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VersaMax PLC User`s Manual, GFK-1503C

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1. The EZ Program Store device IC200ACC003 can be used to store and update the configuration application program and reference table data of a VersaMax PLC A programmer and PLC CPU are used to initially write data to the device Chapter 1 Introduction 1 6 Power Supplies An AC or DC Power Supply provides 5V and 3 3V power to the modules in the rack Additional power supplies can be installed on special booster carriers if needed No booster supply is needed to power conventional I O modules CPU models IC200CPU005 and IC200CPUEO0S require the use of an expanded 3 3V power supply See the table below GE Fanuc VersaMax T IC200PWR001 or USED Oro ret ODDSO Available Power Supplies and Carrier The following VersaMax power supplies and carrier are available
2. communications CPU001 CPU002 CPU005 ina gt E cPU001 F T CPU005 PwR Pw C xO i RUN RUN A FAULT FAULT E Force O Force C7 E port 1C200CPU001 rorr1 porT2 port2 IC200CPU005 CE UL tl PORTL 1 m 1 I y 3 o o T o 1 o _ o o o i Ta 26 ea 6 So 1 T J r ae RS232 E RS232 j SS PORT D port T usTED i E cus a c O amp so C cc o amt ce HAZ LOC O o J Stirs J o I no cont eq FOR HAZ LOC 5 EAE 5 8 J CLASS IDIV 2 GROUPS ABCD of 0 ao Sa ea oo o2 oe i o2 9 0 J J R5485 1 a RS485 1 l Features Non volatile flash memory for program storage Programming in Ladder Diagram Sequential Function Chart and Instruction List Battery backup for program data and time of day clock Run Stop switch Floating point real data functions Embedded RS 232 and RS 485 communications 70mm height when mounted on DIN rail with power supply Compatible with EZ Program Store device 2 2 VersaMax PLC User s Manual March
3. Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Timers OnDelay Timer 119 90 90 69 15 Timer 110 80 81 60 15 OffDelay Timer 110 80 81 60 15 Counters Up Counter 90 90 70 70 13 Down Counter 93 90 70 70 13 Math Addition INT 62 12 50 10 13 Addition DINT 60 12 50 10 19 Addition REAL 139 12 99 10 17 Subtraction INT 62 12 50 10 13 Subtraction DINT 60 12 50 10 19 Subtraction REAL 139 12 100 10 17 Multiplication INT 70 12 50 10 13 Multiplication DINT 99 12 50 10 19 Multiplication REAL 155 12 108 10 17 Division INT 80 12 60 10 13 Division DINT 70 12 51 10 19 Division REAL 244 12 160 10 17 Modulo Division INT 84 12 60 10 13 Modulo Division DINT 80 12 60 10 19 Square Root INT 85 12 60 10 10 Square R oot DINT 126 12 70 10 13 Square Root REAL 514 12 340 10 11 Scale INT 112 12 78 10 22 Scale WORD 110 12 73 10 22 Trigonometric SIN REAL 1432 12 945 10 11 COS REAL 1437 12 945 10 11 TAN REAL 2135 20 1400 20 11 ASIN REAL 1838 12 1200 10 11 ACOS REAL 1793 12 1200 10 11 ATAN REAL 820 12 542 10 11 Logarithmic LOG REAL 878 12 577 10 11 LN REAL 821 12 542 10 11 GFK 1503C Appendix A Performance Data A 3 A 4 Sizes of Exponential Functions Radian Conversion R
4. GFK 1503C Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Conversion Convert INT to REAL 60 12 40 10 10 Convert REAL to INT 683 12 455 10 13 Convert DINT to REAL 60 12 40 10 13 Convert REAL to DINT 673 12 451 10 13 Convert WORD to REAL 60 12 40 10 10 Convert REAL to WORD 642 12 429 10 13 Convert BCD to INT 57 12 40 10 10 Convert INT to BCD 167 12 120 10 10 Convert BCD to REAL 70 12 50 10 10 Truncate to INT 188 12 130 10 2 13 Truncate to DINT 179 12 128 10 13 Control Call a Subroutine 60 12 40 10 7 Do 0 130 12 130 10 13 PID ISA Algorithm 231 85 150 57 16 PID IND Algorithm 231 85 150 57 16 Service Request 6 71 12 60 10 10 7 Read 221 12 173 10 10 7 Set 2610 12 2211 10 10 14 169 12 139 10 10 15 100 12 72 10 10 16 110 12 80 10 10 18 346 12 251 10 10 23 377 12 361 10 10 26 30 912 12 912 10 10 29 72 12 60 10 10 Nested MCR ENDMCR 31 33 31 33 4 Combined Drum Sequencer 267 222 184 152 34 DO I O timing is the time to output values to discrete output module Service Request 14 Clear Fault Table timing was done when fault table contained no faults Service Request 26 30 Interrogate I O timing was done when I O configuration was empty and both an MDL740 16pt out and MDL640 1 6pt in were physically present Appendi
5. impede system operation if installed Single Ended Inter Rack Connection IC200CBL600 PIN PIN N 4 SINGLE w Yr w Expansion VersaMax TIOCLK 2 TIOCLK folo r c TRUN 14 T RUN Receiver PU or NIU a a Serial Port T_IODT 18 Tio E IC200ER M002 erial Por T RERR 15 TRER B ivi 10 TRIRQ_ 11 TRIRQ_ Receiving 12 T_FRAME 10 T_FRAME 2 Port 16 TRSEL 19 TRSEL 4 23 o 1 SHIELD 16 PIN 16 PIN 26 PIN 26 PIN MALE FEMALE MALE FEMALE Power Sources for Single Ended Expansion Rack Systems When operating the system in single ended mode the power supplies for the main rack and expansion rack must be fed from the same main power source The main rack and expansion racks cannot be switched ON and OFF separately either both must be ON or both must be OFF for proper operation Power for modules in the expansion rack comes from the Power Supply installed on the Expansion Receiver Module If the expansion rack includes any Power Supply Booster Carrier and additional rack Power Supply it must be tied to the same source as the Power Supply on the Expansion Receiver Module VersaMax PLC User s Manual March 2001 GFK 1503C Installing Power Supply Modules GFK 1503C Power supply modules install directly onto the CPU module Expansion Receiver Modules and suppl
6. The main rack is rack 0 Additional racks are numbered 1 to 7 Chapter 5 CPU Configuration 5 3 In a system that uses just one expansion rack which is attached to the expansion bus by a non isolated Expansion Receiver Module IC200ERMO002 the expansion rack must be configured as rack 1 VersaMax PLC Station Main Rack 7 r Ps i ap D pa CPUINIU VersaMax Expansion Rack PS In a system with an Expansion Transmitter Module C200BTMO001 and up to seven expansion racks each with an Isolated Expansion Receiver Module IC200ERMO001 or IC200ERM002 the additional racks are configured as rack 1 through rack 7 VersaMax PLC Main Rack 0 I ETM PS a bc CPU NIU VersaMax ExpansionRack 1 PS 15M with any IC200ERM002 ERMs Po D CG 750M with all IC200ERM001 ERMs ERM a VersaMax ExpansionRack 7 PS XQ D Cy Terminator Plug ERM 5 4 VersaM
7. RS485 LAs Port 1 is an RS 232 port with a 9 pin female D sub connector The pinout of Port allows a simple straight through cable to connect with a standard AT style RS 232 port Port 1 can be configured for either CPU serial communications SNP RTU Serial I O or local Station Manager use If Port 1 has been configured for CPU use it can be forced to local Station Manager operation using the Restart pushbutton Once forced Port remains available for station manager use until the PLC is power cycled or the Restart pushbutton is pressed If Port 1 is configured as a local Station Manager it cannot be used for CPU serial communications or for firmware upgrades using Winloader The Restart pushbutton will NOT toggle it to the CPU serial protocols Port 2 is an RS 485 port with a 15 pin female D sub connector This can be attached directly to an RS 485 to RS 232 adapter IC690ACC901 Port 2 can be used for program configuration and table updates with the EZ Program Store module The following table compares the functions of Port 1 and Port 2 Port 1 Port 2 CPU Protocols SNP slave Defaults to SNP slave Defaults to SNP slave RTU slave Serial I O Local Station Manager Yes see above no Firmware Upgrade PLC in Stop No I O mode Pot1 no not d
8. CONST 7 IN 10 72 VersaMax PLC User s Manual March 2001 GFK 1503C Timer and Counter Functions This section describes the timing and counting functions of the Instruction Set The data associated with these functions is retentive through power cycles OnDelay Stopwatch Timer OffDelay Timer OnDelay Timer Up Counter Down Counter TimeTick Contacts In addition to the Timer functions of the Instruction Set the VersaMax PLC has four time tick contacts These contacts can be used to provide regular pulses of power flow to other program functions The four time tick contacts have time durations of 0 01 second 0 1 second 1 0 second and 1 minute The state of these contacts does not change during the execution of the sweep These contacts provide a pulse having an equal on and off time duration The contacts are referenced as T_10MS 0 01 second T_100MS 0 1 second T_SEC 1 0 second and T_MIN 1 minute The following timing diagram represents the on off time duration of these contacts T XXXXX tS m T L T al X 2 X 2 SEC SEC These time tick contacts represent specific locations in S memory GFK 1503C Chapter 10 Instruction Set Reference 10 73 10 74 Timer and Counter Functions Function Block Data Required for Timers and Counters Each timer or counter uses three words registers of R memory to store the following information When you enter a timer or counter you
9. Bit number BIT When the function receives power flow it begins comparing the bits in the first string with the corresponding bits in the second string Comparison continues until a miscompare is found or until the end of the string is reached The BIT input stores the bit number where the next comparison should start a 0 indicates the first bit in the string The BN output stores the bit number where the last comparison occurred where a 7 indicates the first bit in the string Using the same reference for BIT and BN causes the compare to start at the next bit position after a miscompare or if all bits compared successfully upon the next invocation of the function block the compare starts at the beginning If you want to start the next comparison at some other location in the string you can enter different references for BIT and BN If the value of BIT is a location that is beyond the end of the string BIT is reset to 0 before starting the next comparison Parameters of the Masked Compare Function Input Choices Description Output enable flow Permissive logic to enable the function 1 R Al AQ Reference for the first bit string to be compared For WORD only 1 Q M T 5 G 2 R Al AQ Reference for the second bit string to be compared For WORD only 1 Q M T 5 G M R Al AQ Reference for the bit string mask For WORD only I Q M 1T SS 5B SC G BIT 1 Q M T S G R Al AQ constant Referenc
10. Index 1 Index 2 Index Data move functions Data retentiveness Data types Discrete references Documentation E Elapsed Time read 11 2 End function 7 7 ESD protection CE Mark requirements 4 19 Ethernet Global Data Consumed Data Exchange Definition 6 66 7 Effect of PLC modes and actions on 13 11 3 11 Exchange Status Word 13 20 Timestamping Ethernet Interface 3 11 13 2 Attachment to the LAN Ethernet LEDs 3 9 Ethernet NIU User s Manual Ethernet Restart Pushbutton Ethernet Software 3 11 13 3 Exchange Status Word Ethernet Global Data 13 20 Explanation adding to program logic 10 28 Extra Module diagnostic F Fast powerup effects Fault table 13 17 Fault Tables clear Fault Tables read VersaMax PLC User s Manual March 2001 Field Power LED 1 7 Flash memory Cfg From described operation Floating point Numbers Folder name read FTB protection CE Mark requirements 4 19 Gateway IP Address 6 3 Gateways 13 5 Genius NIU User s Manual 1 2 Global data references Hot insertion Humidity 2 4 3 4 VO carriers1 7 installation 4 2 V O module installation 4 10 I O interrogate IC200CBL105 IC200CBL110 IC200CBL120 IC200CBL230 Initialize Port function 12 14 12 15 Input Buffer Flush Input Buffer Set Up Input references 9 2 9 3 Input Scan 7 3 Instruction Set 8 6 Internal
11. To read write or verify some or all of the data follow these steps 1 Plug the EZ Program Store device into port 2 of the VersaMax PLC CPU The device s LED turns green after about 2 seconds The delay allows time for proper seating of the device GFK 1503C Chapter 15 The EZ Program Store Device 15 5 EZ Program Store Device IC200ACC003 2 Ifthe PLC is in Run mode when the EZ Program Store device is connected the Run LED on the PLC blinks at a 1 Hz rate CPUE05S PWR xO ee RUN FAULT FORCE PORTIC PorT2C Run LED This blinking indicates that the Run Stop switch is enabled regardless of the configuration of the switch 3 If the EZ Program Store device s LED is green and the PLC s Run LED is blinking stop the PLC by moving the Run Stop switch from the On Run position to the Stop Off position RUN ON if i ja STOP OFF If the switch is already on the Stop Off position move it to Run then back to Stop to affirm the change After the mode is changed to Stop No I O the Run LED goes off Note that to change the PLC mode from Run to Stop or from Stop to Run mode when an EZ Program Store device is attached the PLC s Run Stop switch must be used If a programmer computer is also connected to the PLC at the same time the programmer cannot be used to change the PLC mode 4 Start the programming software and change the request timeout values as needed Connect the program
12. 1T _ RTS A CTS B e N RTS B RTS B J x lt ij 8 CTS B RTS A lt T 2 CTS A 1 1 1 1 2 GND T 7 GND SHLD Se oSS Sle w 1 sHLp Upto 15 2 meters 50 ft without isolation gt VersaMax PLC User s Manual March 2001 GFK 1503C RS 485 Multidrop Serial Connections In the multidrop configuration the host device is configured as the master and one or more PLCs are configured as slaves The maximum distance between the master and any slave may not exceed 4000 feet 1200 meters This figure assumes good quality cables and a moderately noisy environment A maximum of 8 slaves can be connected using RS485 in a daisy chain or multidrop configuration The RS485 line must include handshaking and use wire type as specified earlier Master Slave Last Station Station When wiring RS 485 multidrop cables reflections on the transmission line can be reduced by daisy chaining the cable as shown below Make connections inside the connector to be attached to the PLC Avoid using terminal strips to other types of connectors along the length of the transmission line Computer CPU 9 Pin Female to 25 RS 485 Cables i RS 232 RS 485 RS 232 Port Pin Male RS 232 P Make connections RS 485 Port hiel l insi Y o apna aig Cable IC690ACC900 inside D connecto
13. GFK 1503C Chapter 8 Elements of an Application Program 8 7 Timers and Counters ondtr OnDelay Stopwatch Accumulates time while receiving power The current value is reset to Timer zero when the Reset input receives power oftd OffDelay Timer Accumulates time while NOT receiving power tmr OnDelay Timer Accumulates time while receiving power The current value is reset to zero when there is no power flow upetr Up Counter Increments by 1 each time the function receives transitional power dnetr Down Counter Counts down from a preset value every time the function receives transitional power Math Functions add Addition Adds two numbers sub Subtraction e Subtracts one number from another mul Multiplication Multiplies two numbers div Division Divides one number by another yielding a quotient mod Modulo Division Divides one number by another yielding a remainder expt Raises X to the power specified by IN and places the result in Q sin Trigonometric Sine Finds the trigonometric sine of a real number cos Trigonometric Finds the trigonometric cosine of a real number Cosine tan Trigonometric Tangent Finds the trigonometric tangent of a real number asin Finds the inverse sine of a real number acos Finds the inverse cosine of a real number atan Inverse Tangent Finds the inverse tangent of a real number deg Performs a RAD_TO_DEG conversion on a real radian value rad Performs a DEG_TO_RAD conversion on a real degree va
