OP--9001 Communications Master
Contents
1. DL405 CPU Base enO Q Power Supply OP panels Installing the Panel a Connecting a Power Supply to the OP 9001 Power Supply The OP 9001 panel can operate on DC voltages between 8 and 30 VDC rated at 3 75 watts Connections Connect the panel to a power supply within the required voltage range and wattage using the terminal block connector supplied The connector is polarized to prevent reversing the connections The male receptacle on the rear of the panel will only connect in one way with the female connector that is supplied with your OP 9001 panel Pin 1 is the positive connection while Pin 2 is the negative or ground connection You must use an external power supply that can deliver voltages in the 8 to 30 VDC range and can supply 3 75 watts of power i A two prong male connector is on the side of the unit GND Your OP panel is shipped with the female connector Install the connector to a cable for attachment to your power supply 3 4 4 r q 4 4 4 A 4 ower supply is not sold by PLCDirect Model Current Consumed at 12VDC Current Consumed at 24VDC OP 9001 0 31A 0 16A te Installing the Panel Pinout Diagrams for Cabling Connecting Cable2. The connecting cable may vary depending on the CPU used Refer to the following page to confirm the proper cable is chosen for connecting your PLC OP 2CBL PLC RJ12 PLC DB15 1 ov a RJ12 not use 3 3 Din 1 5 4 Dout 5 not used 6 notused 123456 pee a 2 not used 15 not used 3 2 14 not used 7 5 ec ae 13 not used 4 4 RTS 12 not used i PXD o 2 TXD 1 not used 9 not used RJ11 PLC DB15 2 7 1 Din RJ11 1 2 2 Dout 4 5 3 not used 4 0V 1234 DB15 PLC DB15 15 x 2 3 8 YOM O 15 tied 0V 7 CTS Ut 14 tied OV 37 2 6 not used o ST 13 tied OV 14 3 5 not used o eH 13 tied 0V j eo 14 A On line 2 12 not used 3 Din e gt 11 not used 19 e 10 not used 1 2 Dout nooruse 7 1 YOP oa 9 not used 8 13 not used 25 not used 12 notused gt 25 24 not used 11 not used o 3 23 not used DB25 PLC DBI15 Jonot used 2o 22 not used 2 3 3 21 not used E 2 A used 7 o 20 not used a 6 notused o 19 notused 5 5 CTS Er HS ah fee 4 RTS e not use 3 Din 6 16 not used 2 Dout o 15 not used 1 not used 14 not used 8 Pin Mini DIN DB15 CNA 3 Di 7 3 ead 2 5 12 5 0V RS 422 Pinout PLC Panel Din 11 Dout Din 12 Dout Dout 9 Din Dout 10 Din OV 5 0V RTS 4 CTS RTS CTS RJ12 6P6C DB15 OP 2CBL
3. r I O of machinery and processes 1200 to 19200 baud RS232 or RS422 OP 9001 dew a Powe r OM9001 Communications Master Supply 19200 baud R3424 19200 baud RS422 OP 1124 OP 1510 DIP switch is set to Address 01 Base Addr V40600 DIP switch is set to Address 02 Base Addr V2000 DIP switch is set to Address 03 Base Addr V2010 Consumes Consumes Consumes V40600 V40603 V2010 V2017 V2000 V2007 i 64 bits 128 bits 128 bits Power Power Supply 1 Supply Power Introduction za Using the Communications Master 5 Easy Steps Step 1 Plan Your In the next section we provide you with a template for System of Panels planning your multi panel OptiMate system It s main Pages 4 7 purpose is to have you plan in advance what base register addresses you want to use for each panel and to make sure that the consecutive bits consumed by each panel during the mapping process do not overwrite each other You need to know this information when you do the configuration in Step 3 Step 2 Install the Preparing for installation you will want to Cables Panels and the chec
4. y Baud Rate 9600 Parity Odd Stop Bits 1 PLC Timeout 0 3 PLC Address 1 OptiMate Config Editor Ver 2 00 K Sequence 205 Direct Net 305 Direct Net 405 PLC Direct by Koyo Intelligent Peripherals For Controls PLC Direct by Koyo Optimation Inc Intelligent Peripherals For Controls Address Base Reg Optimation Inc K Sequence 405 Address F1 Help ESC Exit T Configuration of the Panel e If you are using a PLCDirect or PLC Modell Port Baud Rates Parity StoP Set the Baud Rate compatible programmable controller Bit Parity and Stop Bits with your OP 9001 you can use the DL230 240 Top 9600 Odd chart shown on the right to help you Bottom DL240 only 1 select the proper baud rate parity and 1200 9600 19 2k Odd None stop bits Odd None 1 U 1200 9600 19 2k If you are using an Allen Bradley SLC 5 03 or 5 04 you must select either 4800 or 9600 baud Your Allen Bradley Bottom i configuration software shows a default 1200 4800 9600 19 2k None baud rate of 1200 so you must change DL430 440 Top 9600 Odd this You must also be connecting Bottom 1 through Channel 0 the bottom serial 1200 9600 19 2k Odd None port and be set to DF 1 full duplex DB15 9600 Odd Top 1200 4800 9600 19 2k None DB25 1200 4800 9600 19 2k Odd None 1 RJ1
5. 8 14 Remember that you must use address 31 only when communicating with a computer for uploading or downloading The letter T in position 6 stands for terminal resistor The final panel in a multi drop panel configuration should have this position turned ON NOTE Each time you change the DIP switch setting you must power cycle the panel Setting the Jumper There is a jumper terminal on the edge of the OP 9001 located between the cable connector of the OP 9001 and the power supply connector This jumper must be in place in order for the OP 9001 to communicate with your computer for downloading or uploading configurations You must remove this jumper when you want the OP 9001 to communicate with your PLC To communicate with your computer jumper in place To communicate with your PLC jumper removed Cg ELLE 2000000 e 16 Configuration of the Panel Configuring Multiple Panels with the OPEditor You configure multiple panels by loading the OPEditor software on a personal computer and selecting the appropriate options The setup options for your system configuration such as type of PLC being used communications protocol and the type of panel being used are handled through an on screen dialogue PLC Direct by Koyo System In order to use the OPEditor software you must have the following components Requirements e IBM 386 or better compatible computer e VGA or SVGA video board and col
