM32 Digital I O Simulator The DSIM32 digital I O simulator can be EHE EE used to test and debug PLC programs be fore they are used in the actual control process This makes the testing process faster easier and safer by avoiding the possibility of erronous PLC programs affect ing the process It is strongly recommended that all PLC programs be tested with the DSIM32 prior to use in the control process DIGITAL l O SIMULATOR gt O 16 EO 17 EPO 18 EPO 19 cb 20 pO 21 Eb 22 gt 23 EO 24 The DSIM32 can be used to simulate up to 32 digital inputs or outputs at a time and is connected to the modules using convenient plugs which replace the detachable screw terminals making connection rapid and trouble free
129. ory at addresses 0 15 After all messages have been defined the configuration information must be trans ferred to the AL2000 This is done by selecting Send File from the File menu Trans fer can be verified by selecting Verify from the menu E FF Automation Oy AL 2000 User Guide The following functions are available in messages Read write operation Modbus Address offset Binary output O Binary memory M Binary memory GM Binary odd BM Binary input 1 Word input W 1 Register output R O Register memory R M Word output 0 gt 1023 W Word memory 0 gt 1023 W M Register general memory R G Word general memory W GM Word output 1024 gt 2047 Word memory 1024 gt 4095 Word output 2048 gt 4095 Word memory 4096 gt 16275 M wo WM wo W M 4 3 Setting Up A MODBUS Slave Control sw Address Page 4 5 25 05 04 FCS sw Address SDO 0001 SDO 1025 SDO 2049 SDO 3073 SDI 0001 SAI 1025 SAO 0001 SAO 1025 SAO 2049 SAO 3073 SAO 5121 SAO 6145 SAO 7169 MODBUS slave can be set on SER1and or SER2 and or SER3 by following the steps described below Example Set The Serial Port 3 to SLAVE baud rate 9600 N 8 1 slave address 2 STR EQ STR EQ STR EQ STR EQ 4 216 set SER3 to SLAVE mode 4 217 set SER3 baud rate to 9600 0 2 243 set Slave address to 2 JI See 4 1 3 Serial Port Configuration for a
130. points of the rack and can be installed into any card place in the rack The RS 422 485 serial interface uses detach able screw terminals for ease of connection The RS 232 and RS 485 serial ports are isolated in two groups to 500VDC The current consumption of CPU Modbus Router is 700 mA at 5 VDC voltage level TECHNICAL FEATURES Mode Serial connections Ser1 9 pin D type Ser2 9 pin D type Ser3 3 screw terminal Addresses Retransmissions On error Send delay Responce timeout Serial channel diagnos tics Modbus Master Slave Not used 3 isolated in 2 blocks 500 VDC RS 232 300 19200 Bd Modbus master slave RS 232 300 19200 Bd ModBus master slave RS 485 300 28800 Bd ModBus master slave Address Address block 0 7 Enabled Disabled 0 250 ms 100 1500 ms Acknowledged messages Warnings Rejected messages Error code and slave address FF Automation Oy AL 2000 User Guide Page 6 1 06 05 00 6 CONTROLLERS 6 1 8 Bit Controllers The AL 2000 PLC system software includes 8 x 8 bit direct digital controllers DDC with PID characteristics The controller parameters are held in R GM s EE Controller Controller Mode Actual value Set point D term term Gain term Output Aux R 0 8 16 etc gives the control program the following information 0 Controller
131. qrt 65535 255 99 in word acc is 25599 8 95 value in WA number in RA percent value after execution the result is in word accumulator WA RA 100 FCN 10 Scaling In WA is the number to be scaled in RA is the address of word memory pointer that contains the scaling parameters The range of scale word memories is freely selectable The order of scaling parameters is WM 100 low limit of measured input 0 4095 WM 101 high limit of measured input 0 4095 WM 102 low range scaled output eg 10 C WM 103 high range scaled output eg 115 C FF Automation Oy AutoLog 2000 Instruction Manual Page 11 17 12 12 2000 0800 low limit of input 4 20 mA 100 wanted output 0 1000 tenths of percent 4095 high limit of input 101 0000 low limit of output 102 1000 high limit of output 103 100 parameters start address to RA 0 01 word input to be scaled into WA 001 set bit accumulator to 1 010 call scaling function 200 save the result to WM 200 Example Zjzzzzzzzz O OtSOSOEOZEZO z STOP 11 Scaling returns sign integer and decimat part In WA is the number to be scaled in RA is the address of word memory pointer that points to the scaling parameters Pointer offset O points to W M area offset 32768 points to W O area The range of scale word memories is freely selectable The order of scaling parameters is 100 low limit of measured input 0 4095 10