14. To read the word count the first word of the parameter block must contain a zero address 0 read word count address 1 ignored The function returns the current word count in the second word of the parameter block 0 current word count address address 1 To change the word count the first word of the parameter block must contain a one address 1 change word count new word count 0 or 32 address 1 The PLC will change the number of words to be checksummed to the new value GFK 1503C Chapter 11 The Service Request Function 11 9 Example of SVCREQ 6 In the example when enabling contact FST_SCN is set the parameter blocks for the checksum function are built Later in the program if input I0137 turns on the SVCREQ reads the number of words being checksummed The parameter block for the Read function is located at RO150 151 The ADD function adds 32 to the current word count in RO151 and places the result in RO153 The parameter block for the Change function is located at RO00152 153 The second SVCREQ then changes to the new word count specified in RO153 FST_SCN XOR_ MOVE INT INT R01507 11 QF RO150 CONST 7 IN QF R0152 00001 R01507 12 ne __ svc_ ADD_ REQ INT CONST FNC R01517 11 QF RO153 CONST 00006 00006 RO150 CONST RO152 A PARM ote o 11 10 VersaMax PLC U
15. 24VDC Power Supply C200PWR001 24VDC Expanded 3 3V Power Supply C200P WR 002 120 240VAC Power Supply C200PWR101 120 240VAC Expanded 3 3V Power Supply C200PWR102 12VDC Power Supply C200PWR201 12VDC Expanded 3 3V Power Supply C200P WR 202 Power Supply Booster Carrier C200PWBO001 Power supplies are described in the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C I O Modules VersaMax IO and option modules are approximately 110mm 4 33in by 66 8mm 2 63in in size Modules can be mounted either horizontally or vertically on several types of available I O Carriers Modules are 50mm 1 956 in in depth not including the height of the carrier or the mating connectors 110mm lt 4 33in 7 7 A q co H H FLD Q OK 02000008008080080880808080 1 23 4 5 6 7 8 9 10 11 1213 14 15 16 IC200MDL750 66 8mm IND CONT EQ FOR HAZ LOC 2 63in CLASS DIV 2 GROUPS ABCD cus Temp Code T4A Ambient 60C usTeD OUTPUT 12 24VDC CLASS ZONE 2 GROUP IIC pithy CE POSGRP 5A 32PT Ex nA IIC T4 OC lt To lt 60C Ex nV T4 Demko No 88Y 125014 E157515 PLOT 17 18 19 20 21 22 23 24 25 26 2 2829 30 31 32 1734567 831 e0000808080808080088 08080808
16. 30 0 3A 20 Space 30 0 32 2 Mon 30 leading 0 Example Read Date and Time in Packed ASCII Format Mon Oct 5 1998 at 11 13 00pm address address 1 address 2 address 3 address 4 address 5 address 6 address 7 address 8 address 9 address 10 address 11 address 12 Chapter 11 The Service Request Function 0 read 83h ASCII 4 digit 39 9 31 1 38 8 39 9 31 1 20 space 20 Space 30 0 35 5 30 leading 0 31 1 20 Space 3A 31 1 33 3 31 1 30 0 3A 20 space 30 0 32 2 Mon 30 leading 0 11 13 11 14 Example of SVCREQ 7 In the example when called for by previous logic a parameter block for the time of day clock is built It requests the current date and time then sets the clock to 12 noon using BCD format The parameter block is located at location R0300 Array NOON has been set up elsewhere in the program to contain the values 12 0 and0 Array NOON must also contain the data at RO0300 BCD format requires six contiguous memory locations for the parameter block FST_SCN an MOVE MOVE INT INT CONST 7 IN QF NOON CONST IN QF MIN_SEC 04608 00000 10016 T0001 bd MOVE MOVE SVC_ INT INT REQ CONST IN Q R0300 CONST IN Q R0301 CONST FNC 00000 00001 00007 R0300 PA
17. Example of the EXPT Function In the example the value of AIO01 is raised to the power of 2 5 and the result is placed in R0001 AI001 R0001 CONST 2 50000E 00 10 56 VersaMax PLC User s Manual March 2001 GFK 1503C Math and Numerical Functions Radian Conversion Functions When Degree Radian Conversion function receives power flow the appropriate conversion radians to degrees or degrees to radians is performed on the Real value in input IN and the result is placed in output Q The OK output will receive power flow unless IN is NaN Not a Number Enable RAD_F OK TO DEG Input 7 IN Q Output Parameters of the Radian Conversion Function Input Choices Description Output enable flow When the function is enabled the operation is performed IN R Al AQ constant IN contains the real value to be operated on ok flow none The OK output is energized when the function is performed without overflow unless IN is NaN Q R Al AQ Output Q contains the converted value of IN Example In the example 1500 is converted to DEG and is placed in ROOO1 CONST L IN Q R0001 1500 000 85943 67 GFK 1503C Chapter 10 Instruction Set Reference 10 57 Relational Functions The Relational functions can be used to compare two numbers and to determine whether a number lies within a specified range Equal Test two numbers for equali
18. REAL OK TRUN INT Value to be converted 4 IN Q Output Parameters of the Truncate Function Input Choices Description Output enable flow When the function is enabled the conversion is performed IN R Al AQ constant IN contains a reference for the real value to be truncated ok flow none The OK output is energized when the function is performed without error unless the value is out of range or IN is NaN Q R Al AQ Q contains the truncated INT or DINT value of the original For integer only I Q M T value in IN G Example In the example the displayed constant is truncated and the integer result 562 is placed in T0001 10002 REAL F OK TRUN INT CONST IN QF T0001 5 62987E 02 GFK 1503C Chapter 10 Instruction Set Reference 10 47 Math and Numerical Functions This section describes the Math and Numerical functions of the Instruction Set Standard Math Functions Addition Subtraction Multiplication Division Modulo Division Scaling Function Square Root Trigonometric functions Logarithmic Expontial functions Convert to Degrees Convert to Radians Converting Data for the Math and Numerical Functions The program may need to include logic to convert data to a different type before using a Math or Numerical function The description of each function includes information about appropriate data types The section Data Type Conversio
19. Simple isolated network configuration 6 3 Simple Network Time Protocol 13 8 Sine function 10 54 Size of a main program or subroutine 8 3 5 25 11 Standard Sweep mode 7 4 Station Manager software 3 11 13 3 Status address location 6 3 Status references 9 3 9 5 Subnet mask Subroutines Call function 7 7 10 22 calling 8 4 number of block declarations 8 4 number of calls 8 4 Surge protection SVCREQ Change programmer communications window 3 11 2 Change programmer communications window mode 3 11 7 Change system communications window 4 11 2 Change system communications window mode 3 11 8 Change read checksum 6 11 2 Change read checksum task state and number of words to checksum 6 Change read constant sweep timer 1 11 2 1 1 4 Index 4 VersaMax PLC User s Manual March 2001 GFK 1503C Change read time of day clock 7 Clear Fault Tables 14 Fault Tables read 15 Interrogate I O 26 or 30 Read ire sed Power Down Time 29 Read Elapsed Time Clock 16 Read folder name 10 11 2 11 17 Read I O Override 18 Read Master Checksum 23 Read PLC ID 11 J11 2 11 18 Read sweep time 9 11 2 11 16 Read window values 2 11 2J 11 6 Reset watchdog timer 8 11 2 11 15 Shut Down the PLC 13 Sweep time read Sweep CPU 7 1 Constant Sweep Time 7 5 Standard Sweep 7 4 System
20. Task identifier TASK Parameters of the COMMREQ Function Input Choices Description Output enable flow When the function is energized the communications request is performed IN R Al AQ IN contains the first word of the command block SYSID 1 Q M 1 G R SYSID contains the rack number most significant byte and slot Al AQ constant number least significant byte of the target device TASK RAI AQ constant TASK contains the task ID of the process on the target device FT flow none FT is energized if an error is detected processing the COMM REQ 1 The specified target address is not present SYSID 2 The specified task is not valid for the device TASK 3 The data length is 0 4 The device s status pointer address in the command block does not exist GFK 1503C Chapter 10 Instruction Set Reference 10 39 Data Move Functions Communication Request Command Block for the COMMREQ Function The Command Block starts at the reference specified in COMMREQ parameter IN The length of the Command Block depends on the amount of data sent to the device The Command Block contains the data to be communicated to the other device plus information related to the execution of the COMM REQ The Command Block has the following structure address Length in words address 1 Wait No Wait Flag address 2 Status Pointer Memory address 3 Status Pointer Offset addres
21. address address 1 ignored Enable Constant Sweep Mode To enable Constant Sweep mode enter SVCREQ function 1 with this parameter block address address 1 0 or timer value Note If the timer should use a new value enter it in the second word If the timer value should not be changed enter 0 in the second word If the timer value does not already exist entering 0 causes the function to set the OK output to OFF Change the Constant Sweep Time To change the timer value without changing the selection for sweep mode state enter SVCREQ function 1 with this parameter block address l address 1 new timer value Read the Constant Sweep State and Time To read the current timer state and value without changing either enter SVCREQ function 1 with this parameter block address l address 1 ignored 11 4 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Successful execution will occur unless 1 A number other than 0 1 2 or 3 is entered as the requested operation 2 The sweep time value is greater than 500ms 0 5 seconds 3 Constant sweep time is enabled with no timer value programmed or with an old value of 0 for the timer After the function executes the function returns the timer state and value in the same parameter block references 0 disabled address 1 enabled address 1 current timer value Example of SVCREQ 1 In this example if contact OV_SWP is set the C
22. address seconds from power on low order address 1 seconds from power on high order address 2 100 microsecond ticks The first two words are the elapsed time in seconds The last word is the number of 100 microsecond ticks in the current second Example of SVCREQ 16 In the example when internal coil M0233 is on the SVCREQ with a parameter block located at RO127 reads the system s elapsed time clock and sets internal coil MO0234 When coil M0233 is off the SVCREQ with a parameter block at RO131 reads the elapsed time clock again The subtraction function finds the difference between the first and second readings which have been stored in the SVCREQ parameter blocks The subtraction ignores the hundred microsecond ticks The difference between the two readings is placed in memory location R0250 M0223 M0234 md SVC_ G REQ CONST FNC 00016 R0127 PARM M0233 M0234 M0234 ZA SVC_ SUB_ R REQ D INT CONST FNC R0131 7 11 QF R0250 00016 R0131 PARM R0127 4 12 Chapter 11 The Service Request Function 11 23 SVCREQ 18 Read I O Override Status Use SVCREQ 18 to check for any overrides in the CPU s I and Q memories Output Parameter Block for SVCREQ 18 This function has an output parameter block only Its length is 1 word address 0 No overrides are set 1 Overrides are set Example of SVCREQ 18 The following SVCREQ reads the
23. 11 12 SVCREQ 7 Parameter Block Content BCD Format In BCD format each time and date item occupies one byte so the parameter block has six words 2 Digit Year The last byte of the sixth word is not used When setting the date and time this byte is ignored when reading date and time the function returns 00 Parameter Block Format Example High Byte Low Byte Read Date and Time in BCD format Sun July 3 1998 at 2 45 30 p m l change or 0 read address 0 read 1 BCD format address 1 1 BCD format month year address 2 07 J uly 98 year hours day of month address 3 14 hours 03 day seconds minutes address 4 30 seconds 45 minutes null day of week address 5 00 06 Friday 4 Digit Year The parameter block has six words All bytes are used Parameter Block Format Example High Byte Low Byte Read Date and Time in BCD format Sun July 3 1998 at 2 45 30 p m l change or 0 read address 00 00 read 81h BCD format 4 digit address 1 00 81h BCD 4 digit year year address 2 19 year 98 year day of month month address 3 03 day 07 J uly minutes hours address 4 45 minutes 14 hours day of week seconds address 5 06 Friday 30 seconds VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C SVCREQ 7 Parameter Block Content Packed ASCII Format In Packed ASCI
24. Communication Request COMMREQ This important function allows the CPU to communicate with intelligent modules in the system for example communications modules The basic format of the COMMREQ function is shown in this chapter The detailed parameters needed to program specific communications tasks are provided in the documentation for each module VersaMax PLC User s Manual March 2001 GFK 1503C Data Move Functions Move Data The Move function copies data as individual bits from one location to another Because the data is copied in bit format the new location does not need to be the same data type as the original When the Move function receives power flow it copies data from input parameter IN to output parameter Q as bits If data is moved from one location in discrete memory to another for example from I memory to T memory the transition information associated with the discrete memory elements is updated to indicate whether or not the Move operation caused any discrete memory elements to change state Data at the input parameter does not change unless there is an overlap in the source and destination MOVE Enable INT OK Value to be Moved IN Q7 Output Note that if an array of Bit type data specified in the Q parameter does not include all the bits in a byte the transition bits associated with that byte which are not in the array are cleared when the Move function receives power flow Th
25. PORTI Amber STAT IP Address has not been configured PORT 1 Available for Station Manager use Waiting for IP Address Lan Amber LAN Ethemet interface is offline Attempting to STA 9 Slow blink green recover if possible PORTI Amber STAT IP Address has not been configured PORT 1 PLC CPU is controlling Port 1 Waiting for IP Address LN Amber LAN Ethemet interface is offline Attempting to STAT J Slow blink green recover if possible PORTI Amber STAT IP Address has not been configured PORT 1 Available for Station Manager use _ Operational If LAN is off the problem may be LAN Green fickering LAN Ethernet interface is online Flickers during Network cable not connected either STAT Green aan nee at the PLC or at the hub port of No exception detecte Hud ectedjfailed PORT 1 PLC CPU is controlling Port 1 ub disconnectedytaned Operational a Network cable not properly LAN Green fickering LAN Ethernet interface is online Flickers during i T ae STAT creen activity If STAT is amber an exception condition port amber STAT No exception detected has occurred PORT 1 Forced to Station Manager use Operational LN Amber LAN Ethemet interface is offline Attempting to STAT Green recover if possible Porti off STAT No exception detected PORT 1 PLC CPU is controlling Port 1 Operational Lan Amber LAN Ethemet interface is offline Attempting to STAT Green reco