6. Consumes V2000 V2007 DIP switch is set to Address 03 Base Addr V2010 Consumes V2010 V2017 Base Addr V40600 Consumes Power Supply Planning Your Memory Mapping Memory Consumption for Mapping Process NOTE For PLCDirect and compatibles remember that the V Memory and R Memory addresses are numbered in octal not decimal For example V2007 and V2010 are consecutive registers V2008 and V2009 do not exist OP 1124 Consumes 64 consecutive bits 4 sixteen bit registers DL205 DL405 and A B 8 eight bit registers DL305 only OP 1224 Consumes 128 consecutive bits 8 sixteen bit registers DL205 DL405 and A B 16 eight bit registers DL305 only OP 1312 Consumes 224 consecutive bits 14 sixteen bit registers DL205 DL405 and A B 28 eight bit registers DL305 only CEEE asass DOUCE Consumes 128 consecutive bits 8 sixteen bit registers DL205 DL405 and A B 16 eight bit registers DL305 only OP 1510 m m a rT Data Registers DL205 DL405 DL305 A B Function m 1 2 1 Lamps 1 16 ON OFF m 1 1 2 1 Lamps 17 24 ON OFF m 2 1 2 1 Lamps 1 16 flash m 3 1 2 1 Lamps 17 24 flash
7. a ee ag D to the System select Add Panel to the System PE ERE a Then press the lt Enter gt key a Panel in The SAEN ae eee Print System Highlights Print System Details Download To Master Save System To Disk Save As F1 Help ESC Exit J 29 Configuration of the Panel Step 8 Select the Panel to be Configured or Upload an Existing Panel Configuration Step 9 Download the Configuration to the Respective Panel Step 10 Assign a Unique Panel Address If you have previously configured an OP panel as a single panel and now you are including it in a multi panel system select Get Configuration from Panel If you have no existing configuration and you are now adding a panel that must be configured move the selector bar to the appropriate model name Then press the lt Enter gt key Each panel has to store its own configuration Consequently each time you finish a configuration connect the respective panel then set its DIP switch to address 31 for downloading All the slide switches representing weighted decimal digits are turned to the ON position in order to indicate address 31 Switch found on OP panels gt Address 14 4 2 44 8 16 31 938r7cl So that the OP 9001 can distinquish one panel from the next you must assign a unique address in the range of O through 30 to each panel via its address dip switch Make
8. panel initial setup requirements and much more How the OP 9001 Communicates PLCDirect DL205 or DL405 family DIP Switch for setting addresses ON T termination resistor Numbers with ON positions are added together Above example shows Address 05 14 4 5 aa Introduction The OP 9001 communicates with your OptiMate panels via two RS422 ports at a baud rate of 19200 It communicates with your PLC at the rate you indicate during configuration Depending on brand and model of PLC this will be some rate between 1200 and 19200 baud Later on in this manual we will show you how to select the communcation baud rate between your OP 9001 and PLC This is done with the same OPEditor software that you use to configure the individual OptiMate panels The OP 9001 knows which OptiMate panel is sending information to it because each OP panel has a unique address assigned via its respective DIP switch You can have up to 31 panels connected to a single OP 9001 Addresses 0 thru 30 are available for this purpose See the diagram below for more about DIP switch settings Shown below is a sample configuration using a PLCDirect programmable controller a pushbutton panel OP 1224 a lamp annunciator panel OP 1124 and a menu driven operator panel OP 1510 Notice that each panel has a unique address and that each panel has been assigned specific memory inside the PLC for the purpose of mapping your configurations
9. 1 OP 3CBL RJ11 DB15 OP 4CBL 1 OP 4CBL 2 OP ACBL 2 9 not used 10 not used 11 not used 12 not used 13 not used 14 not used 15 not used CO0 0 0 DB15 1 not used 2 Dout 3 Din 4 not used 5 0V 6 not used 7 not used 8 not used Choosing Your Connecting Cables Depending on which PLC you are using you may require as many as two cables Here are the requirements e OP ACBL 1 all units require this cable for configuration This is a 9 pin female to 15 pin male cable that connects your personal computer to the OP panel This cable is also used to connect an OP panel to the Allen Bradley SLC 500 CPUs listed e CPU Cables You will also need the appropriate cable to connect your CPU to the OP panel Use the chart shown to the right to choose the correct communications cable requires RS232 Data Communications Unit D3 232 DCU kk g also DC versions Installing the Panel DL105 GE Series 90 30 All Models 311 351 RS232 RS422 OP GCBL 1 Serial Port GE Fanuc All Models RS232 RS422 OP GCBL 1 Series 90 Micro Serial Port SIMATIC T1305 SIMATIC T1405 435 CPU PPX 435 CPU La Installing the Panel Custom Cables for Connecting Panels to the OP 9001 You must build your own cables for connecting the
10. 4 Select the Source for your Configuration 0 cece eee Step 5 Enter the Correct PLC Brand and Type 00 c cece eee eens Step 6A Select Configure Protocol and the PLC Subtype unnn eee eee eee Step 6B Set the Baud Rate Parity and Stop Bits 20 0 cece ee Step 6C Set the TIMGOUE 5 2 3 2 4 ioe eas oa barevsg oes Gi er ee ae beaneRN sheer w ees Ea ed Step 6D Set the PLC Address for the Port Used 0 00 cece cece teen eens Step 7 Add the Panel to the Systema Sota ates wey MeuGee ad even a hen Shoe ae Step 8 Select Panel to be Configured or Upload Existing Panel Configuration Step 11 Repeat Steps 8 10 for each OP panel 0 ccc cece Step 12 Download the System Configuration to the OP 9001 cece eee Troubleshooting Observing the LEDs on the OP 9001 0c ccc cece cece teen teen eens Requesting Data from PLC But No Response cece cece cece e eee eeaes OP 9001 Not Communicating Properly with the Panels 0 0 00 cece eee eee Trouble Communicating with Computer During Configuration 00 2c eee eee Sections Introduction pT This table provides an overall description of the topics covered within this manual Introduces the physical and functional characteristics Also provides 7 introduction to planning your system 1 Introduction j ARST