132. r accumulator equal to the exclusive or function of its old value and the constant d BA Variable Affected No Example RMO 201010101 B 11111111 8 1 10101010 B XOR W I M O Operation Set the word accumulator equal to the exclusive or function of its old value and variable n Variable Affected No Example W M 33 1011 0110 0110 1100 B M 24 0000 0010 1111 0100 B 12 1011 0100 1001 1000 B Operation Set the word accumulator equal to the exclusive or function of its old value and the constant d BA RA WA Variable Affected No No No Example W M 45 0001 1101 1111 0000 B 0010 0011 0010 1110 B WM 21 0011 1110 1101 1110 B FF Automation Oy 11 44 AutoLog 2000 Instruction Manual 12 12 2000 Subroutines The PLC s main program ends with an STP instruction It is possible to write subroutine programs which start with the SBR n command n is subroutine number and ends with the RET command The maximum number of subroutines is 32 numbers 0 31 The STOP command must be appear after the subroutines this ends the PLC program The PLC system program ignores all SBR and RET instructions which appear before STP instruction If the RET instruction is missing from a subroutine the PLC executes the next subroutine s until the a RET command is found If no RET command is found program executes until the STOP command is reached and the PLC system program does not return to main pr
133. r high limit Dark Input is cali Input signal is in brated the range E FF Automation Oy Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog signal Analog input 0 Analog input 1 Analog input 2 Analog input 3 Analog input 4 Analog input 5 Analog input 6 Analog input 7 Analog input 8 Analog input 9 Analog input 10 Analog input 11 Analog input 12 Analog input 13 Analog input 14 Analog input 15 AL 2000 User Guide Page 5 27 11 09 2000 Examples for connecting mA transducers to MIC 16 board External Internal Active transducer External Internal Passive transducer FF Automation Oy l 5 28 AL 2000 User Guide 11 09 2000 5 3 5 TIC8 Thermocouple Input Module The TIC8 is a thermocouple input module with 8 x 12 bit analog inputs isolated as a group 500 VDC isolation i
134. r is reset to O If the number in the word accumulator is not a BCD number the result is indeterminate RA WA Variable Affected No Example Reset bit accumulator W M 30 0000 0011 0110 0011 B 363 BCD iconst 0000 0000 0011 0110 B 36 BCD W M 30 0000 0011 0010 0111 B 327 BCD MID Operation Subtract the variable n and the bit accumulator from the word accumulator assuming that they are BCD numbers If the result is less than 0 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 If the numbers are not BCD numbers the result is indeterminate RA WA Variable Affected Yes No Example Reset bit accumulator Subtract contents of word memory 45 a BCD number from word memory 30 MIN R Cd Operation Subtracts the constant d and the bit accumulator from the register accumulator If the result is less than 0 the bit accumulator is set to 1 otherwise the bit acc is reset to 0 RA WA Variable Affected No No Example Subtract the constant 100 the 16 bit number in register memories RM 100 101 underflow occurs subtract 1 from RM 12 FF Automation Oy 11 28 AutoLog 2000 Instruction Manual 12 12 2000 MIN R M On Operation Subtracts the variable n and the bit accumulator from the register accumulator If the result is less than 0 the bit accumulator is set to 1 otherwise the bit accumulator is reset to 0 RA WA Variable Affected
135. re RS232 connection 5 function keys 240 x 128 pixel graphic LCD display backlit AL1096T front panel mounted enclosure RS232 connection touch screen max 10 x 8 touch keys 240 x 128 pixel graphic LCD display backlit 7 2 AL1095A B Display Keypad Units OOOOOOOO an2a AL1095B ols 12X3 dene OD Connection to PLC s bus by system cable length 1 m 8x21 character alphanumeric LCD display 128x64 pixel graphic display backlit 8 LED indicator lights AL1095A 16 keys 0 F model A 4 keys 0 3 model skandinavian cyrillic characters selectable by jumper supply voltage through system cable from PLC s supply unit clock calendar battery backup the unit can be fitted with a clien designed face plate encapsulated front panel mount front panel seal IP54 FF Automation Oy 7 2 AL 2000 User Guide 06 05 00 7 3 AL1093 Display keypad Units There are three versions of the AL1093 unit These are AL1093C AL1093D and AL1093F All AL1093 units have 2 x 16 character alphanumeric display 16 key hexa decimal keypad and 6 LED indicator lights AL1093 unit can be connected to any Autolog PLC In addition to displaying the values and time date information the AL 1093 unit can also display text using the PRT instruction the LCD display is backlighted The clock and calendar functions are battery backed up All AL1093 models are front panel moun type