26. VersaMax PLC User s Manual March 2001 GFK 1503C Port 1 RS 232 GFK 1503C Pin Assignments for Port 1 Port 1 is an RS 232 port with a 9 pin female D sub connector It is used as the boot loader port for upgrading the CPU firmware The pinout of Port 1 allows a simple straight through cable to connect with a standard AT style RS 232 port Cable shielding attaches to the shell Pin Signal Direction Function E e a poo OVIGND signal reference Clear to Send ipui rs o Request to Send outbul Shell SHLD Cable Shield wire connection 100 Continuous shielding cable shield connection RS232 Point to Point Connection In pointtopoint configuration two devices are connected to the same communication line For RS232 the maximum length is 15 meters SOft A PC 9 Pi CPU Serial Port Port 1 a 4 7 9 pin female 9 pin male gt 2 D 2 TXD 3 8 3 RXD q 8 5 GND 7 CTS 2 ro 8 RTS Y V JV aw The shield must connect to shell of connectors on both ends of the cable Chapter 4 Installation 4 13 Connector and Cable Specifications for Port 1 Vendor Part numbers below are provided for reference only Any part that meets the same specification can be used Cable Computer cable overall braid over foil shield Belden 9610 5 conductor t 30 Volt 80 C 176 F 24 AWG tinned copper 7x32 stranding 9 Pin Male Type Vendor Pl
27. enam R If this bit 3 is 1 CPUE 05 is operating in full duplex Ethernet mode Full duplex or half duplex operation is automatically negotiated between the CPUE05 and its immediately connected network device usually a network hub If this bitis 0 CPUE05 is operating in half duplex Ethernet mode This bitis only valid if bit 13 LAN OK is 1 This bitis 1 while the Ethernet interface is able to communicate on the network If the network is not accessible due to local or network problems this bitis 0 When communication resumes it is automatically set to 1 This bit is 1 whenever the Ethernet interface has a resource problem i e lack of data memory The bit is reset to 0 on a subsequent PLC sweep The Ethernet interface may or may not be able to continue functioning depending on the severity of the problem Use the PLC Fault Table to identify the problem The Station Manager STAT B and LOG commands can also provide more information When this bit is 1 the Ethernet interface is properly initialized When this bitis 0 all other Ethernet status bits are invalid Chapter 13 Ethernet Communications 13 19 13 20 Checking the Status of an Ethernet Global Data Exchange To check the status of any Ethernet Global Data exchange monitor the value in the Exchange Status word selected during Ethernet Global Data configuration The PLC automatically writes exchange status information in this location when a
28. 0 Jo 0 Jo fo jo jt 1444 1 WORD1 11 Qf RESULT pice worb2 2 RESULT 0 0 0 1 1 1 0 0 0 0 jo Jo 1 ofolo 10 4 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Exclusive OR GFK 1503C The Exclusive OR function compares each bit in bit string I1 with the corresponding bit in string I2 If the bits are different a 1 is placed in the corresponding position in the output bit string Enable XOR_F OK WORD Input 1 11 Qf Output Input 2 7 12 Each scan that power is received the Exclusive OR function examines each bit in string I1 and the corresponding bit in string I2 beginning at the least significant bit in each For each two bits examined if only one is 1 then a is placed in the corresponding location in bit string Q The Exclusive OR function passes power flow to the right whenever power is received If string I2 and output string Q begin at the same reference a 1 placed in string I1 will cause the corresponding bit in string I2 to alternate between 0 and 1 changing state with each scan as long as power is received Longer cycles can be programmed by pulsing the power flow to the function at twice the desired rate of flashing the power flow pulse should be one scan long oneshot type coil or selfresetting timer The Exclusive OR function is useful for quickly comparing two bit
29. 16 Bit Differential Current 8 Channels C200ALG 262 Analog Input Module 15 Bit Voltage 15 Channels C200ALG 263 Analog Input Module 15 Bit Current 15 Channels C200ALG 264 Analog Input Module 16 BitRTD 4 Channels C200ALG620 Analog Input Module 16 Bit Thermocouple 7 Channels C200ALG630 Analog Output Modules Analog Output Module 12 Bit Current 4 Channels C200ALG 320 Analog Output Module 12 Bit Voltage 4 Channels 0 to 10VDC Range C200ALG 321 Analog Output Module 12 Bit Voltage 4 Channels 10 to 10VDC Range C200ALG 322 C200ALG325 Analog Output Module 12 Bit Current 12 Channels Analog Output Module 16 Bit Voltage Current L500VAC Isolation 4 Channels C200ALG331 Analog Mixed I O Modules Analog Mixed Module Input Current 4 Channels Output Current 2 Channels C200ALG 430 Analog Mixed Module 0 to 10VDC Input 4 Channels Output 0 to L0VDC 2 Channels IC200ALG431 Analog Mixed Module 12 Bit 10 to 10VDC Input 4 Channels Output 10 to C200ALG432 10VDC 2 Channels GFK 1503C Chapter I Introduction 1 9 Carriers Carriers provide mounting backplane communications and field wiring connections for all types of VersaMax modules I O modules can be installed on carriers or removed without disturbing field wiring There are three basic I O Carrier types Terminal style I O carriers Modules mount parallel to the DIN rail Compact Terminal style I O Carriers Modules mount perpendicular to the DIN rail Connector
30. 4401 O Read Bytes 4402 O Read String 4403 00 0 a0 12 12 VersaMax PLC User s Manual March 2001 GFK 1503C Overlapping COMMREQs Some of the Serial I O COMMREQs must complete execution before another COMMREQ can be processed Others can be left pending while others are executed COMMREQS that Must Complete Execution m Autodial 4400 m Initialize Port 4300 m Set Up Input Buffer 4301 Flush Input Buffer 4302 m Read Port Status 4303 m Write Port Control 4304 m Cancel Operation 4399 m Serial Port Setup FFFO COMMREQs that Can be Pending While Others Execute The table below shows whether Write Bytes Read Bytes and Read String COMMREQs can be pending when other COMMREQs are executed NEW COMMREQ Currently Initialize SetUp Write Cancel pending Port String Operatio COMMREQs Control n 4399 4304 Write Bytes 4401 Read Bytes No Yes Yes No No Yes Yes No No Yes No 4402 Read String No Yes Yes No No Yes Yes No No Yes No 4403 GFK 1503C Chapter 12 Serial I O SNP RTU Protocols 12 13 12 14 Initialize Port Function 4300 This function causes a reset command to be sent to the specified port It also cancels any COMMREQ currently in progress and flushes the internal input buffer RTS is set to inactive Example Command Block for the Initialize Port Function VALUE VALUE MEANING decimal hexadecimal address 0001 0001 Data block length address 1 addres
31. AQ constant N contains the number of places the array is to be rotated ok flow none The OK output is energized when the rotation is energized and the rotation length is not greater than the array size Q l Q M T SA SB SC G R Al AQ Output Q contains the first word of the rotated array Example In the example whenever input I0001 is set the input bit string in location ROOOL is rotated 3 bits The result is placed in R0002 The input bit string ROOO1 is not changed by the function If the same reference is used for IN and Q a rotation will occur in place 10001 WORD MSB LSB R0001 TT T T T OOo 0 fo Jo o foo jojo j R0001 7 IN Q R0002 R0002 after MSB LSB CONST an 10001 is set 1 1 0 0 0 0 0 0j0 0 0 jo jo 1 1 1 10 10 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Bit Test The Bit Test function tests a bit within a bit string to determine whether that bit is currently 1 or 0 The result of the test is placed in output Q Each sweep power is received the Bit Test function sets its output Q to the same state as the specified bit If a register rather than a constant is used to specify the bit number the same function block can test different bits on successive sweeps If the value of BIT is outside the range 1 lt BIT lt 16 length then Q is set OFF A string
32. In this mode the CPU performs all parts of its sweep normally Each sweep executes as quickly as possible with a different amount of time consumed each sweep m The PLC may instead operate in Constant Sweep Time mode In this mode the CPU performs the same series of actions but each sweep takes the same amount of time m The PLC may also be in either of two Stop modes O Stop with I O Disabled mode O Stop with I O Enabled mode GFK 1503C 7 1 7 2 Parts of the CPU Sweep Start of Sweep Housekeeping VO NO Enabled 2 Input Scan Run NO Mode YES olution VO NO Enabled YES Output Scan Programmer Communications System Communications Application Program Checksum Calculation and Verification of Physical and Programmed Configuration Start Next Sweep VersaMax PLC User s Manual March 2001 Housekeeping Data Input Program Execution Data Output Programmer Service System Communications Scan Time of CPU GFK 1503C Parts of the CPU Sweep Start of Sweep Housekeeping Application Program Logic Scan Programmer Communications Window System Communications Window GFK 1503C Chapter 7 CPU Operation 7 3 Housekeeping includes the tasks necessary to prepare for the start of the sweep Before starting the actual sweep the CPU Calculates the sweep time Schedules the start of the next sweep Determines the mode of the next sweep Updates the fault reference tables Resets the
33. Setwhen an application fault occurs Cleared when the PLC transitions from STOP to RUN mode SA0004 8 reserved SA0009 CFG_MM_ Setwhen a configuration mismatch is detected during power up or a configuration store Cleared by powering up the PLC after correcting the condition SA0010 HRD_CPU Set when the diagnostics detects a problem with the CPU hardware Cleared by replacing the CPU module SA0011 LOW_BAT Setwhen a low battery fault occurs Cleared by replacing the battery then powering up the PLC SA0012 13 reserved SA0014 LOS_IOM__ Set when an I O module stops communicating with the CPU Cleared by replacing the module and cycling system power SA0015 LOS SIO Set when an option module stops communicating with the CPU Cleared by replacing the module and cycling power on the main rack SA0016 18 reserved SA0019 ADD_IOM Setwhen an I O module is added Cleared by cycling PLC power and when the configuration matches the hardware after a store SA0020 ADD SIO Setwhen an option module is added Cleared by cycling PLC power and when the configuration matches the hardware after a store SA0021 26 reserved SA0027 HRD_SIO Set when a hardware failure is detected in an option module Cleared by replacing the module and cycling PLC power SA0028 30 reserved SA0031 SFT SIO Set when an unrecoverable software fault is detected in an option module Cleared by c
34. a 0 is placed in string Q in that location The Logical OR function can be used to combine strings or to control many outputs with one simple logical structure The Logical OR function is the equivalent of two relay contacts in parallel multiplied by the number of bits in the string It can be used to drive indicator lamps directly from input states or to superimpose blinking conditions on status lights Enable AND_ OK WORD Input 1 11 QJ Output Input 2 12 GFK 1503C Chapter 10 Instruction Set Reference 10 3 Bit Operation Functions Logical AND Logical OR Parameters of the Logical AND and Logical OR Functions Input Choices Description Output enable flow When the function is enabled the operation is performed 1 Q M T S G R Al AQ Constant or reference for the first word of the first string constant 2 Q M T S G R Al AQ Constant or reference for the first word of the second string constant ok flow none The OK output is energized whenever enable is energized Q l Q M T SA SB SC not Output Q contains the result of the operation S G R Al AQ Example of the Logical AND Function In the example when input I0001 is set the 16bit strings represented by nicknames WORD1 and WORD2 are examined The results of the Logical AND are placed in output string RESULT 10001 AND worD1 0 0 0 1 1 1 14 1 1 1Jo o 1 ojojo Uoni 1 1 0 1 1 1
35. commnt Comment A rung explanation svcreq Service Request A special PLC service function mer Master Control Relay Starts a master control relay range An MCR causes all rungs between the MCR and its subsequent ENDMCR to be executed with no power flow Up to 8 MCRs can be nested endmer End Master Control Ends a master control relay range Relay jump Jumps to a specified location indicated by a LABEL in the logic label Label The target location ofa J UMP instruction Multiple J ump instructions can reference the same label drumseq Drum Sequencer future Operates like a mechanical drum sequencer selecting a 16 set of outputs Chapter Program Data 9 This chapter describes the types of data that can be used in an application program and explains how that data is stored in the VersaMax PLC s memory m Data memory references m Retentiveness of data m Using names and descriptions for program references m System status references m Time tick contacts How program functions handle numerical data GFK 1503C Ll Data Memory References The PLC stores program data in both bit memory and word memory Both bit memory and word memory are divided into different types with specific characteristics By convention each type is normally used for a specific type of data as explained below However there is great flexibility in actual memory assignment Individual memory locations are indexed using alphanumeric identifiers
36. communications task 20 of the CPU rack 0 slot 0 If an error occurs processing the COMMREQ Q0110 is set MO0021 COMM REQ Q0110 R0032 IN FT C CONST _ o000 SYSID CONST TASK 00020 GFK 1503C Chapter 12 Serial I O SNP RTU Protocols 12 3 Configuring Serial Ports Using the COMMREQ Function The following tables list the command block values required for setting up a Serial Port for SNP RTU and Serial I O All values are in hexadecimal unless otherwise indicated The BLKMV commands that are used to create the command block are described in the example It is important to note that 2 parameters have been added to the RTU and Serial IO port configuration COMMREQ receive to transmit delay and RTS drop delay When these parameters are included ina COMMREQ the data block length must be set to 12H If a value of 10H is used the COMMREQ will still be processed however the receive to transmit and RTS drop delays would not be recognized It is also important to note that if a COMMREQ containing the receive to transmit delay and RTS drop delay is sent to a CPU that does not support these delay features the CPU will accept and process the COMMREQ but will ignore the receive to transmit RTS drop delay and turnaround delay i e turn around delay will be ignored only for the RTU and Serial IO protocols in this case Note Either the old form length 10H or the new form length 12H of the COMMREQ
37. process being controlled Two key questions when setting up a PID loop are 1 How big is the change in PV when we change CV by a fixed amount or what is the open loop gain 2 How fast does the system respond or how quickly does PV change after the CV output is stepped Many processes can be approximated by a process gain first or second order lag and a pure time delay In the frequency domain the transfer function for a first order lag system with a pure time delay is PV s CV s G s K e Tp s 1 Tc s Plotting a step response at time t0 in the time domain provides an open loop unit reaction curve CV Unit Step Output to Process PV Unit Reaction Curve Input from P rocess 0 632K Tp Tc The following process model parameters can be determined from the PV unit reaction curve K Process open loop gain final change in PV change in CV at time t0 Note no subscript on K Tp Process or pipeline time delay or dead time after t0 before the process output PV starts moving Tc First order Process time constant time required after Tp for PV to reach 63 2 of the final PV Usually the quickest way to measure these parameters is by putting the PID block in Manual mode and making a small step in CV output by changing the Manual Command Ref 13 and plotting the PV response over time For slow processes this can be done manually but for faster processes a chart recorder or computer graphic data logg