11. be individually configured for all of its features You will have to repeat Repeat Steps 8 10 for Steps 8 thru 10 for each panel you add to your system Notice that as you add panels to your each OP panel configuration they are shown on the righthand side of your screen along with the panel address and the base register address Each panel requires certain blocks of consecutive memory for its mapping process and you must be careful in assigning the base register addresses In our Memory Planning section of this manual we presented you with a table that shows the consecutive memory requirements for each panel and PLC combination Assign a base register address that will not conflict with the other panels by overwriting their configuration Keep in mind as you refer back to the individual User Manuals for each OptiMate panel the configuration examples were based on single panel systems that had to communicate directly with the PLC For this reason they are setup in a single panel scheme using the communications protocol of the PLC For example you use K sequence or DirectNET for the PLCDirect and compatibles The communications protocol for multi panel systems will always be set for OptiMate HEX except for the OP 9001 communications master The panels do not talk to the PLC directly they talk instead to the OP 9001 communications master Step 12 When you have completely finished OptiMate Config Editor Ver 2 00 g Oa D
12. fuse rated for 1 ampere Table of Contents Introduction Is this Manual Right for You z sccc cease ae dieeiee vedi oes okie ews we eden cesar Menu dies Additional Manuals S rse a a a gp eaae aae es SG nee a oa T Sod a rere a is gee How the OP 9001 Communicates 0 0 00 00 eee eee eee eens Using the Communications Master 5 Easy StepS cece eee e eee eee ees Step 1 Plan Your System of Panels Pages 4 7 0 00 cee Step 2 Install the Panels and the OP 9001 Pages 8 16 cee eee eee ee Step 3 Configure the System and the Individual Panels Pages 17 22 Step 4 Download the Configurations to Each Panel Page 21 cece Step 5 Download the System to the OP 9001 Master Page 22 0 eee ee eee Planning Your Memory Mapping Memory Consumption for Mapping Process 0 cce eee e ee eee eee eee eee eens Using a Memory Planner iiicidccs cece aes ceeinee ee ieees cee e eer eee aan Installing the Panel Panel Specifications ouea see Ske oes Vee ei ee Se eh ag bk Physical Specifications ses sse sau eeee cee eae suk EEEE EUNE AGRA Reese TOSE eee tes CPUS S Upported n eiaeaen hee cca Atte aie aaah cao et ton Sed arm de a at decane ERRER Environmental Specifications 0 cece ene eee eens Operating Specifications fs ccccm acne thy aeteties e E Oe a ers ee ee aie a ee eee DIMENSI NS iieii earth a shrek 0 eee cask ota Pena cheese aan a a cao aria
13. multiple panels to your OP 9001 Since the proper cable choice really depends on your application we offer the following connectors For electrically noisy environments we recommend a good shielded cable such as Belden 9729 or equivalent This type of cable will require the solder type connectors If you re going 30 feet or less you can use ribbon cable For ribbon cable we recommend Belden 9L28015 or 3M 3365 15 See the chart below for more details concerning the Belden cable e OP CMCON 1 pack of 4 ribbon cable connectors e OP CMCON 2 pack of 4 solder type connectors Ribbon cable with DB15 male connectors attached Panels can be connected directly to the OP 9001 ports or be daisy chained to other OP panels OP 9001 Power Source Belden 9729 Specifications No twisted pairs 2 Power Supply Nom Impedance ohms 100 Nom Capacitance pF m 41 Wire Gauge AWG 24 OP panels Note Panels can be located as far away as 4000 feet from the OP 9001 when using shielded cable Belden 9729 or equivalent Flat ribbon connections can be used for a distance of 30 feet maximum For ribbon cable we recommend Belden 9L28015 or 3M 3365 15 Notice in the diagram below that the receive and transmit lines are wired straight through for each of the panels connected to the OP 9001 For example pin 9 of the OP 9001 is the Tx line and pin 9 of the panel is the Rx line This keeps you from having
14. to twist cable wires The matchup between Tx and Rx is handled internally by the OP 9001 Ribbon or Shielded Cable 1 OP 9001 o o o ojojojo jo 9 Rx 15 10 Rx 11 Tx 1 12 Tx Panel 2 12 Tx Panel 3 12 ooo ooo0oo0o0000 1 Installing the Panel Setting the Panel DIP Switches and OP 9001 Jumper Assigning Addresses A6 position DIP switch on the rear of each individual panel allows you to assign a hardware to the Panels address to your panel Each panel must have a unique address You can use any address Connected to the between 0 and 30 when communicating between a panel and the OP 9001 Master OP 9001 Communications panel Address 31 however is reserved See the note that follows NOTE You must use Address No 31 when you are using the OPEditor software to download or upload your panel configurations to each individual panel Switch On SW1 Position 12l als lel v Address Value 1 2 4 helr a ON ENABLE OFF DISABLE ol ez How to Set the To set the address on any of the individual panels so that they can communicate with the Operator Panel OP 9001 simply set the apppropriate switches on the dip switch to the desired address The Addresses figure below shows the binary weighting of each switch position Notice that it is in decimal format To select address 14 for example you would press switches 2 3 and 4 down to the right and switches 1 3 and 5 to the left 2 4
15. 2 1200 4800 9600 19 2k Odd None Step 6C When the OP 9001 sends a message to the PLC and either does not receive a response or Set the Timeout does not understand the response it will wait the timeout period before resending the message The default timeout period is 0 3 seconds You can change this if you like The range is from 0 2 seconds to 25 5 seconds Step 6D Each PLCDirect or compatible has OptiMate Config Editor Ver 2 00 SE a OS Bite eh Cehe Set the PLC Address addresses associated with its Sub Type Direct Net 205 as for the Port Used communications ports Some port Bariy Odd Optimation Inc addresses are fixed and some are PLE Timeout 0 3 Iiaitgeri keener ra conii configurable Check your respective PLC User Manual for the address available for the port connected to your OP 9001 Make sure your OPEditor setting matches the number assigned to the port For Allen Bradley SLC 5 03 or 5 04 you must connect to Channel 0 the bottom ae raa serial port set for DF1 full duplex You can set the PLC address to any number in the range of O through 255 using the A B software Make sure the OPEditor setting matches the A B configuration The default is PLC Address 1 Step 7 Since this is the first time that you are OptiMate Config Editor Ver 2 00 g Om Bi tkcelm ey as CA 40 Add the Panel configuring a multi panel system