136. rites the state of bit accumulator into bit output memory Register accumulator is pointing to the bit variable to be written BA RA WA Variable Affected No No No Yes Example STR R C 008 program sets the state of bit accumulator into output 8 R M On Operation Loads the content of the register accumulator into the variable whose address is the value of the variable given as the instruction parameter BA RA WA Variable Affected No No Yes Example STR Initialize pointer EQ R M 021 STR posite derivation EQ input 0 STR every time input goes active INC Increment pointer amp STR save EQI Seconds into memory 2 EQI W M On Operation Loads the content of the word accumulator into the variable whose address is the value of the variable given as the instruction Accessible addresses are W M vari ables 0 to 16383 W O variables 0 to 4095 check from memory tables BA RA WA Variable Affected No No No Yes Example STR Initialize pointer EQ STR Load hour amp minutes into WA value of word accumulator into memory 11 EQU R Cd Operation If the constant d is equal to the register accumulator the bit accumulator is set to 1 if unequal the bit accumulator is reset to O RA WA Variable Affected No No Example There may be several successive comparisons FF Automation Oy AutoLog 2000 Instruction Manual Page 11 15 12 12 2000 EQU R M On Operation Affected
137. rnet LAN 10 100 AUI 10BaseT The board can be equipped with PC104 extension board to connect additional Keyboard PC104 devices foy Mouse The FLASH disks are available in 16 MB 24 MB and 48 MB sizes and are ideal for use in poor environmental conditions where standard disk systems would be unreliable A separate disk module is also available for con nection to the CPU2000L This has space for two standard IDE floppy or hard disk drives and can be installed in the mounting rack alongside the CPU2000L E FF Automation Oy AL 2000 User Guide Page 5 37 11 09 2000 5 4 4 CPU2000SER Module The CPU2000SER is serial communication ACT ERR expansion CPU module The module is similar with the CPU2000S except that it is not able to control any I O points of the rack The module can be installed into any card place in the rack When AL2000SER module is used it doubles the number of variables in the rack The RS 422 485 serial interface uses detach able screw terminals for ease of connection The RS 232 and RS 485 serial ports are isolated in two groups to 500VDC The current consumption of CPU2000SER is 700 mA at 5 VDC voltage level FF Automation Oy 5 38 11 09 2000 AL 2000 User Guide 5 4 5 CPU Modbus Router Module The CPU Modbus Router is serial modbus com munication CPU module The module is not able to control any I O
138. s provided by opto isolators and DC DC converters The current consumption of TIC8 is 600 mA The input ranges of the TIC8 are as follows 50 to 150 C 0 4000 20 bits C 250 to 1372 C 0 3244 2bits C 50 to 150 C 0 4000 20 bits C 200 to 730 C 0 3720 4 bits C The following LED indicators are located on the front edge of the module ACT green Module is in operation ERR red The operating system has discovered a fault in the module 0 7 red Status of analog inputs TIO TI7 STEADY LIGHT input not scaled FLASHING LIGHT input at upper lower limit or not connected NO LIGHT input in use and OK Thermocouples can be connected using normal cable but for longer lengths screened cable is recom mended Both earthed and floating thermocouples may be connected to the TIC8 as shown below Connections for floating thermocouple i zal Connections for earthed thermocouple E FF Automation Oy Thermocouple Input 0 Thermocouple Input 1 Thermocouple Input 2 Thermocouple Input 3 Thermocouple Input 4 Thermocouple Input 5 Thermocouple Input 6 Thermocouple Input 7 0 20 mA current input AL 2000 User Guide 5 3 6 MOC16 Analog Output Module The MOC16 is an analog output module with 16 x 12 bit individually isolated analog outputs The current consumption of MOC16 is 700 mA Outputs 4 20 mA 0 4000 200 bits mA There are 32 indicator LEDs for inputs and