38. specific guidelines as well as the following specifications Environmental Vibration IEC 68 2 6 1G 57 150Hz 0 012in p p 10 57Hz Shock IEC 68 2 27 15G 11ms Operating Temp 0 deg C to 60 deg C ambient Storage Temp 40 deg C to 85 deg C Humidity 5 to 95 noncondensing Enclosure P rotection IEC529 Steel cabinet per IP 54 EMC Emission Radiated Conducted EMC Immunity Electrostatic Discharge RF Susceptibility Fast Transient Burst Surge Withstand Conducted RF Isolation Dielectric Withstand Power Supply Input Dips Variations VersaMax PLC CISPR 11 EN 55011 CISPR 22 EN 55022 FCC 47 CFR 15 EN 61000 4 2 EN 61000 4 3 ENV 50140 ENV 50204 mMm 61000 4 4 ANSI IEEE C37 90a EC255 4 mMm 61000 4 5 mMm 61000 4 6 UL508 UL840 IEC664 EN 61000 4 11 User s Manual March 2001 protection from dust amp splashing water Industrial Scientific amp Medical E quipment Group 1 Class A Information Technology Equipment Class A referred to as FCC part 15 Radio Devices Class A 8KV Air 4KV Contact 10V___ m 80Mhz to 1000Mhz 80 AM rms 10Vims m 900MHz 5MHZ 100 AM with 200Hz square wave 2KV power supplies 1KV 1 0 communication Damped Oscillatory Wave 2 5KV power supplies 1 0 12V 240V 1KV communication Damped Oscillatory Wave Class Il power supplies I O 12V 240V 2 kV cm P S 1 kV cm I O and communication modules 10V 0 15 to 80Mhz 8
39. system software fault restarted LAN IF LAN system software fault resuming gt odule software corrupted requesting reload Catastrophic internal system error Contact GE Fanuc Automation NA odule state doesn t permit Comm_Req COMMREQ received when Ethernet interface cannot process discarded COMMREQ Make sure Ethernet interface is configured and online Unsupported feature in configuration Attempt has been made to configure a feature not supported by the Ethernet interface Check CPU revision order upgrade kit for CPU and or Ethernet interface Ifthe problem persists contact GE Fanuc Automation NA 13 18 VersaMax PLC User s Manual March 2001 GFK 1503C Checking the Status of the Ethernet Interface GFK 1503C The application program can monitor the status of the Ethernet interface using the status bits described below The beginning address of the data is the Status Address entered when configuring the CPU See Configuring the Ethernet Interface in chapter 6 for details The Ethernet interface updates these status bits every PLC I O scan The Ethernet status bits normally occupy a single block of memory Most of these bits are reserved Five are of interest for checking the status of the Ethernet interface Bit 3 Full Duplex Bit 13 LAN OK Bit 14 Resource Problem Bit 16 LAN Interface OK Brief Description 1 2 Reserved always 0 3 ull duplex Reserved always 0 Ce
40. the coil represented by E1 is turned ON whenever reference E2 or E6 is ON The coil represented by E1 is turned OFF whenever reference ES or E3 is ON A O E6 E5 amp E3 Retentive SET Coil Retentive SET and RESET coils are similar to SET and RESET coils but they are retained across power failure or when the PLC transitions from to Run mode A retentive SET coil sets a discrete reference ON if the coil receives power flow The reference remains ON until reset by a retentive RESET coil Retentive RESET Coil This coil sets a discrete reference OFF if it receives power flow The reference remains OFF until set by a retentive SET coil The state of this coil is retained across power failure or when the PLC transitions from Stop to Run mode Chapter 10 Instruction Set Reference 10 67 10 68 Table Functions The Table functions are used to Copy array data ARRAY MOVE Search for values in an array The maximum length allowed for these functions is 32 767 for any type Data Types for the Table Functions Table functions operate on these types of data INT Signed integer DINT Double precision signed integer BOOL Bit data type BYTE Byte data type WORD Word data type Applies to Array Move only VersaMax PLC User s Manual March 2001 GFK 1503C Table Functions Array Move The Array Move function copies a specified number of elements from a sour
41. 7 ING CONST IN6 01500 00000 const N7 const N7 00000 00000 ALW_ON T0001 iz ma PID_ IND R0001 SP CVF AQ0002 Al0003 py M0001 1 MAN M0004 UP M0004 H DN isa R0100 ADD_ INT R0113 7 11 QF R0113 R0002 4 12 M0003 1 SUB_ INT R0113 7 11 QF R0113 R0002 12 The block can be switched to Manual mode with M1 so that the Manual Command R113 can be adjusted Bits M4 or M5 can be used to increase or decrease R113 and the PID CV and integrator by 1 every 100 MSec solution For faster manual operation bits M2 and M3 can be used to add or subtract the value in R2 to from R113 every PLC sweep The T1 output is on when the PID is OK Chapter 14 The PID Function 14 17 Chapter The EZ Program Store Device 15 This chapter describes the VersaMax EZ Program Store device which can be used to transfer program configuration and reference tables data from one PLC to one or more others of the same type Green IC200ACC003 OK Amber Active PLC EZ PROGRAM STORE f Blink i Error Contents of this chapter Description of the EZ Program Store device Details of Using the EZ Program Store device Read Write Verify Data with a Programmer Present Write Data to a PLC CPU without a Programmer Present GFK 1503C 15 1 IC200ACC003 EZ Program Store Device 15 2 The EZ Program Store device IC200ACC003 can be used to store a
42. Bit Sequencer 10 16 The Bit Sequencer function performs a bit sequence shift through an array of bits Enable BIT_ OK SEQ Reset R Direction DIR Number STEP tarting Address ST Address The operation of the function depends on the previous value of the parameter EN R Current EN Previous EN Current Execution Execution Execution Bit Sequencer Execution OFF OFF OFF Bit sequencer does not execute OFF OFF ON Bit Sequencer increments decrements by 1 OFF ON OFF Bit sequencer does not execute OFF ON ON Bit sequencer does not execute ON ON OFF ON OFF Bit sequencer resets The reset input R overrides the enable EN and always resets the sequencer When R is active the current step number is set to the value passed in via the step number parameter If no step number is passed in step is set to 1 All of the bits in the sequencer are set to 0 except for the bit pointed to by the current step which is set to 1 When Enable is active and Reset is not active the bit pointed to by the current step number is cleared The current step number is incremented or decremented based on the direction parameter Then the bit pointed to by the new step number is set to 1 The parameter ST is optional If it is not used the Bit Seqencer function operates as described above except that no bits are set or cleared The function just cycles the current step number through its l
43. CERM E Single ended A PLC or NIU I O Station connected directly to one expansion rack with non isolated Expansion Transmitter Module IC200ERMO002 Maximum cable length is 1 meter VersaMax PLC or NIU I O Station Main Rack Ps gt Dc CPU NIU 1M Z VersaMax Expansion Rack IC200CBL600 PS l og am 1 12 VersaMax PLC User s Manual March 2001 GFK 1503C VersaMax Modules for Expansion Racks All types of VersaMax I O and communications modules can be used in expansion racks Some VersaMax analog modules require specific module revisions as listed below Module Module Revision C200ALG320 B or later C200ALG321 B or later C200ALG322 B or later C200ALG 430 C or later C200ALG431 C or later C200ALG432 B or later Available Expansion Modules The following Expansion Modules and related products are available Expansion Modules Expansion Transmitter Module C200ETM001 Expansion Receiver Module Isolated C200ERM001 Expansion Receiver Module Non isolated C200ERM002 Cables Expansion Cable 1 meter C200CBL601 Expansion Cable 2 meters C200CBL602 Expansion Cable 15 meters C2
44. Carrier please see the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 1 14 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Profibus DP Network Slave Module The Profibus DP Network Slave Module IC200BEM002 is a communications module that exchanges PLC reference table data on the Profibus network The VersaMax PLC CPU can read and write this data as though it were conventional bit and word type I O data Multiple Profibus DP Network Slave Modules may be used in the same VersaMax PLC Each one can read up to 244 bytes of data from the network and send up to 244 bytes of output data The total amount of combined inputs and outputs is 384 bytes For information about the Profibus DP Network Slave Module refer to the VersaMax System Profibus Network Modules User s Manual GFK 1534 revision A or later DeviceNet Network Control Module The DeviceNet Network Control Module IC200BEM103 is a communications module that can be configured to operate as a master as a slave or as both simultaneously It can exchange up to 512 bytes of input data and 512 bytes of output data with other devices on the DeviceNet network The VersaMax PLC CPU can read and write this data as though it were conventional bit and word type I O data The Network Control Module operates as a Group 2 Only Client master and can communicate only with Group 2 Slave devices It can also operate as a Group 2 Only or a UCM
45. DMA failure 2 1 RAM failure 2 2 stack error 2 3 shared memory interface error 2 4 firmware CRC error 3 1 unidentified instruction or divide by 0 3 2 unexpected SWI interrupt 3 3 prefetch abort error 3 4 data abort error 3 5 unexpected IRQ request 3 6 unexpected FIQ interrupt 3 7 reserved exception error 4 1 fatal operating system startup or EEPROM error GFK 1503C Chapter 13 Ethernet Communications 13 15 13 16 Ethernet LEDs Indications Actions Waiting for Ethernet configuration data from Use the PLC programmer to update CPU the configuration then store the LAN O of PORT 1 PLC CPU is controlling Port 1 configuration to the PLC STAT J Slow blink green Power cycle the PLC Port off m Clear faults and press the Restart pushbutton for less than 5 seconds to restart the Ethernet interface Waiting for IP Address IP address has not been configured or LAN Green fickering LAN Ethernet interface is online Flickers during has been configured as 0 0 0 0 STAT CB Slow blink green activity Use the PLC programmer to STAT IP Address has not been configured i PORT O of PORT 1 PLC CPU is controling Port 1 configure a non zero IP address a Waiting for IP Address LAN Green fickering LAN Ethernet interface is online Flickers during STAT J Slow blink green activity
46. Delay Timer Function mmmaomm ronmpgpow p Input Choices Description Output address R The function uses three consecutive words registers of R memory to store the following Current value CV word 1 Preset value PV word 2 Control word word 3 Do not use this address with other instructions Careful Overlapping references cause erratic operation of the timer enable flow When enable receives power flow the timer s current value is incremented PV 1Q M T G R Al PV is the value to copy into the timer s preset value when the timer is AQ constant none enabled or reset Fora register R OV reference the PV parameter is Specified as the second word of the address parameter For example an address parameter of R 0001 would use R 0002 as the PV parameter Q flow none Output Q is energized when the current value is less than the preset value The Q state is retentive on power failure no automatic initialization occurs at powerup time tenths hundredths or Time increment for the low bit of the PV preset and CV current value thousandths of seconds 10 80 VersaMax PLC User s Manual March 2001 GFK 1503C Timer and Counter Functions Up Counter The Up Counter function counts up to a designated value The range is 0 to 32 767 counts When the Up Counter reset is ON the Current Value of the counter resets to 0 Each time the enable input transitions f
47. Discrete Input Type 2 P Discrete Output Type 1 Oooo Discrete Output w ESCP Per Point 116 Fault R eporting Discrete Output Type 2 ntelligent Discrete Input 20 P oints ntelligent Discrete Output 12 P oints 1 Intelligent Analog Input 4 Channels 58 89 89 90 12 26 81 05 13 xk Intelligent Analog Input 7 Channels Intelligent Analog Input 8 Channels Moa gt DI gt SIPIPIPIPRI D al ee aa e a 5 Ee a e 5 E E BAA E Ea Pm a colololojo l ol o amp e fo Je e Je Je o o lo lols5 l5 l5 FlsislslzZlelz Sis lois Iisisisc SIS Sl S refol xr Ee loflrRlmol AttToalo olSlSsls S z z ESIS S NS slo L 23 2 S S5 S Slala SIS S S a 2 2 S O o oy 14r QIlIn lIn ans wn Intelligent Analog Output 4 Channels 212 es PLC Network Comm Profibus DP x Xk Slave Mixed modules have both and input and output scan time values Network Communications Modules NCM Scan Impact Times vary depending upon the network configuration GFK 1503C Appendix A Performance Data Modules Located in Single ended Expansion Rack The table below shows timing for modules located in a single ended expansion rack with a non isolated Expansion Receiver module C200ERMO002 This type of system does NOT have an Expansion Transmitter module IC200ETMO001 in the main rack CPU005 CPUE05 Module Type Local Single Rack Discrete Output w ESCP Per Point Fault R eporting 27 79 ntelligent D
48. Non volatile flash memory for program storage Battery backup for program data and time of day clock Run Stop switch Floating point real data functions Embedded RS 232 and RS 485 communications Embedded Ethernet interface 70mm height when mounted on DIN rail with power supply VersaMax PLC User s Manual March 2001 GFK 1503C CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory IC200CPUE05 Module Specifications 4 95 126mm x 5 04 128mm Program storage System flash battery backed RAM Backplane current consumption no serial port converter or EZ 5V output 3 3V output IC200C PUEOS Program Store device 160mA 650mA with serial portconverterorEZ 5V output Program Store device 260mA Floating point Boolean execution speed 0 5ms K typical Realtime clock accuracy for timer 100ppm 0 01 or 9sec day functions Time of day clock accuracy 23ppm 0 0023 or 2sec day 30C 100 ppm 0 01 or 9sec day full temperature range Embedded communications RS 232 RS 485 Ethernet interface Configurable memory 64K bytes maximum connections Physical interface 10BaseT RJ 45 configuration based exchanges 100 data ranges and 1400 bytes of data per exchange 1200 total data ranges across all exchanges Time Synchronization NTP client only Selective Consumption of EGD yes Load EGD configuration from PLC yes to programmer Remote Station Manager over U
49. PLC Fault Table Descriptions PLC Fault User Action Backplane communications with PLC fault lost Check that PLC CPU is running normally usually in Run mode request Check to make sure you are not sending COMMREQs faster than the Ethernet interface can process them Bad local application request discarded request Check for valid COMMREQ command code Bad remote application request discarded Try to validate the operation of the remote node request Can t locate remote node discarded request Error reported when message received where IP address cannot be resolved Error may indicate that remote host is not operational on the network Check that remote host is operational on network and its addresses are correct Comm_req Bad task ID programmed Message from PLC for unknown Ethernet interface task Check COMMREQ function block Comm_req Wait mode not allowed Check COMMREQ to make sure sent in no wait mode LAN data memory exhausted check parms The Ethernet interface does not have free memory to process resuming communications LA Veri trat connection iis are rotbeing exceeded I F capacity exceeded discarded request Verify that connection limits are not being exceeded transceiver fault Off network until fixed Ethernet interface is not properly connected to the network Check the connection to the network hub or switch LAN system software fault aborted connection TESUMINg Internal system error LA