16. DA Quebec 1 800 463 3627 Ontario Manitoba 1 800 263 4961 Western Canada 1 800 445 7266 Step 6A Select Configure Protocol and the PLC Subtype Select Configure Protocol Here we are selecting the communications protocol that will be used between the PLC and the OP 9001 This will take you to another screen that gives you a selection of PLC Subtype The default subtype for PLCDirect is indicated In this example shown the default is Direct Net 205 To change this press the lt Enter gt key Select the desired protocol for the CPU subtype that you are using Refer to the appropriate CPU User Manual for the correct protocol corresponding to the communications port you are using Make sure your choice here matches the CPU port into which you will actually be connected On some PLCDirect models one port is K sequence and another may be DirectNet On others you may only have one protocol available a Configuration of the Panel Step 4 When you select Multi Panel Select the Configuration another menu appears OptiMate Config Editor Ver 2 00 MEA EAER eohas Source for your that allows you to choose from the Read Sysiem From Disk 8 Configuration following actions Interrogate Master Optimation Inc Configure A New System Intelligent Peripherals For Cont
17. Data Registers DL205 DL405 DL305 A B Function n 1 2 1_ Pushbuttons 1 16 ON OFF n 4 1 2 1_ Pushbuttons 17 24 ON OFF n 2 1 2 1 LEDs 1 16 flash n 3 1 2 1 LEDs 17 24 flash n 4 1 2 1 LEDs 1 16 ON OFF n 5 1 2 1 LEDs 17 24 ON OFF n 6 1 2 1 Force Function Data 1 16 n 7 1 2 1 Force Function Mode Data 17 24 Data Registers DL205 DL405 DL305 A B Function p 1 2 1 Location 1 data p 1 1 2 1 Location 2 data p 2 1 2 1 Location 3 data p 3 1 2 1 Location 4 data p 4 1 2 1 Location 5 data p 5 1 2 1 Location 6 data p 6 1 2 1 Location 7 data p 7 1 2 1 Location 8 data p 8 1 2 1 Location 9 data p 9 1 2 1 Location 10 data p 10 1 2 1 Location 11 data p 11 1 2 1 Location 12 data p 12 1 2 1 Force data flags p 13 1 2 1 Data to be forced Data Registers DL205 DL405 DL305 A B Function q 1 2 1 Top line message selection q 1 1 2 1 Bottom line message selection q 2 1 2 1 Top line data menu function n 3 1 2 1 Decimal point top line q 4 1 2 1 Bottom line data q 5 1 2 1 Decimal point bottom line q 6 1 2 1 Status register q 7 1 2 1 Control register q 2 holds Function Number for the OP 1510 only See OP 1510 M manual o ae Planning Your Memory Mapping Using a Memory Planner On Page 7 we have included a template for planning your memory mapping in a multi panel configuration The following example shows the memory requirements and assignments for three OP panels connected to a DL405 programmable control
18. Explains memory mapping in a multi panel configuration 2 Memory Mapping Shows how to prepare for system installation including specifications and 3 Installation and mounting instructions Includes connecting cables part numbers and Specifications specifications 4 Configuring Your Panels Shows how to configure the panel The OP WINEDIT for windows contains Help windows which will assist with configuring the panels 5 Trouble Shooting Shows you how to diagnose and correct common problems Introduction Is this Manual Right for You Additional Manuals The OP 9001 Communications Master provides an intelligent interface between your programmable controller PLC and two or more OptiMate panels This manual shows you how to install configure and operate your OP 9001 Communications Master It includes wiring diagrams and power requirements as well as the information you need for selecting the proper connecting cables OP 9001 Power Source DL405 CPU Base T OMFOD Communications Master Power BRY 8 to 30 VDC OptiMate Panels There are several other manuals you will find helpful or necessary e Respective PLC User Manuals Shows you the memory conventions programming instruction sets data or file types communications protocol etc e Respective OptiMate operator panel User Manuals Shows you the memory mapping requirements modes of operation ladder logic needed for operation of the respective
19. OP 9001 Communications Master Manual Number OP 9001 M WARNING Thank you for purchasing automation equipment from PLCDirect We want your new DirectLOGIC automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time Itis your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the latest revision of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for your product design installation or operation If you have any qu
20. ake sure its setting matches the setting you indicated in your configuration Remember also that no two panels can have the same setting 2 If Step 2 checks out OK then make sure the panel is set for Optimate HEX protocol If Step 3 is OK then check your cabling 4 Make sure that any DIP switch setting changes have been followed by a power cycle of the panel You must turn the power OFF then ON for the new setting to take place Here are some common causes of this problem 1 The OPEditor is a DOS program you cannot shell out of Windows or try to run the OPEditor from Windows Make sure you have completely exited Windows before trying to do your configuration 2 In some rare cases you may have a TSR or a device driver that is conflicting with the OPEditor communications To check this if you are using MS DOS 6 0 or above press the F8 key when you see the message Starting MS DOS on the screen This allows you to decide line by line for your CONFIG SYS and AUTOEXEC BAT files whether or not you want certain drivers or TSRs to be loaded We suggest that you only load HIMEM SYS in your CONFIG SYS file and you not run the AUTOEXEC BAT file at all After your system loads HIMEM SYS and then you are asked if you want to run your AUTOEXEC BAT say NO You will then be given a DOS prompt Change to your OPEditor subdirectory by typing CD C OP or whatever alternative path and subdirectory is applicable Once you are in your OPEdit