139. s error for SER2 Number of non answered Modbus slave address for SER3 Type number of detected Modbus error for SER3 FF Automation Oy R O 128 131 R O 132 135 R O 136 139 R O 140 143 R O 160 183 R O 192 RO 196 R O 200 R O 204 R O 207 R O 208 R O 209 RO 210 RO 211 RO212 RO213 RO214 RO215 RO 216 RO217 RO 218 RO 219 R O 220 R O 221 R O 222 R O 223 R O 224 R O 225 R O 226 R O 227 R O 228 R O 229 R O 230 R O 231 R O 232 R O 233 R O 234 R O 235 R O 236 R O 237 R O 238 R O 239 AL 2000 User Guide Page 9 2 11 09 2000 Update interval for controller groups 1 4 default 5 500ms Pulse interval for 12 bit PID controller groups 1 4 Closing bits for 12 bit PID controller groups 1 4 Opening bits for 12 bit PID controller groups 1 4 Reserved for Counters on old AL2000SAC SCP boards Closing control bits for 8 bit PID controllers 0 7 Opening control bits for 8 bit PID controllers 0 7 Pulse interval for 8 bit PID controllers 0 7 Control for LEDs on display unit Bit information from keys 0 7 Bit information from keys 8 F Last character received from the keyboard SER1 data length and parity in terminal mode Reserved for test information Selected language SER1 communication speed SER1 mode programming terminal MODBUS SLAVE MASTER SER2 mode terminal EVS MODBUS SLAVE MODBUS MASTER SER3 mode terminal EVS MODBUS SLAVE MODBUS MASTER SER3 communication speed SERS data length and p
140. s in the PCON24 module F1 T1 6A slow blow fuse for supply to the AL 2000 F2 T1A slow blow fuse for auxiliary power supply T2 5A slow blow fuse for supply to the PCON24 There are two LED indicators on the PCON24 module AUX green PLC green Auxiliary supply ON Supply to POWDC ON AL 2000 PCON24 AUX PLC 24 V OO 1 OA 2 FPLC Faux F3 FIN CAUTION In order to prevent electric shock disconnect mains supply before making any power connections FF Automation Oy AL 2000 User Guide Page 5 3 06 05 00 5 1 2 PCON230 Power Connecting Module AL 2000 The PCON230 is a power connecting module PCON230 for supply voltages of 230 VAC The PCON230 drives the POWAC power supply module Supply voltage 180 265 VAC supply voltage should be connected to these screw terminals The PCON230 module is equipped with a high frequency filter to remove interference and pro tection against excessive input voltages The PCON230 is fitted with a T2 5A slow blow fuse for short circuit protection 230 VAC CAUTION In order to prevent electric shock disconnect mains supply before making any power connections FF Automation Oy 5 4 AL 2000 User Guide 06 05 00 5 1 8 POWDC 25 W Power Supply Module The POWDC 25W is a power supply module AL 2000 designed for use with the PCON24 power con POWDC necting module and supplies the following vo
141. sfer data error correcting MODEMs should be used as data transfer errors may lead to operational problems However if an error cor recting protocol like MODBUS is used error correcting MODEMS are not necessary CONTROL Software Dial up Telephone line SERRA AL2000 PLC liE FF Automation Oy AL 2000 User Guide Page 4 7 06 05 00 Only approved MODEMs should be connected to the telephone network Carrierless MODEMs are usually used over short distances maximum cable length 15km Typically a four wire system is used in order to realise a network CONTROL Software Fixed Line Modem DS 2856 D D Connection Numbers b B 5 5 AL 2000 AL 2000 AL 2000 Carrierless can be used for point to point connection MODEMs are usually mains powered If a battery back up is required the MODEM must be capable of being powered by a battery When a MODEM is used the following definitions should be made in the PLC Data Transfer Protocol Baud Rate Data format in terminal mode SER1 RO213 2 4 RO214 0 1 2 3 or 4 RO210 Oto4 SER2 RO215 Oor4 229 0 1 2 3 or 4 RO219 Oto4 SER3 216 Oor4 217 0 1 2 3 or 4 RO218 0to4 See also REGISTER MEMORIES OUTPUTS AND VARIABLES FF Automation Oy E 4 8 06 05 00 AL 2000 User Guide The following is a program example using MODEM communication C 000 O 212 C 000