50. Q 12 Range for constants in doubleprecision signed integer T operations is minimum maximum DINT ok flow none The OK output is energized when the function is performed without overflow unless an invalid operation occurs Q All data types R Al Output Q contains the result of the operation AQ INT only 1 Q M T G Data Types for Standard Math Functions Standard math functions operate on these types of data INT Signed integer DINT Double precision signed integer REAL Floating Point The input and output parameter data types must be the same 16 bits or 32 bits GFK 1503C Chapter 10 Instruction Set Reference 10 49 10 50 Math and Numerical Functions Add Subtract Multiply Divide Avoiding Overflows Be careful to avoid overflows when using Multiplication and Division functions If you have to convert Integer to Double Precision Integer values remember that the CPU uses standard 2 s complement with the sign extended to the highest bit of the second word You must check the sign of the low 16 bit word and extend it into the second 16 bit word If the most significant bit in a 16bit INT word is 0 positive move a 0 to the second word If the most significant bit in a 16bit word is 1 negative move a 1 or hex OFFFFh to the second word Converting from Double Precision Integer to Integer data is easier because the low 16 bit word first register is the integer portio
51. The integrator value is adjusted if the CV rate limit is exceeded If Minimum Slew Time is 0 there is no CV rate limit Set Minimum Slew Time to 0 while tuning or adjusting PID loop gains 14 7 Address 12 Address 13 14 8 ow 5 bits used Bit 0 to 2 for Manual Command CV Counts Errort OutP olarity Deriv Tracks CV in Auto or Sets CV in Manual The low 5 bits of this word are used to modify three standard PID settings The other bits should be set to 0 Set the low bit to 1 to modify the standard PID Error Term from the normal SP PV to PV SP reversing the sign of the feedback term This is for Reverse Acting controls where the CV must go down when the PV goes up Set the second bit to a 1 to invert the Output Polarity so that CV is the negative of the PID output rather than the normal positive value Set the fourth bit to 1 to modify the Derivative Action from using the normal change in the Error term to the change in the PV feedback term The low 5 bits in the Config Word are defined in detail below it 0 Error Term When this bitis 0 the error term is SP PV When this bit is 1 the error term is PV SP Bit 1 Output Polarity When this bit is 0 the CV output represents the output of the PID calculation When itis set to the CV output represents the negative of output of the PID culation it 2 Derivative action on PV When this bit is 0 the erivative action is applied to the error
52. YM and G references have associated transition and override bits T S WSA SB and SC references have associated transition bits only The CPU uses transition bits for transitional coils When override bits are set the associated references can only be changed from the programmer Chapter 9 Program Data 9 3 Ll Retentiveness of Data Data is retentive if it is automatically saved when the PLC is stopped or power cycled The following data is retentive Program logic Fault tables and diagnostics Overrides Word data R AI WAQ Bit data I SC G fault bits and reserved bits Word data stored in Q and M Data in Q or M references that are used as function block outputs or with retentive coils M retentive coils M negated retentive coils SM retentive SET coils RM retentive RESET coils The last time a Q or M reference is used with a coil the coil type determines whether the data is retentive or non retentive For example if Q0001 was last programmed as the reference of a retentive coil the Q0001 data is retentive However if QO001 was last programmed on a non retentive coil then the QO001 data is non retentive Q or M references that have been made retentive by specifically declaring them to be retentive Q and M references default to non retentive The following data is non retentive 9 4 The states of transition coils T data S WSA and SB data but SC bit da
53. address time since start of sweep Example of SVCREQ 9 In the following example the elapsed time from the start of the sweep is always read into location RO200 If it is greater than 100ms internal coil M0200 is turned on SVC_ REQ CONST o 00009 FNC R0200 R0200 PARM CONST 0100 VersaMax PLC User s Manual March 2001 M0200 GFK 1503C SVCREQ 10 Read Folder Name GFK 1503C Use SVCREQ 10 to read the name of the currently executing folder Output Parameter Block Format for SVCREQ 10 The output parameter block has a length of four words It returns eight ASCII characters the last is a null character 00h If the program name has fewer than seven characters null characters are added to the end Low Byte High Byte Example of SVCREQ 10 In this example when enabling input 10301 goes OFF register location R0099 is loaded with the value 10 which is the function code for the Read Folder Name function The Program Block READ_ID is then called to retrieve the folder name The parameter block is located at address RO100 10301 READ _ID MOVE UINT CONST IN QJ R0099 0010 Program Block READ_ID SVC_ REQ R0099 FNC R0100 PARM Chapter 11 The Service Request Function 11 17 SVCREQ 11 Read PLC ID Use SVCREQ 11 to read the name of the PLC executing the program Output Pa
54. complete the requested connection The remote modem is already in use retry the connection request later Modem responded with NO CARRIER Modem is unable to complete the requested connection Check the local and remote modems and the telephone line 8 08h Modem responded with NO DIALTONE Modem is unable to complete the requested connection Check the modem connections and the telephone line Modem responded with ERROR Modem is unable to complete the requested command Check the modem command string and modem 10 0Ah Modem responded with RING indicating that the modem is being called by another modem Modem is unable to complete the requested command Retry the modem command later 11 0Bh Unknown response received from the modem Modem unable to complete the request Check the modem command string and modem Response should be CONNECT or OK 50 32h COMMREQ timeout The COMMREQ did not complete within a 20 second time limit GFK 1503C Chapter 12 Serial I O SNP RTU Protocols 12 11 Serial I O COMMREQ Commands The following COMMREQs are used to implement Serial I O m Local COMMREQs do not receive or transmit data through the serial port O Initialize Port 4300 Set Up Input Buffer 4301 Flush Input Buffer 4302 Read Port Status 4303 Write Port Control 4304 O Cancel Operation 4399 m Remote COMMREQs receive and or transmit data through the serial port o Autodial 4400 O Write Bytes
55. for operations like moving data stored in memory performing math operations and controlling communications between the CPU and other devices in the system Some program functions such as the Jump function and Master Control Relay can be used to control the execution of the program itself Together this large group of Ladder Diagram relays coils and functions is called the Instruction Set of the CPU VersaMax PLC User s Manual March 2001 GFK 1503C The Instruction Set The VersaMax PLC CPU provides a powerful Instruction Set for building application programs As a guide to the programming capabilities of the VersaMax PLC all of the relays coils functions and other elements of the Instruction Set are summarized on the following pages Complete reference information is included in the documentation and online help for the programming software Contacts Normally Open Passes power if the associated reference is ON Normally Closed Passes power if the associated reference is OFF lt gt Passes power to the right if the preceding continuation coil is set ON Coils Normally Open Sets the associated reference ON if the coil receives power Otherwise OFF Negated Sets the associated discrete reference ON ifthe coil does not receive power Otherwise OFF Positive If power flow was OFF to this coil the last time it was executed and is ON this time Transition then the coil
56. function always passes power flow when power is received unless the data is out of range Enable Be D4 OK INT Value to be converted 7 IN Q Output Parameters of the Convert to Signed Integer Function Input Choices Description Output enable flow When the function is enabled the conversion is performed IN For BCD 4 1 Q M T G R Al IN contains a reference for the BCD 4 REAL or AQ constant Constant value to be converted to integer For REAL R Al AQ ok flow none The OK output is energized whenever enable is energized unless the data is out of range or NaN Not a Number Q Q M T G R Al AQ Output Q contains the integer form of the original value in IN Example In the example whenever input I0002 is set the BCD 4 value in PARTS is converted to a signed integer and passed to the Addition function where it is added to the signed integer value represented by the reference RUNNING The sum is output by the Addition function to the reference TOTAL 10002 BCD4 ADD To INT INT PARTS IN QF R0001 RO001 7 IN1Q fF TOTAL RUNNING 7 IN2 GFK 1503C Chapter 10 Instruction Set Reference 10 43 10 44 Data Type Conversion Functions Convert to Double Precision Signed Integer The Convert to Double Precision Signed Integer function outputs the double precision signed integer equivalent of real data The original data is not changed b
57. in byte mode P C Q Discrete output memory in byte mode P C T Discrete temporary memory in byte mode P C M Discrete momentary memory in byte mode P C SA Discrete system memory group A in byte mode P C SB Discrete system memory group B in byte mode P C SC Discrete system memory group C in byte mode P C G Discrete global data table in byte mode P C The Data Ranges in a Global Data Exchange The variable ranges in an exchange are defined in the Ethernet Global Data configuration in hardware configuration There can be Up to 1200 data ranges for all EGD exchanges for one CPUE0S Up to 100 data ranges per exchange A length of 1 byte to 1400 bytes per exchange The total size of an exchange is the sum of the data lengths of all of the data ranges configured for that exchange Different exchanges may share some or all of the same data ranges even if the exchanges are produced at different rates A consumer does not have to consume all of the data from a produced exchange A consumed exchange may be configured to ignore specified data ranges See Selective Consumption in chapter 6 13 10 VersaMax PLC User s Manual March 2001 GFK 1503C Effect of PLC Modes and Actions on Ethernet Global Data The usual PLC mode for Ethernet Global Data operation is Run with I O enabled In that mode Ethernet Global Data remains configured and exchanges are both produced and consumed If the PLC mode is set to Stop with I O disa
58. in user logic space for each instance of the function in a ladder diagram application program Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Bit Logical AND 60 12 50 10 13 Operation Logical OR 60 12 50 10 13 Logical Exclusive OR 60 12 50 10 13 Logical Invert NOT 50 12 40 10 10 Shift Bit Left 134 12 80 10 14 78 16 Shift Bit Right 129 12 80 10 16 31 16 Rotate Bit Left 110 12 70 10 18 45 16 Rotate Bit Right 111 12 70 10 18 41 16 Bit Position 76 12 57 10 13 Bit Clear 70 12 56 10 13 Bit Test 60 12 44 10 13 Bit Set 70 12 56 10 13 ask Compare WORD 158 12 110 10 25 ask Compare DWORD 150 12 100 10 25 Bit Sequencer 150 109 101 TI 0 24 16 Data Move ove INT 45 12 32 10 2 83 10 ove BIT 80 12 60 10 10 76 13 ove WORD 46 12 32 10 2 82 10 ove REAL 60 12 47 10 2 75 13 Block Move INT 60 12 50 10 28 Block Move WORD 60 12 50 10 28 Block Move REAL 113 12 94 10 13 Block Clear 100 12 83 10 4 63 11 Shift R egister BIT 130 12 94 10 0 45 16 Shift Register WORD 120 12 100 10 2 76 16 COMM_REQ 175 175 120 120 13 Commreq sent to HSC module GFK 1503C Appendix A Performance Data A 5 Sizes of Table Functions The size of a function is the number of bytes consumed in user logic space for each instance of the functio
59. is configured for 115 2K baud a major error code 12 OcH and a minor error code 2 02H is returned in the COMMREQ status word This will occur for any unsupported baud rate VersaMax PLC User s Manual March 2001 GFK 1503C Example COMMREQ Data Block for Configuring Serial I O Protocol GFK 1503C First 6 words Address 6 Address 7 Address 8 Address 9 Address 10 Address 11 Address 12 Address 13 Address 18 21 Address 22 Address 22 Notes The data block length Address 0 for a COMMREQ that includes the Receive to transmit delay and RTS drop delay should be 12H not 10H Both forms Length Values Meaning Reserved for COMMREQ use FFFOH Command 0005 Protocol 0005 Serial IO 0 Slave Port Mode 4 4800 5 9600 6 19200 Data Rate 7 38400 8 57600 CPU models IC200C PU005 and CPUE05 only 0 None 1 Odd 2 Even Parity 0 Hardware 1 None Flow Control 0 255 units of 10ms e g Turnaround Delay 10 100ms 0 Long Timeout 0 7 bits 1 8 bits Bits per Character 0 1 stop bit 1 2 stop bits Stop Bits not used Interface 0 2 wire 1 4 wire Duplex Mode not used Device Identifier 0 255 units of 10ms e g 10 100ms Receive to transmit delay 0 255 units of 10ms e g 10 100ms RTS drop delay 10H and 12H are supported If Serial I O is configured for 115 2K baud a major error code 12 OcH anda minor e
60. is halted is indeterminate In addition the final character received by the device the CPU is sending to is also indeterminate Chapter 12 Serial I O SNP RTU Protocols 12 23 Read Bytes Function 4402 This function causes one or more characters to be read from the specified port The characters are read from the internal input buffer and placed in the specified input data area The function returns both the number of characters retrieved and the number of unprocessed characters still in the input buffer If zero characters of input are requested only the number of unprocessed characters in the input buffer is returned If insufficient characters are available to satisfy the request and a non zero value is specified for the number of characters to read the status of the operation is not complete until either sufficient characters have been received or the time out interval expires In either of those conditions the port status indicates the reason for completion of the read operation The status word is not updated until the read operation is complete either due to timeout or when all the data has been received If the time out interval is set to zero the COMMREQ remains pending until it has received the requested amount of data or until it is cancelled If this COMMREQ fails for any reason no data is returned to the buffer Any data that was already in the buffer remains and can be retrieved with a subsequent read request Exam