21. ed if this equipment is used in a manner not specified in this manual Only replacement parts supplied by PLCDirect or its agents should be used A listing of international affiliates is available at our Web site http www picdirect com If you need technical assistance please call the technical support group at PLCDirect 3505 Hutchinson Rd Cumming GA 30040 U S A at 800 633 0405 They are available Monday through Friday from 9 00 A M to 6 00 P M Eastern Standard Time Their Web Site address is http www plcdirect com All electrical circuits connected to the communications port receptacle are rated as Safety Extra Low Voltage SELV Operating Temperature 0 0 to 50 C Storage Temperature 00005 20 to 70 C Operating Humidity aaaea 95 non condensing Air Composition 0 00 0 cece eens No corrosive gases permitted No preventative maintenance is required To clean the exterior of the panel disconnect the input power and carefully wipe the panel with a cloth moistened with plain water There are no internal fuses for the input power circuits so external circuit protection is needed to ensure the safety of service personnel and the safe operation of the equipment itself To comply with EU specifications the input power must be fused Use a fuse rated at twice the input current rating of the panel For example if the panel has an input current rating of 0 5 amperes use a
22. ee ee ee nees Removable Terminal Block 2 position Absolute Maximum Voltage 32 VDC Diagnostics 0 0 0 e eee eee ee Power On CPU Communication Link 00 eee RS232 or RS422 4800 9600 and 19200 baud 15 pin female D type connector Only 4800 and 9600 baud will work with Allen Bradley PLCs e Installing the Panel 9 Dimensions All dimensions are given in inches 8 2 gt l 1 Power Connector RS232 RS422 Port To PLC we 9 3 p as aay J J7 O em OM9001 Communications Master 3 5 5 2 Opti Mate O J1 J2 Sa i Bos g7 0 RS422 Ports To Single or Multiple Drop panels a 8 2 _ J 0o o Installing the Panel Power and Cabling Requirements What Are Your Application Needs By using an OptiMate OP 9001 Communications Master you can connect multiple Optimate units up to a single CPU Up to 31 individual units can be connected in a daisy chain fashion to the OP 9001 Communications are via RS422 between the OP 9001 and the operator interfaces If you use a good quality shielded cable you can have a total distance of up to 4000 feet between the OP 9001 and the last operator interface unit in the chain If you only have a short distance up to 30 feet you can use ribbon cable and easy to install crimp on ribbon connectors OP 9001 Power Source fi
23. es not exist for your PLC OP 9001 Not Communicating Properly with the Panels Trouble Communicating with Computer During Configuration Planning Your Memory Mapping es 3 Ifyou are using a PLCDirect or compatible PLC make sure the PLC portis set to HEX If you don t have the port set to HEX the LED may indicate that everything is OK but in fact no communication between the OP 9001 and the PLC is taking place 4 Ifthe baud rate and memory allocation seem to be OK perhaps your cable is bad If you built your own cable check the pinout specifications on Page 12 The LEDs on the bottom edge of the OP 9001 are used to troubleshoot communication between the OP 9001 and the panels The OP 9001 should be sending requests green to the connected panels and receiving responses red When the OP 9001 and the panels are communicating correctly the LED indicators on the OP 9001 should flicker constantly or appear to glow amber and the LEDs on the panels should barely flicker The amount of flicker will depend upon how may panels you have connected to the OP 9001 Fewer panels mean less flicker If the OP 9001 is not communicating properly here are some things to check and correct if necessary 1 Check the LEDs on the back of each panel These LEDs should glow red when receiving requests and glow green when sending data to the OP 9001 If any one of the panels is not communicating check the DIP switch on the back of the panel and m
24. estions concerning the installation or operation of this equipment or if you need additional information please call us at 1 800 633 0405 This publication is based on information that was available at the time it was printed At PLCDirect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product Trademarks This publication may contain references to products produced and or offered by other companies The product and company names may be trademarked and are the sole property of their respective owners PLCDirect disclaims any proprietary interest in the marks and names of others Stage is a trademark of Koyo Electronics Industries Co LTD Think amp Do Software is a trademark of Think amp Do Software Inc Texas Instruments is a registered trademark of Texas Instruments Inc TI TIWAY Series 305 Series 405 T1305 and T1405 are trademarks of Texas Instruments Inc Siemens and SIMATIC are registered trademarks of Siemens AG GE is a registered trademark of General Electric Corporation Series One is a registered trademark of GE Fanuc Automation North America Inc MODBUS is a registered trademark of Gould Inc IBM is a registered trademark of International Business Machines MS DOS and Microsoft are re