142. splay and moves the cursor to the beginning of the first line CR Return Enter Moves the cursor to the beginning of the present line NAK Moves the cursor one character to the left without clearing that po sition If the cursor is at the beginning of a line it goes to the end of the previous line lt ESC gt Y Moves the cursor to line 1 column 8 lt line gt lt col gt Line 1 4 column 1 40 maximum numbers along displays 7 8 Display Modes All display keypad units have several display modes Some modes are not available for every unit e g those without clock and calendar functions and reduced keypads The display modes are outlined below and defined by register output R O 240 Content Function Mode 0 normal Mode Mode 1 Mode 2 Mode 3 Mode 4 the entire display is reserved for PRT outputs Mode 5 as mode 0 but the B key disabled changes Mode 6 display locked doesn t allow any changes in display 7 8 1 Normal display mode Mode 0 RO 240 0 Key Function 0 9 Numeric keys Set clock calendar Enter parameters into register variables Display register variables Next display entry Display address in register variable display mode Return to clock display FF Automation AL 2000 User Guide Page 7 5 06 05 00 A Set Clock Calendar The clock calendar is set as follows display continue 1 xx year two digits D or F 2 XX month two digits 01 1
143. t edge of the module ACT yellow green Module is in operation ERR red The operating system has discovered a fault in the module SP F green The spare fuse is available and working 0 15 red Outputs O0 O15 are ON Each output is protected by a separate T5A slow blow fuse The fuses are mounted in sockets located directly behind the output screw terminals and are easily replaceable In the event of a fuse blowing a spare fuse is located in a socket directly behind the LED indicators The SP F LED on the front edge of the module indicates if the spare fuse is work ing and mounted in its socket This provides a simple way to check fuses A spare fuse should always be installed in the module s spare fuse socket The output wires are connected to the screw terminals as shown below U 1 Uo Uo Un Uo Um UL Uo z External Internal 220VAC OO M as N E A E za wap U UO WNP gt WOY UOP Uo z li FF Automation Oy AL 2000 User Guide 5 2 11 DIOS2 Digital Input Output Module The DIO32 is hybrid module combining the half of the DIC32DC and half of the DOC32EP modules to give 16 isolated digital inputs and 16 digital outputs The current consumption of DIO32 is 250 mA The outputs hav
144. t signals are not in the same range e g If the input signal range is 0 1000 and the output signal range is 0 100 we need a value P 1000 This would result in a gain of 1 All controllers provide three point control outputs in the form of bit data in register out puts R 136 143 Controller No Close output R O 136 bit Open output R O 140 bit Controller No Close output R O 137 bit Open output R O 141 bit Controller No Close output R O 138 bit Open output R O 142 bit Controller No Close output R O 139 bit Open output R O 143 bit The pulse interval i e the dead time that the controller will wait for the process response to settle is programmed into register outputs R 132 135 The time range is from 0 15 to 25 5s corresponding to the numbers 1 255 R O 132 Controllers 0 7 R O 133 Controllers 8 15 RO 134 Controllers 16 23 R O 135 Controllers 24 31 A typical application controlling the temperature of the circulating water in a central heating system is shown over the page le FF Automation Oy AL 2000 User Guide Page 6 7 06 05 00 The mixing valve is controlled by a pulse driven actuator motor The dead time in an ap plication of this kind can be several seconds as changes in the water temperature will not immediately be detected by the sensor It is therefore futile to give further drive pulses to the valve before the true effect of the previous action is known This dead time can