61. is shifted into the Shift Register at R0001 The word shifted out of the Shift Register from RO100 is stored in output MO0005 NXT_CYC SHFR_ CLEAR WORD R Qb Mo0005 Q0033 IN RO001 7 ST Example 2 In this example the Shift Register operates on memory locations M0001 through MO100 MO0001 is defined as type Boolean of length 100 When the reset reference CLEAR is active the Shift Register function fills M0001 through MO100 with zeros When NXT_CYC is active and CLEAR is not the Shift Register function shifts the data in MO0001 to M0100 down by one bit The bit in Q0033 is shifted into MO001 while the bit shifted out of MO0100 is written to M0200 NXT_CYC SHFR _ CLEAR BIT R QF M0200 Q0033 IN M0001 ST 10 38 VersaMax PLC User s Manual March 2001 GFK 1503C Data Move Functions Communication Request The Communication Request COMMREQ function communicates with an intelligent module Many types of COMM REQs have been defined The information below describes only the basic format of the function When the function receives power flow a command block of data is sent to the specified module After sending the COMMREQ the program can either suspend execution and wait for a reply for a maximum waiting period specified in the command or resume immediately Enable COMM REQ First word of command block IN FT Location sysID
62. is turned ON Otherwise the coil is turned OFF Negative If power flow was ON to this coil the last time it was executed and is OFF this time Transition then the coil is turned ON Otherwise the coil is turned OFF S SET Sets the associated discrete reference ON if the coil receives power It remains set until reset by an R coil R RESET Sets the associated discrete reference OFF if the coil receives power It remains reset until set by an S coil SM Retentive SET Sets the associated reference is set ON if the coil receives power The reference remains set until reset by an RM coil Its state is retained through power failure and STOPTORUN transition RM Retentive Resets the associated discrete reference OFF if the coil receives power The RESET reference remains reset until set by an SM coil Its state is retained through power failure and STOPTORUN transition M Negated Sets the associated discrete reference ON if the coil does not receive power The Retentive state is retained through power failure and STOPTORUN transition Otherwise OFF M Retentive Sets the associated discrete reference ON if the coil receives power The state is retained through power failure and STOPTORUN transition Otherwise OFF lt gt If power to the coil is ON the continuation coil sets the next continuation contact ON If power is OFF the continuation coil sets the next continuation contact OFF
63. must enter a beginning address for these three words registers Do not use consecutive registers for the 3 word timer counter blocks Timers and counters will not work if you place the current value of a block on top of the preset for the previous block Enable DNCTR Q time Reset R Preset 7 py Value Address The control word stores the state of the boolean inputs and outputs of its associated function block in the following format 15 14 13 12 11 10 9 8 7 e s5 4 a 2 1 0 Be eee a a Reset input Enable input previous execution Q counter timer status output EN enable input Bits 0 through 11 are used for timer accuracy not for counters N If the Preset Value PV is not a constant PV is normally set to a different location than the second word Some applications use the second word address for the PV such as using R0102 when the bottom data block starts at R0101 Itis then possible to change the Preset Value while the timer or counter is running The first CV and third Control words can be read but should not be written or the function will not work VersaMax PLC User s Manual March 2001 GFK 1503C Timer and Counter Functions On Delay Stopwatch Timer A retentive OnDelay Stopwatch Timer ONDTR increments while it receives power flow and holds its value when power flow stops Time may be counted in tenths 0 1 hundredths
64. of the shift register in bits or words Length is defined as the words length of IN R flow When R is energized the shift register located at ST is filled with zeros IN 1 Q M 1 G R IN contains the value to be shifted into the first bit or word of the shift Al AQ constant register ForSHFR_BIT any discrete reference may be used it does not need to be byte aligned ST Q M T SA SB ST contains the first bit or word of the shift register For SHFR_BIT any SC G R Al AQ discrete reference may be used it does not need to be byte aligned ok flow none OK is energized whenever the function is enabled and R is not enabled Q Q M T SA SB Output Q contains the bit or word shifted out of the shift register For SC G R Al AQ SHFR_BIT any discrete reference may be used it does not need to be byte aligned CAUTION the use of overlapping input and output reference address ranges in multiword functions is not recommended it may produce unexpected results GFK 1503C Chapter 10 Instruction Set Reference 10 37 Data Move Functions Shift Register Example 1 In the example the shift register operates on register memory locations R0001 through RO100 R0001 is defined as type Word of length 100 When the reset reference CLEAR is active the Shift Register words are set to zero When the NXT_CYC reference is active and CLEAR is not active the word from output status table location Q0033
65. or VersaMax I O Station system Expansion racks can be located up to 750 meters from the main VersaMax PLC or VersaMax I O Station rack Expansion racks can include any VersaMax I O option or communications module VersaMax provides automatic addressing that can eliminate traditional configuration and the need for hand held devices Multiple field wiring termination options provide support for two three and four wire devices For faster equipment repair and shorter Mean Time To Repair the hot insertion feature enables addition and replacement of I O modules while a machine or process is running and without affecting field wiring VersaMax I O may be remotely located Remote I O interfaces for Genius DeviceNet Profibus and Ethernet are available GFK 1503C Chapter I Introduction 1 3 CPU Modules for VersaMax PLCs A VersaMax PLC consists of a group of VersaMax modules with a VersaMax CPU and attached power supply in the first position VersaMax PLC CPU VersaMax Modules power supply le Ee A i ar ia GEEN g f mi J A I alli el i f 4 D A ie YI RA re pees posez All VersaMax CPUs provide
66. password for that level If the wrong password is entered the change is denied and a fault is logged in the PLC fault table A request to change to a privilege level that is not password protected is made by supplying the new level and an empty password Notes on Using Passwords To re enable passwords after passwords have been disabled the PLC must be power cycled with the battery removed for long enough to completely discharge the super capacitor and erase the PLC s memory Ifthe passwords prevent changing the run stop mode firmware upgrades cannot be performed if the PLC is in run mode The Run Stop switch if configured will place the PLC in run or stop mode regardless of the passwords The OEM Protection Feature The OEM protection feature is similar to the passwords and privilege levels and provides an even higher level of security The feature is enabled or disabled using a 1 to 7 character password called the OEM key When OEM protection is enabled no write access to the PLC program and configuration is permitted Reading the configuration from the PLC is permitted In this mode no user flash operations are allowed When the OEM key password has been created the OEM key can be locked in two ways by choosing the locked setting from the programming software or by power cycling the PLC The OEM key locked status does not change when PLC communications are suspended Clearing Logic Configuration and References It
67. power flow is off and resets to zero when power flow is on Time may be counted in tenths 0 1 hundredths 0 01 or thousandths 0 001 of a second Range is 0 to 32 767 time units The state of this timer is retentive on power failure no automatic initialization occurs at powerup Enable OFDT gt Q 1 00s Preset Value py y Current Value Address 3 words When the Off Delay Timer first receives power flow it passes power to the right and the Current Value CV is set to zero The function uses word 1 register as its CV storage location The output remains on as long as the function receives power flow If the function stops receiving power flow from the left it continues to pass power to the right and the timer starts accumulating time in the Current Value The Off Delay Timer does not pass power flow if the Preset Value is zero or negative If multiple occurrences of the same timer with the same reference address are enabled during a CPU sweep the Current Values of the timers will be the same Each time the function is invoked with the enabling logic set to OFF the Current Value is updated to reflect the elapsed time since the timer was turned off When the Current Value CV is equal to the Preset Value PV the function stops passing power flow to the right and the timer stops accumulating When the function receives power flow again the current value resets to zero When this timer is used in a pr
68. producer consumer period expires the value is set for the entire period an Ethernet Global Data configuration is stored to the PLC the PLC powers up and it has an Ethernet Global Data configuration the Ethernet interface configured for Ethernet Global Data is restarted If the application program uses the Exchange Status word to check exchange status it must clear this word to 0 once a non zero value is written to it That allows the application program to detect a new exchange status in subsequent sweeps The Exchange Status word uses the error codes below to report exchange status See also the Troubleshooting Common Ethernet Difficulties section later in this chapter an Error Description 0 Exchange status has not Produced Initial value until the first producer period refresh occurs been updated Consumed The data has not been refreshed and timeout has not expired 1 No error Produced The produced exchange is producing data Consumed The data has been refreshed on schedule 3 NTP error Consumed only The CPU is configured for network time synchronization but is not synchronized ee Produced and Consumed Error configuring the exchange For CPUE05 4 Specification error this error does NOT indicate a consumed exchange size miscomparison 6 Refresh timeout without Consumed only The timeout period has expired but data has not been data refreshed from the network
69. references Inverse cosine function Inverse sine function Inverse tangent function IP address Configuration Isolated network IP Address 6 3 IP addressing GFK 1503C Keying dials on carrier 1 7 L Label instruction Ladder Diagram 8 6 LAN OK bit LEDs 2 7 8 8 13 15 Logic program storing to flash memory detailed explanation 7 9 Logical NOT function Logical XOR function Loss of Module diagnostic Main prog am 8 3 Manuals 1 2 Math functions 8 8 3 8 Memory allocation Memory bit 9 3 Mode switch 2 6 Modem Hayes compatible Module color code Module dimensions Module keying Module latch Module orientation on I O carriers 1 10 Modules per station Mounting holes Multidrop connections 4 17 NaN GFK 1503C Index Normally closed contact Normally open contact Not a Number NOT function OK LED 1 7 OnDelay Stopwatch Timer 10 75 Output references 9 2 Output references discrete 9 3 Output scan 7 3 Override bits Override status read p Panel mounting PID function time interval PLC configuring PLC Fault Table PLC ID read PLC Sweep calls Serial YO 12 10 Point to point RS 422 connections 4 13 16 2 5 3 5 Port 1 Port 2 Port Status read Ports 10BaseT Power Down Time read Power flow and retentiveness 10 64 Power supply 1 15 Power supply installati
70. resets the Current Value to the Preset Value PV l Q M T G R Al AQ PV is the value to copy into the counters Preset Value when the constant none counter is enabled or reset Q flow none Output Q is energized when the Current Value is less than or equal to zero 10 82 VersaMax PLC User s Manual March 2001 GFK 1503C Timer and Counter Functions Down Counter Example 1 In the example the down counter identified as COUNTP counts 500 new parts before energizing output QO005 NEW_PRT Q0005 CTD C NXT_BAT R CONST 4 0500 BY COUNTP Example 2 Keeping Track of Parts in a Temporary Storage Area The following example shows how the PLC can keep track of the number of parts in a temporary storage area It uses an up down counter pair with a shared register for the accumulated or current value When parts enter the storage area the up counter increases the current value of the parts in storage by 1 When a part leaves the storage area the down counter decrements by 1 decreasing the inventory storage value by 1 The two counters use different register addresses When a register counts its current value must be moved to the current value register of the other counter 100003 CTU 100001 R 100009 CONST 7 py 00005 100003 R0100 MOVE_ INT 100001 E R0100 IN Q R0104 100003 CTD 10
71. result available via output Q The function passes power flow when power is received unless the specified conversion would result in a value that is outside the range 0 to 9999 Enable J INT F OK TO BCD4 Value to be converted N QF Output Parameters of the Convert to BCD 4 Function Input Choices Description Output enable flow When the function is enabled the conversion is performed IN 1 Q M T G R Al AQ IN contains a reference for the integer value to be constant converted to BCD 4 OK flow none The OK output is energized when the function is performed without error Q 1 Q M T G R Al AQ Output Q contains the BCD 4 form of the original value in IN Example In the example whenever input I0002 is set and no errors exist the integer at input location 10017 through 10032 is converted to four BCD digits and the result is stored in memory locations Q0033 through Q0048 Coil Q1432 is used to check for successful conversion 0002 Q1432 t INT_ BCD4 10017 IN Q Q0033 10 42 VersaMax PLC User s Manual March 2001 GFK 1503C Data Type Conversion Functions Convert to Signed Integer The Convert to Signed Integer function outputs the integer equivalent of BCD 4 or Real data The original data is not changed by this function When the function receives power flow it performs the conversion making the result available via output Q The
72. sensitive no spaces crsp_tout Transfer R esponse timeout value in seconds 16 0010H 10 3600 0e10H fflush ARP cache timeout interval in seconds 0 604800 93a80H 600 0258H gctl_port UDP port for Ethemet Global Data control 7937 1f01H 0 65535 ffffH messages gdata_port UDP port for point to point Ethernet Global Data 18246 4746H 0 65535 ffffH messages gbcast_ttl IP time to live for global broadcast messages hop 1 1H 0 255 00ffH count gucast_ttl IP time to live for point to point messages hop 16 10H 0 255 OOffH count gXX_udp UDP port for host group XX 18246 4746H 0 65535 ffffH gXX_ttl IP time to live for host group multicast messages 1 1H 0 255 OOffH hop count gXX_addr IP group address for host group XX must be 224 0 7 XX 224 0 0 2 class D address 239 255 255 255 ittl IP header default time to live hop count 64 0040H 0 255 00ffH ifrag_tmr IP fragment timeout interval in seconds 3 0003H 0 65535 ffffH wnodelay TCP nodelay option 0 inactive 1 active 0 000H 0 1 wkal_idle TCP keepalive timer value in seconds 240 00f0H 4 0 0 65535 ffffH minutes wkal_cnt TCP keepalive probe count 2 0002H wkal_intvl TCP keepalive probe interval in seconds 60 003cH wms TCP maximum segment lifetime in seconds 30 001eH wsnd_buf TCP send buffer size in bytes 4096 1000H 0 32767 7fffH wrcv_buf TCP receive buffer size in bytes 4096 1000H nmin_polll NTP min poll interval f