25. f the panel If you later want to add remove or modify a panel configuration you can do so by merely selecting any of these options from the above menu You can also print the system highlights or the detailed version of your configuration by clicking on these menu options By using Save System To Disk or Save As options of the menu you can also make sure you have a backup copy of your configurations panel or system stored somewhere besides in a panel or the OP 9001 Gee Planning Your Memory Mapping Troubleshooting Observing the LEDs The steps shown below explain how to use the built in communication LEDs to make sure the communications of your configuration are working properly on the OP 9001 Requesting Data from PLC But No Response 1 2 Make sure you have downloaded your system configuration to the OP 9001 and that you have downloaded the panel configurations to each respective panel Remove the jumper from the OP 9001 and make sure all of the dip switch settings on your individual panels are set to unique addresses These addresses of course must be the same panel addresses you assigned during configuration Attach the cable from the PLC to the OP 9001 Attach the cabling between the OP 9001 and the multiple panels Apply power to the PLC the OP 9001 and all of the respective panels Make sure anytime you remove or replace the OP 9001 jumper that you also power cycle the OP 9001 Power cycle means to turn
26. gistered trademarks of Microsoft Corporation Windows and Windows NT are trademarks of Microsoft Corporation OPTOMUX and PAMUX are trademarks of OPTO 22 Copyright 1998 PLCDirect Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of PLCDirect Incorporated PLCDirect retains the exclusive rights to all information included in this document Manual Revisions If you contact us in reference to this manual remember to include the revision number Title OP 9001 Communications Master Manual Number OP 9001 M Original 2 96 Cover Copyright Original Issue Contents Manual Revisions 1 23 Index Rev A 6 98 Downsize format Made minor corrections before reprinting EU Information This product is manufactured in compliance with European Union EU Directives and carries the CE mark The following information is provided to comply with EU documentation requirements Technical Support SELV Circuits Environmental Specifications Preventative Maintenance and Cleaning External Fuse Protection for Input Power NOTE Products with CE marks perform their required functions safely and adhere to relevant standards as specified by EC directives provided they are used according to their intended purpose and that the instructions in this manual are adhered to The protection provided by the equipment may be impair
27. h parallel port LPT1 or LPT2 to use for printing your configuration Next you must press lt ESC gt to return to the first screen again Here you will need to select Multi Panel Configuration Even though you will be configuring each individual panel as well as the OP 9001 it is all done through this Multi Panel Configuration path You do not use the Single Panel Configuration for any reason when you are configuring a multi panel system OptiMate Config Editor Ver 1 11 Single Panel Configuration Multi Panel Configuration Interrogate Master PLC Direct by KOYO USA 1 800 633 0405 CANADA Quebec 1 800 463 3627 Ontario Manitoba 1 800 263 4961 Western Canada 1 800 445 7266 F1 Help ESC Exit OptiMate Contig Editor Ver 1 11 Select Com Port COM2 In Use Select Printer Port LPT1 In Use PLC Direct by Koyo Optimation Inc Intelligent Peripherals For Controls PLC Direct by KOYO USA 1 800 633 0405 CANADA Quebec 1 800 463 3627 Ontario Manitoba 1 800 263 4961 Western Canada 1 800 445 7266 F1 Help ESC Exit OptiMate Config Editor Ver 1 14 P Dire Oyo Editor Setup Single Panel Configuration Multi Panel Configuration Interrogate Master F1 Help ESC Exit PLC Direct by KOYO USA 1 800 633 0405 CANA
28. iikcem ey ChS Download the configuring every individual panel pre rype PLc pirea a System belonging to your system you are then Scnlsits Protocol Optimation Inc Configuration to the ready to download the overall system to Remove panei rom System Intelligent Peripherals For Controls Modify Panel In The System A OP 9001 your OP 9001 panel Don t forget to place vores rint System Highlights the downloading jumper on the OP 9001 Print System Details You access this through the edge of the Save System To Disk panel When you are finished downloading Sone you need to remove the jumper before the OP 9001 can communicate with the PLC Make sure also that you have reset the DIP switch on the OP panels to match the unique address you gave them during configuration F1 Help ESC Exit Do not leave the panels set to address 31 or otherwise the OP 9001 will not be able to communicate with them If you want to download your system to a disk or save it as a file you will notice the last two options on the above dialogue allow you to do just that It is a good idea to always store your configuration on your hard drive or a floppy as well as download it to the OP 9001 NOTE Remember that you must have the download jumper in place in order to download the system from the computer to the OP 9001 The jumper is located between the DB15 connector and the power supply connector on the open edge o
29. jumper on the OP 9001 Set the Jumper for Downloading Lae Planning Your Memory Mapping Planning Your Memory Mapping When using more than one OP panel in a system it is important that you plan ahead to make sure the memory mapping for one panel does not overwrite the memory mapping for another panel Let s take a look again at a typical system Notice that each panel shown consumes a fixed amount of memory for its mapping For example The OP 1124 needs 64 consecutive bits the OP 1224 needs 128 consecutive bits and the OP 1510 needs 128 consecutive bits When you are planning your system you have to make sure that your panels don t compete for the same memory space To help you with this process we have given you a memory assignment template on Page 7 We have also included a chart on Page 6 that shows you the memory requirements for each of the currently available OP panels O of machinery and processes PLCDirect 1200 to 19200 baud RS232 or RS422 DL205 or DL405 family OP 9001 djam oe ge Li Power OM900 Communications Master Supply ee De Stes 19200 baud RS422 OP 1124 OP 1510 mm SS Se 0 2 Bs Opt Mar a DIP switch is set O to Address 01 DIP switch is set to Address 02 Base Addr V2000