145. table voltage source and a V meter with enough accuracy 0 1 Connect the adjustable voltage source to the analogue input terminals SIGN SING and I Analog input 2 1 number 2 into R O 221 2 and number 1 into R O 222 1 Other inputs must be adjusted with Cv Voltage source corresponding numbers in R O 221 and in R 222 Input 3 5 R O 221 3 and i RO 222 5 l p When calibrating analog input 2 1 insert SIGN FF Automation Oy iE 10 10 AL 2000 User Guide 06 05 00 10 5 4 Temperature input with PT100 sensor You need an adjustable resistance reference 0 1 250 with an accuracy of 0 1 Connect the adjustable resistance in the following way to terminals I SIGN SIGN and l Analog input 2 1 When calibrating analog input 2 1 insert number 2 into R 221 2 and number 1 into R O 222 1 Other inputs must be adjusted with Adjustable resistance reference corresponding numbers in R O 221 and in R O 222 Input 3 5 R O 221 and RO 222 5 The calibration of an analog input is made as follows 1 Start the adjustment by setting number one 1 to R O 220 The calib ration program moves to step two 2 and waits you to insert the lower calibration values into R O 224 and R O 225 Adjust the level of the analog signal to lower calibration value In order to make the calibration of the Pt100 input as accurate as bossible over the measurement range it
146. tages can be either AC or DC The input AL 2000 voltage ranges are as follows PWR3 AC supply 180 265VAC DC supply 20 32VDC POW FAILC The PWRS supplies the following voltages to the AL2000 sav 5V 3A The following LED indicators are located on the front edge of the module 5V green 5V supply ON POW FAIL red Supply voltage too low 24V green Auxiliary supply ON There are three fuses provided on the PWR3 module Fin T315mA slow blow fuse for overload protection Faux 1 slow blow fuse for auxiliary power supply Fplc 1 slow blow fuse for supply to the AL2000 CAUTION In order to prevent electric shock disconnect mains supply be fore making any power connections li FF Automation Oy AL 2000 User Guide Page 5 7 06 05 00 5 2 Digital I O Modules All digital I O modules are fitted with detachable screw terminals for I O wiring These ter minals can be removed from the module without disconnecting the wiring There are two labelling conventions for the screw terminals depending on whether the terminal is an in put or an output Input Black text on a white background Output White text on a black background The numbers of the inputs or outputs are shown on both the screw terminals and the LED indicators these being decimal numbers from 0 31 In the ALPro software inputs and outputs are defined as follows Inputs lt I O slot number gt lt input number on I O module Outputs
147. ted No No No Example When the sequence register sis at step 98 jinvert output 71 INC R M On Operation If the bit accumulator is 1 add 1 to register variable n If the variable was 255 the new value is 0 and the bit accumulator is set to 1 otherwise the bit accumulator is reset to O If the bit accumulator was 0 the variable is not incremented The value of the variable is loaded into the register accumulator BA RA WA Variable Affected Yes Yes No Yes Example STR P 001 Increment register memory 0 once per second INC R M 000 INC W M On Operation If the bit accumulator is 1 add 1 to variable n and load the new value of the variable into the word accumulator If the variable was 65535 the new value is 0 and the bit accumulator is set to 1 otherwise the bit accumulator is O If the bit accumulator was 0 the variable is not incremented but only loaded into the word accumulator BA RA WA Variable Affected No Yes Example P 001 Increment word memory 3 INC W M 003 per second INV Operation Changes the bit accumulator to its one s complement BA RA WA Variable Affected Yes No No No Example STR 0 Bit accumulator AND NO 00 sis zero after this INV and one after this FF Automation Oy 11 24 AutoLog 2000 Instruction Manual 12 12 2000 LES R Cd Operation If the constant d is less than the register accumulator the bit accumulator is set to 1 otherwise
148. ted to PLC s connector Example PLC receives a character from keypad STR 209 Read the character from keypad LES C 000 If value 0 EQ 209 reset the buffer PRT T and output the character STOP The keypad status is stored in the bits of R O 207 and R O 208 When no key is being pressed all bits are set to 0 When a key is pressed the bit corresponding to that key is set to 1 The keys and their corresponding bit are shown below R O 207 bit 76543210 RO208 76543210 key 76543210 key FEDC BA 98 7 6 Control of LED Indicators The LED indicators other outputs from display are controlled by the bits of R 204 An LED output can be set on by setting the approriate bit to 1 and subsequently turned off by setting the bit to 0 The LEDs and their corresponding bits are shown below R O 204 bit 0123 4 5 LED 01112131415 FF Automation l 7 4 AL 2000 User Guide 06 05 00 7 7 Display Control Characters Mnemonic Function BS Back space Moves the cursor one character to the left and clears that position If the cursor is at the beginning of a line it moves to the end of the previous line HT Tabulator Moves the cursor one character to the right without clearing that position If the cursor is at the end of a line it goes to the beginning of the next line LF Line Feed Moves the cursor to the next line FF Form Feed Clears the di