73. slots Configuring CPU parameters Configuring CPU memory allocation Configuring serial port parameters Storing a configuration from a programmer Autoconfiguration 5 1 Using Autoconfiguration or Programmer Configuration VersaMax PLCs can be either autoconfigured or configured from a programmer using configuration software Both types of configuration are described in this chapter Autoconfiguration Autoconfiguration occurs at powerup when the PLC CPU automatically reads the configuration of the modules installed in the system and creates the overall system configuration Modules that have software configurable features can only use their default settings when autoconfigured Software Configuration Most PLC systems use a customized configuration that is created using configuration software and stored to the CPU from a programmer The CPU retains a software configuration across power cycles After a software configuration is stored to the CPU the CPU will not autoconfigure when power cycled The configuration software can be used to Create a new configuration Store write a configuration to the CPU Load read an existing configuration from a CPU Compare the configuration in a CPU with a configuration file stored in the programmer Clear a configuration that was previously stored to the CPU The CPU stores a software configuration in its non volatile RAM Storing a configuration disables autoco
74. strings or to blink a group of bits at the rate of one ON state per two scans Parameters of the Exclusive OR Function Input Choices Description Output enable flow When the function is enabled the operation is performed 1 1 Q M T S G R Al Constant or reference for the first word to be XORed AQ constant 2 Q M 1 G R Al Constant or reference for the second word to be XORed AQ constant ok flow none The OK output is energized whenever enable is energized Q 1 Q M T SA SB SC Output Q contains the result of the operation not S G R Al AQ Chapter 10 Instruction Set Reference 10 5 Bit Operation Functions Exclusive OR Example In the example whenever 10001 is set the bit string represented by the nickname WORD3 is cleared set to all zeros IO001 WORLDS u OF WORD worrs 2 11 WORD3 12 WORD3 Q WORDS 10 6 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Logical Invert NOT The Logical Invert NOT function sets the state of each bit in the output bit string Q to the opposite of the state of the corresponding bit in bit string I1 All bits are altered on each scan that power is received making output string Q the logical complement of I1 The function passes power flow to the right whenever power is received A length of 256 words can be selected Enable NOT_ OK WORD Input 1 1 Q O
75. the CPUE05 will synchronize itself to an external NTP time server if one exists atampi Hin Pt Time Stamp R 91 Time Stamp Optional place for the PLC to put the timestamp Exchange A list of 1 to100 data ranges that will be received in the exchange Data is received Data Ranges as a contiguous set of bytes The total size of all combined elements can be up to 1400 bytes For consumed exchanges S memory types and override references are not allowed See Table 4 2 for valid memory types Note If the consumed exchange length does not match that of the produced exchange PLC Faults and Ethernet exception entries occur The list of data ranges to be received in an exchange specifies sang ah Pit 104 eve in Butt ma o a CS GFK 1503C Chapter 6 Ethernet Configuration 6 7 6 8 Selective Consumption Not all data ranges within a produced exchange need to be consumed by each PLC For example a producer is producing an exchange consisting of a 4 byte floating point value followed by a 2 byte integer followed by a 2 byte analog value If the consuming PLC wants to consume only the analog value and place it into AI003 the consumer might be configured as shown below ofset Reference Low Point High Point Deseripton o wee 6 lore fat anditeger Note that the total length of the exchange must be the same in producer and consumer even if the consumer is ignoring bytes at the end of the message Fai
76. the transfer after the data in the PLC was erased Try the update again by disconnecting and reconnecting the device and pressing the pushbutton If the second update fails contact the update provider for service Update errors are reported as USD Flash Read faults in the PLC Fault Table The first two bytes of extra fault data describe the fault GFK 1503C Chapter 15 The EZ Program Store Device 15 9 Appendix Performance Data A This section presents performance data collected on the VersaMax CPUs IC200CPU001 CPU002 CPU005 and CPUE0S The data includes base sweep time sweep impact of boolean instructions function block sweep impact times function block sizes and I O module scan time data Base Sweep Time The table below shows the base sweep time with the default program in Run mode no I O modules present or configured and no serial connections to either serial port Modea Time in milliseconds CPU001 002 1 605 CPU005 1 039 CPUE05 1 910 Boolean Instruction Time This table shows the typical sweep impact time for boolean instructions Modi Typical Time in microseconds GFK 1503C A 1 Function Block Timing The following tables show the sweep impact times and size information for all supported function blocks of the CPU Sweep Impact Times The tables show two sweep impact times are shown for each function An Increment time is shown for functions that can have variable length inputs table
77. value 100 R2 contains the value 0 0001 RANGE Q0001 Cy RO001 L1 Q R0002 L2 AIO01 7 IN Output coil Q0001 is On only if the value presently in AI0001 is within the range 0 to 100 IN Value AI001 Q State Q0001 lt 0 OFF 0 100 ON gt 100 OFF GFK 1503C Chapter 10 Instruction Set Reference 10 61 10 62 Relay Functions Normally Open Contact Normally Closed Contact Normally Open Coil Retentive SET Coil SM Retentive RESET Coil RM Negated Retentive Coil M Negated Coil Retentive Coil M SET Coil S RESET Coil R Positive Transition Coil T Negative Transition Coil 4 Vertical Link vert Horizontal Link horz Continuation Coil lt gt Continuation Contact lt gt Each relay contact and coil has one input and one output Together they provide logic flow through the contact or coil Input Output VersaMax PLC User s Manual March 2001 GFK 1503C Relay Functions Normally open Normally closed Continuation Contacts GFK 1503C A contact is used to monitor the state of a reference Whether the contact passes power flow depends on the state or status of the reference being monitored and on the contact type A reference is ON if its state is 1 it is OFF if its state is 0 Type of Contact Displ
78. value for BIT is outside the range 1 lt BIT lt 16 length Then OK is set OFF Enable BIT_ OK SET_ WORD First word IN Bit number of IN 7 BIT Parameters of the Bit Set and Bit Clear Functions Input Choices Description Output enable flow When the function is enabled the bit operation is performed IN 1 Q M T SA SB SC IN contains the first word of the data to be operated on G R Al AQ BIT Q M T G R Al AQ BIT contains the bit number of IN that should be set or cleared constant Valid range is 1 lt BIT lt 16 length ok flow none The OK output is energized whenever the bit input is valid and enable is energized Example In the example whenever input I0001 is set bit 12 of the string beginning at reference RO0040 is set to 1 10001 m oaa BIT F WORD R0040 4 IN Q CONST 4 BIT 00012 10 12 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Masked Compare The Masked Compare function compares the contents of two separate bit strings It provides the ability to mask selected bits Input string 1 might contain the states of outputs such as solenoids or motor starters Input string 2 might contain their input state feedback such as limit switches or contacts Enable 7 MASK_ COMP WORD Input 1 11 MC Miscompare Input2 12 Qf Output Bit string mask 7 M BN Bit number of last compare
79. 0 0 Oj 0 O 1 1 0 1 1 1 0 1 14 1 0 Of 1 0 0 0 1 1 0 1 1 1 0 0 1 0 0 0 1 0 0 Oj 0 1 OF 1 0 1 0 0 1 oa o The PLC uses six types of references for data stored in bit memory l Normally used for discrete inputs and viewable in the Input Status Table Q Normally used for physical output references and viewable in the Output Status Table A Q reference may be either retentive or non retentive depending on its use in the program M Normally used to represent internal references A specific M reference may be either retentive or non retentive depending on its use in the program T Used for temporary references that can be used many times in a program Data with T references is not retained through loss of power or RUN TO STOP TO RUN transitions T references cannot be used with retentive coils S System status references which have specific predefinitions G coils S SA SB and SC can be used for any type of logic contact SA SB and SC can be used for retentive coils S can be used as inputs to functions or function blocks SA SB and SC can be used as inputs or outputs of functions and function blocks Used for Global Data Data in G references is retained through power loss G references can be used with contacts and retentive coils but not on non retentive Transition Bits and Override Bits 1 Q
80. 0 AM rms 1 5KV During Operation Dips to 30 and 100 Variation for AC 10 Variation for DC 20 GFK 1503C IC200CPU001 CPU with 34kB Configurable Memory IC200CPU002 CPU with 42kB Configurable Memory IC200CPU005 CPU with 64kB Configurable Memory GFK 1503C Serial Ports The two serial ports are software configurable for SNP slave or RTU slave operation 4 wire and 2 wire RTU are supported If a port is being used for RTU it automatically switches to SNP slave mode if necessary Both ports default to SNP slave and both automatically revert to SNP slave when the CPU is in Stop mode if configured for Serial I O Either port can be software configured to set up communications between the CPU and various serial devices An external device can obtain power from Port 2 if it requires 100mA or less at SVDC porn My Port 1 is an RS 232 port with a 9 pin female D sub connector The pinout of Port 1 allows a simple straight through cable to connect with a standard AT style RS 232 port RS232 PORT2 Port 2 is an RS 485 port with a 15 pin female D sub connector This can be attached directly to an RS 485 to RS 232 adapter IC690ACC901 oo0o00o oo0o o WLLL oo00000 fe O e eo 6 e Q o HHHH RS485 The followin
81. 0 Q FLD OK Individual Point LEDS on Discrete Modules L Field Power LED indicates presence of power from external Color code Red AC Blue DC Gold Mixed Gray Analog other Module Description OK LED indicates presence of power from VersaMax power supply VersaMax I O modules are described in the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 Chapter I Introduction 1 7 1 8 Available I O Modules The following types of VersaMax I O Modules are available Discrete Input Modules nput 120VAC 8 Point Grouped Module C200MDL140 nput 240VAC 8 Point Grouped Module C200MDL141 nput 120VAC 8 Point Isolated Module C200MDL143 nput 240VAC 4 Point Isolated Module C200MDL144 nput 120VAC 2 Groups of 8 16 Point Module C200MDL240 nput 240VAC 2 Groups of 8 16 Point Module C200MDL241 nput 120VAC 16 Point Isolated Module C200MDL243 nput 240VAC 8 Point Isolated Module C200MDL244 nput 125VDC Positive Negative Logic Grouped 8 Point Module C200MDL631 nput 125VDC Positive Negative Logic Grouped 16 Point Module C200MDL632 nput 48VDC Positive Negative Logic Grouped 16 Point Module C200MDL635 nput 48VDC Positive Negative Logic Grouped 32 Point Module C200MDL636 nput 24VDC Positive Negative Logic 2 Gro
82. 0 01 or thousandths 0 001 of a second The range is 0 to 32 767 time units The state of this timer is retentive on power failure no automatic initialization occurs at powerup When this function first receives power flow it starts accumulating time current value When this timer is encountered in the ladder logic its Current Value is updated Enable ONDTR Q 1 00s Reset R Preset Value py Current Value Address When the Current Value equals or exceeds the Preset Value PV output Q is energized As long as the timer continues to receive power flow it continues accumulating until the maximum value is reached Once the maximum value is reached it is retained and output Q remains energized regardless of the state of the enable input If multiple occurrences of the same timer with the same reference address are enabled during a CPU sweep the current values of the timers will be the same Parameters of the On Delay Stopwatch Timer Function Input Choices Description Output address R The function uses three consecutive words registers of R memory to store the following Current value CV word 1 Preset value PV word 2 Control word word 3 Do not use this address with other instructions Careful Overlapping references cause erratic timer operation enable flow When enable receives power flow the timer s Current Value increments R flow When R receives power flow i
83. 000 or 0 to 32000 to match analog scaling or from 0 to 10000 to display variables as 0 00 to 100 00 If the process and control variables do not use the same scaling scale factors are included in the PID gains Example of the PID Function The example shown below includes typical inputs S0007 enable ii Aiat Power flow out if OK R00010 Set Point 21000 SP CVF AQo001 Control Variable 2 A10001 py T3099 Process Variable 20950 MAN uP 4 DN R00100 RefArray is 40words Chapter 14 The PID Function 14 5 Parameter Block for the PID Function Address Address 1 Address 2 Address 3 Address 4 Address 5 14 6 The parameter block for the PID function occupies 40 words of R memory Many of the 40 words are used by the PLC and not configurable Every PID function call must use a different 40 word memory area even if all 13 configurable parameters are the same The first 13 words of the parameter block must be specified before executing the PID function Zeros can be used for most default values Once suitable PID values have been chosen they can be defined as constants in a BLKMOV so they can be changed by the program as needed Internal Parameters in RefArray The PID function reads 13 parameters and uses the rest of the 40 word RefArray for internal PID storage Normally you would not change these values If you call the PID block in Auto mode after a long d
84. 0002 R 100009 CONST 7 py 00005 100002 R0104 MOVE_ INT 7100003 R0104 IN Q R0100 See the pages on Math functions for an example of using the Addition and Subtraction functions to provide storage tracking GFK 1503C Chapter 10 Instruction Set Reference 10 83 Chapter The Service Request Function 11 This chapter explains the Service Request SVCREQ function which requests a special PLC service It describes SVCREQ parameters for the VersaMax CPU SVCREQ Function Numbers Format of the SVCREQ Function GFK 1503C SVCREQ 1 SVCREQ 2 SVCREQ 3 SVCREQ 4 SVCREQ 6 SVCREQ 7 SVCREQ 8 SVCREQ 9 SVCREQ 10 SVCREQ 11 SVCREQ 13 SVCREQ 14 SVCREQ 15 SVCREQ 16 SVCREQ 18 SVCREQ 23 Change Read Constant Sweep Timer Read Window Times Change Programmer Communications Window Mode Change System Communications Window Mode Change Read Number of Words to Checksum Read or Change the Time of Day Clock Reset Watchdog Timer Read Sweep Time from Beginning of Sweep Read Folder Name Read PLC ID Shut Down Stop PLC Clear Fault Read Last Logged Fault Table Entry Read Elapsed Time Clock Read I O Override Status Read Master Checksum SVCREQ 26 30 Interrogate I O 11 1 SVCREQ Function Numbers Each Service Request has its own function number as listed in the following table Function Description 1 Change Rea