30. k the individual specifications These OP 9001 include dimensions power requirements Pages 8 16 cabling requirements and NEMA ratings We include information you will need for mounting r i e cutout dimensions cabling requirements components needed etc This manual includes only the specifications for the OP 9001 Review the individual OptiMate User Manuals for each respecitive panel used External Power Step 3 Configure the You need the OptiMate OPEditor I and the software in order to configure the OptiMate ndividual Panels system and all the individual panels Suni ese Pages 17 22 At the time of publication we have a Baio Version 1 11 2005 DOS version with the introduction of a Windows version due in early 1996 This software is the same regardless of whether you are connecting to a PLCDirect or Allen Bradley product Step 4 Download the As you configure the OP 9001 for a multi panel Configurations to system you will be configuring each panel as a part Each Panel of the overall configuration process After each panel Page 21 is configured you will then download the configuration to the individual panel Step 5 Download the After all the panels have been downloaded System to the with their respective configurations you then OP 9001 Master download the overall scheme to the OP 9001 Page 22 itself This requires that you set a
31. ler Refer to the chart on Page 5 to find out how many registers of consecutive memory are required for each panel Memory does not have to be consecutive between the various panels DL405 5 OP Panel Memory Planner 1 PLC Address for OP 9001 OP 9001 tw OP 1124 OP 1224 OP 1510 Panel Original Mapping Remapping Name 7 Base Final Word z A p kideen PETRE Relationship Function OP 1124 Y40600 Y40603 OP 1224 2000 V2007 2000 V 40600 V2001 440601 OP 1510 Status Register v2017 40603 Control Register 2016 v 40602 Notice that we have remapped some addresses to take advantage of select features that require individual bit manipulation We have kept things simple here to make the example easy to understand For the OP 1224 for example we have only remapped the pushbuttons and have elected not to use some other features that would require remapping i e LED separation force function etc On the other hand we have remapped the status and control registers of the OP 1510 By thinking out memory allocation for the original mapping and remapping we can prevent possible memory overlap in either area Refer to your respective OP panel User Manuals to dete
32. n aaa she o e Rael Power and Cabling Requirements 0c eee e eee eee eee eee eee eee e eee eens Assessing Your Application Needs 00 cece teen eae Connecting a Power Supply to the OP 9001 cece eee eee eee eee eens Power Supply Connections 2 ic e0eevace i sere ee ee el eve ee ere ea See Pinout Diagrams for Cabling 2c 22 sc0c ebeiesaecteaeees cet eeasesea sees eteiaeeense Choosing Your Connecting Cables 0 2c cece cece cece eee eee eee eee eeeeeee Custom Cables for Connecting Panels to the OP 9001 0c cece eee eee eee eens Setting the Panel DIP Switches and OP 9001 Jumper e eee cece eee ee eens Assigning Addresses to the Panels Connected to the OP 9001 0 cece eae How to Set the Operator Panel Addresses 0 0 cece cette eee e eens Communication LED Indicators 00 cc cece eee eee eee eee WBWWWW WN La Table of Contents Configuring Multiple Panels with the OPEditor System ASQUIFGINGIMNS seres tierie aw eo wim Kawi s ne bee HORE he a E eels he eo awed How to Install seasea adda ee tae ee aed Get ea aed E R OEE Step by Step Procedure 2 2 cic eee ee Se eee ee Se en eae wee eee bee oe ene ee eee wes Step 1 Load the OPEditor and Complete the Editor Setup 00 cee ee eee Step 2 Select the LPT and COM ports 0 0 0 c cece eee teens Step 3 Select Multi Panel Configuration 0 0 cece teen ee Step
33. or monitor e DOS 5 0 or higher and 3 1 2 disk drive e Atleast 1 meg of hard drive space and 1 meg of RAM At the time of publication of this manual we are providing a DOS version of the OptiMate OPEditor configuration software In early 1996 Optimate we will have a Windows version available oye crane Editor sion 1 11 2 95 OMCFGO1 There is only one installation disk for this software You must have a 3 1 2 inch drive in order to install it We suggest you make a backup copy of this disk before making the installation How to Install Here are the easy steps for successful installation of the software 1 Insert the disk in the 3 1 2 floppy drive of your computer 2 Fromthe DOS prompt execute the INSTALL EXE file For example if the disk is in drive A and you are logged onto your hard drive type the following EEE A install press lt Return gt 3 You will be prompted to accept the default directory C OP or change it Make the choice and press Enter 4 The software will automatically insert files in the directory you have named These will use about 400 kilobytes of hard drive space You should view the OPTITEXT WRI file to take advantage of demo files and other useful information The main file is OPEDITOR EXE The other files are for fonts and configuration information Two subdirectories are created 1 modules and 2 systems These are used to store your configuration data 5 You will automatically be ret
34. or subdirectory type OPEDITOR w Index Baud rate 16 Cable requirements 7 cables 13 shielded cable 14 Communications Master 10 Connector Specification 12 Programming Cable 12 Connector Specifications 13 PLC to Panel Cable 12 DCM 13 DCU 13 Dimensions for Mounting 9 DIP switch 15 DirectSOFT 1 DOS 16 Downloading 21 GE Series 1 13 Jumper Settings 15 M Memory Consumption 5 Memory Mapping 4 Memory Planner 6 N NEMA 3 O Operation 2 OP CMCON 1 14 OP CMCON 2 14 OPEditor 17 21 Pinout Diagrams 12 Power Supply 11 R Ribbon cable 10 RS422 12 pinouts 12 S SIMATIC 13 SLC500 13 5 03 13 index lt 5 04 13 Slice I O 13 Specification Storage Temperature 5 Specifications 8 communication link 8 diagnostics 8 operating humidity 8 operating temperature 8 power budget 8 power connector 8 weight 5 15 System requirements 16 TI305 13 T1405 13 Troubleshooting 22