149. time and date An electrolytic capacitor preserves the memory contents for approximately one minute after disconnecting the power and removing the CPU module from its slot during this time the battery can be changed without losing the memory contents However it is recommended that the battery be changed while the module is powered up thus avoiding any risk of losing the memory contents NOTE After a battery change during CPU operation R O 36 should be manually reset to OK However if the battery is changed during power down time R O 36 is automatically updated by the system program next time the CPU is powered up 10 4 Fuse Replacement The power connector modules and the relay output modules are equipped with fuses All fuses are located in separate sockets and are thus easily replaceable Fuses are replaced in the following way 10 4 1 PCON24 There are three fuse holders on the front panel of the module which house T1 6A T1A and T2 5A 5 x 20mm slow blow fuses IEC 127 111 standard The LED indicators on the front panel of the unit can be used to determine which of the three fuses is blown as shown below AUX PLC Blown Fuse ON OFF FPLC F1 T1 6A OFF ON FAUX F2 T1A OFF OFF FIN F3 2 5 1 Turn the fuse holder cap anti clockwise about a quarter of a turn 2 Remove the cap and replace the blown fuse with a new one 3 Replace the cap Push and turn the cap clockwise until locked FF Automation Oy l
150. tomatically upon power up This configuration can later be changed Group 1 Group 2 14 Group 3 22 Group 4 28 29 30 For Example if we require three controllers with 100ms update intervals and two con trollers with 500ms update intervals Group 1 required interval 100ms 1 controller No 0 Group 2 required interval 100ms 1 controller No 8 Group 3 required interval 100 1 controller No 16 Group 4 required interval 500ms 5 controllers No 24 28 Controllers 0 8 and 16 can be used for the three 100ms update interval controllers and two of the five controllers 24 28 can be used as the 500ms update interval controllers Group 1 2 3 4 5 Group 2 10 11 12 13 Group 3 18 19 20 21 Group 4 26 27 28 29 Mode W GM 0 8 16 etc gives the control program the following information Controller not in use Controller in automatic mode Controller in automatic inverted mode Controller in manual mode le FF Automation Oy AL 2000 User Guide Page 6 5 06 05 00 6 3 Three Point Controllers There are 32 three point controllers available Controllers 16 23 24 31 Control interval Pulse interval Valve closing bit Valve opening bit Controller parameters are stored in W GM 0 255 Controller Controller Controller Controller 0 1 2 31 8 16 Mode Actual value Set point D time 100ms time 100ms Gain term Output Aux WDM 6 3 1 Control Algorithm The control
151. vailable baud rates 218 set SER data configuration 8 N 1 The slave address can be from 1 to 255 If the PLC operates as a slave unit on two or three serial lines the slave address is the same for all slave channels Address 0 is reserved for broadcast messages A slave cannot have this address FF Automation Oy 4 6 AL 2000 User Guide 06 05 00 4 4 Using MODEMs with MODBUS AL2000 RS 232 Serial channels supports modem control status signals Bit 0 Bit 1 Bit2 Bit3 bit4 Bit5 Bit6 Bit7 SERI O system program RTS DTR DSR RI DCD CTS ROS7 controls RTS to modem to modem from modem from modem from modem from modem SER2 1 user controls RO 58 RTS amp DTR Two wire carrier MODEMs are normally used on standard dial up telephone lines MODEMs which conform to the following CCITT recommendations are suitable for use with the AL2000 system V 22 1200 baud V 22bis 1200 2400 baud V 32 4800 9600 baud Using an auto dialing MODEM which recognises AT instructions remote AL2000 units can dial up and send data to a supervising computer The PRT instruction is used to dial telephone numbers PRT 90844992 CR The MODEM reports a connection using the CONNECT response For the specific for mat of AT instructions consult the MODEM manual Data transfer rates of over 1200 baud using telephone lines can give rise to frequent er rors If PRT instructions are used to tran