35. rmine what features need to make use of remapping Remapping is never an issue with the DL450 or Allen Bradley PLCs because of bit of word capability For these PLCs ignore this part of the template Planning Your Memory Mapping Lee OP Panel Memory Planner PLC Address for OP 9001 Panel Registers Original Mapping Remapping Name Needed Base Final Word ET Number E 30 Ea Installing the Panel Installing the Panel In this section you will be given all of the information you need to install the panel Before actually installing the OP 9001 panel it may be helpful to examine the specifications and make sure that the requirements of your application are met Panel Specifications Physical WGIGAI couri ae ren eu sce eeran ER 22 ounces Specifications Panel Fasteners 000c cece enes Four holes to accept four 16x32 machine screws NEMA Rating 2 0 0 eee ee eee eee NEMA 1 CPUs Supported GPUS AAEE EAR aie oot eeu oer DL105 DL205 DL305 DL405 PLCDirect Compatibles SLC 5 03 SLC5 04 Environmental Operating Temperature 0 to 50 C Specifications Storage Temperature 0005 20 to 80 C Operating Humidity aaee 5 to 95 non condensing Air Composition sssaaa nananana No corrosive gases permitted Operating Power Budget Requirement 3 75 VA 8 30 VDC Specifications 310 mA 12 VDC 155 mA 24 VDC Power Connector 00 c e
36. rols Browse the OP Directory for an The OptiMate series existing system configuration Be toed camp Panel if OP 1312 Setpoint Display Panel Enter a path and filename of an OF 1200 op Si T mand hain 2 b OP perator Terminal existing system configuration Upload a system configuration already in the OP 9001 panel Configure a new system You will want to select Configure a New System since you are creating a IFilHelp ESCI Ext configuration file for the first time Step 5 AS soon as you make the above OptiMate Config Editor Ver 2 00 EE y EOR oiiz daa Coy Ze Enter the Correct selection and press the lt Enter gt key x PLC Brand and Type you will go to a screen that allows you to ee eee ees Optimation Inc choose from either PLCDirect or Adf Optima Config Editor Ver 2 00 ES a Om iua CALS a Mc a Allon Bradley Pril e Bradley Optimation Inc N 7 Pril Intelligent Peripherals For Controls After making your selection press the Pal Base Reg lt Enter gt key to return to previous screen F1 Help ESC Exit OptiMate Config Editor Ver 2 00 PLC Type PLC Direct Configure Protocol Add Panel To The System PLC Direct by Koyo Optimation Inc Intelligent Peripherals For Controls Remove Panel From System Modify Panel In The System Print System Highlights Address Base Reg OptiMate Config Editor Ver 2 00
37. sure that the Panel Number setting matches the dip switch setting Switch On gt gt N A Address 1 2 3 OptiMate Config Editor Ver 2 00 Get Configuration From Panel Use Defaults For OP 1124 Use Defaults For OP 1224 Use Defaults For OP 1312 Use Defaults For OP 1500 Use Defaults For OP 1510 F1 Help ESC Exit PLC Direct by Koyo Optimation Inc Intelligent Peripherals For Controls Type Address Base Reg OptiMate Contig Editor Ver 2 00 Protocol OptiMate HEX Panel Address 0 dress 40600 led PLC Direct by Koyo Optimation Inc Intelligent Peripherals For Controls Write Configuration to Panel F1 Help ESC Exit 2m OP 1124 Lamp Panel OptiMate Config Editor Ver 2 00 Protocol OptiMate HEX Panel Address 3 Base Register Address 1 Flas NOTE Remember that you must have the DIP switch on the rear of the OP panel set to address 31 in order for the downloading of your configuration to take place PLC Direct by Koyo Optimation Inc Intelligent Peripherals For Controls Write Contiguration to Panel F1 Help ESC Exit OP 1124 Lamp Panel Configuration of the Panel ioe Step 11 Each panel has to
38. the power OFF then ON With power applied visually inspect the LEDs located beside each connecting port of the OP 9001 e The LED located beside the port for the cable leading to the PLC should blink green when the OP 9001 is sending requests for data to the PLC e The LED should blink red when the OP 9001 is receiving data from the PLC e If the baud rate is such that the request and transfer of data are very fast changing rapidly between the red and green states it will appear that the LED glows amber LED for reporting direction of date flow at the PLC connecting port TSE Cuny LEDs for reporting direction of data flow at the two multiple panel connecting ports If the LED on the top edge of the OP 9001 remains green and never makes the transition to red or amber then you are probably experiencing a lack of response by the PLC When your PLC and the OP 9001 are communicating correctly the LEDs should flicker constantly or appear to glow amber at high baud rates with only a few pauses If it doesn t here s what you do to isolate and solve the problem 1 2 Check your baud rate setting between the PLC and OP 9001 Make sure they are set ata rate that matches your PLC specs and configuration If the baud rate appears to be OK check your panel configurations to make sure you have specified the correct memory allocations and that you have not specified memory that do
39. urned to the DOS prompt after the files and directories have been created and you press the Return key Installation is now complete Configuration of the Panel ie Step by Step Procedure NOTE You do not need to connect the OP 9001 or any of the OP panels to your computer until you are ready to download configuration information Remember that the panels must have their DIP switch set to 31 and that the OP 9001 must have a jumper in place before the configuration can be successfully written You will remove the jumper on the OP 9001 and reset the DIP switch settings on the panels when you Step 1 Load the OPEditor and Complete the Editor Setup Step 2 Select the LPT and COM ports Step 3 Select Multi Panel Configuration connect your configured system to the PLC for actual operation You can operate the OPEditor as aDOS program out of DOS only Do not attempt to operate the program out of Windows If you are in Windows close Windows completely change to the directory in which you have stored the OPEditor executable file default is C OP and then type the file name OPEDITOR from the DOS prompt The first configuration screen has 4 choices You should select the first choice Editor Setup The setup screen provides two serial port options You must specify which of the serial ports COM1 or COM2 that you will be using when communicating with your OP panel The setup screen will also allow you to designate whic
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