152. value set in the program will be used When the PLC is switched on all counters are at zero BA RA WA Variable Affected No No Yes Example Delay of 100 seconds made with a counter 0 LOAD Tnd Operation If the bit accumulator is 1 timer n is loaded with the initial setting d After the instruction the bit accumulator contains the status of the timer 1 timed out 0 running A setting can be defined for the timer with the programming device If itis non zero it will be used if it is zero the time set in the program will be used When the PLC is switched on all timers are at zero BA RA WA Variable Affected Yes Yes No Yes Example STR NI 0 00 LOAD T 008 100 100 second delay EQ 1 00 from input 0 to output 0 LOAD T Cn Operation If the bit accumulator is 1 timer counter n is loaded with an initial setting equal to the contents of the register accumulator After the instruction the bit accumulator contains the status of the timer counter A setting made with the programming device or computer has no effect when this instruction is used BA RA WA Variable Affected No No Yes Example Delay from input to output set via register memory FF Automation Oy 11 26 12 12 2000 AutoLog 2000 Instruction Manual LOAD Operation Affected Example MID Operation Affected Example If the bit accumulator is 1 move the contents of the
153. xcept MR3 mini must be equipped with its own power supply The 230 VAC power supply can be used with all mounting racks however the 24 VDC AC power supply can only be used with the MR5 mounting rack The external power supply cables are connected to the power connecting module and the power supply module generates the voltages required by the AL2000 Supply Power Connecting Power Supply Mounting Voltage Module Module Rack 230 VAC PCON230 POWAC MR5 MR11 MR16 24 VAC DC PCON24 POWDC 24 VAC DC PWR3 MR3 only 230 VAC The protective ground must be connected to the ground terminal on the mounting rack as shown below QD Screw M4x8 The left bottom corner of the AL2000 CAUTION In order to prevent electric shock disconnect mains supply before making any power connections FF Automation Oy E 5 2 06 05 00 AL 2000 User Guide 5 1 1 PCON24 Power Connecting Module The PCON24 is a power connecting module for supply voltages of 24VDC or 24VAC The PCON24 drives the POWDC 25W power sup ply module and can also supply an auxiliary voltage of 24VDC 0 8A for powering sensors or an AL32 PLC etc NOTE The PCON24 can only be used in the small MR5 mounting rack 20 32 VDC or 20 26 VAC Supply voltage POWER IN The supply voltage should be connected to these screw terminals Auxiliary voltage of 24VDC 0 8A is avail able for external use from these terminals AUX There are three fuse
154. y AutoLog 2000 Instruction Manual Page 11 41 12 12 2000 STR S NS d Operation If the current sequence register is not at step d the bit accumulator is set to 1 otherwise it is reset to 0 BA RA WA Variable Affected Yes No No Example STR When sequence register is at EQ step 24 125 is on STR R M O NM NO n Operation Reads the value of a register variable into the register accumulator BA WA Variable Affected No No Example Read contents of register memory 210 into register accumulator STR R Cd Operation Reads the constant d 0 255 into the register accumulator BA WA Variable Affected No No Example Store 19 decimal in register accumulator STR R Sn Operation Reads the number of the current step of sequence register n 0 31 into the register accumulator Register n is made the current sequence register i e subsequent sequence register instructions will affect it WA Variable Affected No Example When sequence register 2 is at step 29 output 5 is on STR Cd Operation Reads the state of variable n into the bit accumulator The accumulator is reset to 0 if d 2 0 for other values of d it is set to 1 WA Variable Affected No Example Initialize bit accumulator FF Automation Oy 11 42 AutoLog 2000 Instruction Manual 12 12 2000 Qn Operation Read the element whose position is given by the register accumulator of shift register n
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