85. 00CBL615 Firmware Update Cable C200CBL002 Terminator P lug included with ETM C200ACC201 Connector Kit C200AC C302 See the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 for information about VersaMax Expansion modules GFK 1503C Chapter I Introduction 1 13 Communications Modules Communications modules provide additional flexibility for VersaMax systems These communications modules install on a VersaMax Communications Carrier Power for the communications module comes from the main system power supply or from a booster supply as shown below VersaMax PLC CPU Optional booster Profibus Network power supply power supply Slave Module e ee a T s E _ N M l 1 i i A al la i a a i i l I D j U DJ Te ree Soss paves Available VersaMax PLC Communications Modules The following VersaMax PLC communications modules are available Communications Modules Profibus DP Network Slave Module IC200BEM002 DeviceNet Network Control Module IC200BEM103 Communications Carrier IC200CHS 006 For information about the Communications
86. 2001 GFK 1503C CPU with 34kB Configurable Memory IC200CPU001 CPU with 42kB Configurable Memory IC200CPU002 CPU with 64kB Configurable Memory IC200CPU005 Module Specifications Size CPU001 002 2 63 66 8mm x 5 04 128mm CPU005 4 20 106 7mm x 5 04 128mm System flash battery backed RAM Backplane current consumption no serial port converter or EZ 5V output 3 3V output IC200CPU001 Program Store device 40mA 100mA IC200C PU002 with serial portconverterorEZ 5V output Program Store device 140mA Backplane current consumption no serial port converter or EZ 5V output 3 3V output IC200C PU005 Program Store device 80mA 290mA with serial portconverterorEZ 5V output Program Store device 180mA Floating poi Embedded communications RS 232 RS 485 Boolean execution speed CPU001 CPU002 1 8ms K typical CPU005 0 5ms K typical Realtime clock accuracy for 100ppm 0 01 or 9sec day timer functions Time of day clock accuracy 23ppm 0 0023 or 2sec day 30C 100 ppm 0 01 or 9sec day full temperature range CPUO0S requires a power supply with expanded 3 3V GFK 1503C Chapter 2 CPU Module Datasheets CPU001 CPU002 CPU005 2 3 CPU with 34kB Configurable Memory IC200CPU001 CPU with 42kB Configurable Memory IC200CPU002 CPU with 64kB Configurable Memory IC200CPU005 VersaMax General Product Specifications VersaMax products should be installed and used in conformance with product
87. 3 2 and 1 NOTE This is the default if no passwords are defined 3 Write to all configuration and logic when the CPU is in Stop mode including word for word changes when supported the addition deletion of program logic and the overriding of discrete 1 0 Read Write Verify user flash Store reference override tables Change sweep mode Plus all access from levels 2 and 1 2 Write to any data memory but this does not include storing tables This includes the toggle force of reference values but does not include overriding discrete 1 0 The PLC can be started or stopped PLC and 1 0 fault tables can be cleared Plus all access from level 1 1 Read any PLC data except for passwords This includes reading fault tables current status performing Most datagrams verifying logic config and loading program and configuration from the PLC No PLC memory Protected May be changed 7 10 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Upon connection to the CPU the programming software automatically requests the CPU to move to the highest unprotected level That gives the programmer access to the highest unprotected level without having to specifically request a particular level Protection Level Request from Programmer A privilege change may be to a lower level or to a higher level The privilege level is changed from the programmer by entering the new level and the correct
88. 503C 10BaseT 10BaseT Port Addition of Module diagnostic 5 12 Analog inputs Analog outputs application program Attachment of the Ethernet Interface to the LAN 13 3 Autoconfiguration 5 25 11 Autodiall 12 21 Battery replacement Baud rates 2 5 3 5 BCLR Bit clear function 10 12 Bit memory 9 3 Bit Operation functions 8 9 Bit set function Bit test function BITSEQ memor required 10 16 BPOS BSET Cable lengths Call function 7 7 Call levels 8 3 3 6 GFK 1503C Index CE Mark installation requirements Cfg From configuration p arameter 5 6 Checksum 7 3112 Change read number of words 11 2 read Checksum task state 11 9 Coils 10 65 continuation coil SET coil Color code on modules 1 7 COMMREQ for Serial O 12 2 Communication Request See COMMREQ Communication window modes 7 3 Communications Carrier Communications window 7 3 Confi guration 5 5 Configuration and register data storing to flash memory 7 9 Constant Sweep Time mode 7 5 Constant Sweep Timer7 5 change read Consumed Data Exchange Definition 6 6 6 7 Contacts Continuation contact normally closed contact normally open contact Continuation coil Continuation contact Control functions 8 11 CALL END 7 7 Conversion functions Cosine function Counters 8 8 function block data 10 74 CPU size 2 3 3 3 CPU sweep 7 1 Current draw
89. C User s Manual March 2001 GFK 1503C Control Functions Do I O GFK 1503C The Do I O function updates inputs or outputs for one scan while the program is running The Do T O function can also be used to update selected I O during the program in addition to the normal I O scan I O is serviced in increments of entire I O modules the PLC adjusts the references if necessary while the function executes enable DO_I0 OK Starting address ST Ending address END Execution of the function continues until all inputs in the selected range have reported or all outputs have been serviced on the I O modules Program execution then returns to the next function If the range of references includes an option module all the input data I and AI or all the output data Q and AQ for that module will be scanned The ALT parameter is ignored while scanning intelligent I O modules or the Ethernet interface The function passes power to the right whenever power is received unless Not all references of the type specified are present within the selected range The CPU is not able to properly handle the temporary list of I O created by the function The range specified includes modules that are associated with a Loss of I O fault Parameters of the Do I O Function Input Choices Description Output enable flow When the function is enabled a limited input or output scan iS p
90. C communicates using the default communications parameters 19 200 baud odd parity one start bit one stop bit and eight data bits If these parameters are re configured the new settings will be used at powerup instead Serial Port Configuration Takes Effect After Removing Programmer If a hardware configuration is stored to the CPU the configuration for the serial port to which the programmer is connected is not actually installed until the programmer is removed After removal of the programmer there is a delay before the new protocol begins operating This delay is equal to the configured T3 time 5 10 VersaMax PLC User s Manual March 2001 GFK 1503C Autoconfiguration When autoconfiguration is enabled and no previous autoconfiguration exists at powerup the CPU automatically reads the configuration of the modules installed in the system and creates an overall system configuration If a previous autoconfiguration is present at powerup the configuration is processed as described on the next page Modules that have software configurable features use their default settings when autoconfigured These features are described in the VersaMax Modules Power Supplies and Carriers Manual GFK 1504 At powerup the CPU by default automatically generates a configuration that includes all of the modules that are physically present in the system starting at slot 1 of rack O the main rack Autoconfiguration of a rack stops at the first
91. CN is ON the Block Move function copies the input constants into memory locations ROO0 10 16 FST_SCN 11 CONST 32767 CONST 32768 CONST 00001 CONST 00002 CONST 00002 CONST 00001 CONST M R010 00001 Chapter 10 Instruction Set Reference 10 35 Data Move Functions Block Clear The Block Clear function fills a specified block of data with zeros When the function receives power flow it writes zeros into the memory location beginning at the reference specified by IN When the data to be cleared is from discrete memory 1 Q M G or T the transition information associated with the references is also cleared The function passes power to the right whenever power is received Enable BLK F OK nable CLR O WORD Word to be cleared IN Parameters of the Block Clear Function Input Choices Description Output enable flow When the function is enabled the array is cleared IN l Q M T SA SB SC G IN contains the first word of the array to be cleared R Al AQ The length of IN must be between 1 and 256 words Length The number of words that will be cleared This is the length of IN ok flow none The OK output is energized whenever the function is enabled Example In the example at powerup 32 words of Q memory 512 points beginning at Q0001 are filled with zeros Q is defined as WORD of length 32 FST_SC
92. CREQ 2 The parameter block has a length of three words High Byte Low Byte address Programmer Window address 1 Mode Value inms System Communications Window All parameters are output parameters It is not necessary to enter values in the parameter block to program this function Example of SVCREQ 2 In the following example when enabling output QO00102 is set the CPU places the current time values of the windows in the parameter block starting at location ROO10 Q00102 SVC_ REQ CONST FNC 00002 R00107 PARM 11 6 VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 3 Change Programmer Communications Window Mode Use SVCREQ 3 to change the programmer communications window mode Limited or Run to Completion The change occurs during the next CPU sweep after the function is called The time of the window cannot be changed it is always 6ms SVCREQ 3 passes power flow to the right unless a mode other than 0 Limited or 2 Run to Completion is selected The parameter block has a length of one word Changing the Programmer Communications Window Mode To change the programmer window enter SVCREQ 3 with this parameter block High Byte Low Byte Example of SVCREQ 3 In the following example when enabling input 1006 goes ON the programmer communications window is enabled and assigned a value of 6ms The parameter block is in reference memory location R0051 10006 M
93. Communications Window7 3 change 11 2 Table functions Tangent function 10 54 Temperature 2 4 3 4 Temporary references Text adding to program logic 10 28 Time of day clock 11 2 Timer Constant Sweep Timer Watchdog 7 4 Timers 8 8 function block data Timestamping EGD Exchanges Timestamping Ethernet Global Data Time tick contacts 9 11 10 73 Transition bits Troubleshooting Using PLC Fault Table 13 17 Unsupported Module diagnostic 5 13 Up Counter 10 81 User program storing to flash memory 7 9 GFK 1503C Index VersaMax Modules Power Supplies and Carriers User s Manual 1 2 VersaMax Rack configuring 5 5 Vibration 2 4 3 4 Vibration resistance W Watchdog timer 7 4 Watchdog timer reset 11 2 Window times read Write Bytes XOR function 10 5 Index 5
94. DP Local Station Manager RS 232 via CPU port Configurable Advanced User yes Parameters CPUEO0S requires a power supply with expanded 3 3V Chapter 3 CPU Module Datasheet CPUEO5 3 3 IC200CPUE05 CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory VersaMax General Product Specifications VersaMax products should be installed and used in conformance with product specific guidelines as well as the following specifications Environmental Vibration IEC 68 2 6 1G 57 150Hz 0 012in p p 10 57Hz Shock IEC 68 2 27 15G 11ms Operating Temp 0 deg C to 60 deg C ambient Storage Temp 40 deg C to 85 deg C Humidity 5 to 95 noncondensing Enclosure Protection IEC529 Steel cabinet per IP 54 EMC Emission Radiated Conducted EMC Immunity Electrostatic Discharge RF Susceptibility Fast Transient Burst Surge Withstand Conducted RF Isolation Dielectric Withstand Power Supply Input Dips Variations VersaMax PLC CISPR 11 EN 55011 CISPR 22 EN 55022 FCC 47 CFR 15 EN 61000 4 2 EN 61000 4 3 ENV 50140 ENV 50204 mMm 61000 4 4 ANSI IEEE C37 90a EC255 4 mMm 61000 4 5 mMm 61000 4 6 UL508 UL840 IEC664 EN 61000 4 11 User s Manual March 2001 protection from dust amp splashing water Industrial Scientific amp Medical E quipment Group 1 Class A Information Technology Equipment Class A referred to as FCC part 15 Radio D
95. D_ISA algorithm has a different form PID Output Ke Error Error dt Ti Td Derivative CV Bias where Kc is the controller gain and Ti is the Integral time and Td is the Derivative time The advantage of ISA is that adjusting the Kc changes the contribution for the integral and derivative terms as well as the proportional one which may make loop tuning easier If you have PID gains in terms or Ti and Td use Kp Kc Ki Ke Ti and Kd Ke Td to convert them to use as PID User Parameter inputs The CV Bias term above is an additive term separate from the PID components It may be required if you are using only Proportional Kp gain and you want the CV to be a non zero value when the PV equals the SP and the Error is 0 In this case set the CV Bias to the desired CV when the PV is at the SP CV Bias can also be used for feed forward control where another PID loop or control algorithm is used to adjust the CV output of this PID loop 14 10 VersaMax PLC User s Manual March 2001 GFK 1503C If an Integral Ki gain is used the CV Bias would normally be 0 as the integrator acts as an automatic bias Just start up in Manual mode and use the Manual Command word Ref 13 to set the integrator to the desired CV then switch to Automatic mode This also works if Ki is 0 except the integrator will not be adjusted based on the Error after going into Automatic mode Independent Term Algorithm PIDIND The following diagram shows how the PID al
96. E decimal hexadecimal MEANING address address 1 address 2 Status word memory type R address 3 Status word address minus 1 R0001 address 4 address 5 address 6 address 7 Operating Notes It is not possible to set the buffer length to zero If zero is entered as the buffer length the buffer size will be set to the 2K bytes default If a length greater than 2K bytes is specified an error is generated Chapter 12 Serial I O SNP RTU Protocols 12 15 12 16 Flush Input Buffer Function 4302 This operation empties the input buffer of any characters received through the serial port but not yet retrieved using aread command All such characters are lost Example Command Block for the Flush Input Buffer Function VALUE VALUE decimal hexadecimal address 0001 0001 Data block length address 1 0000 0000 NOWAIT mode address 2 Status word memory type R address 3 0000 0000 Status word address minus 1 R0001 address 4 0000 on address 6 0000 ono address 6 4302 10CE Flush input buffer command VersaMax PLC User s Manual March 2001 GFK 1503C Read Port Status Function 4303 GFK 1503C This function returns the current status of the port The following events can be detected 1 A read request was initiated previously and the required number of characters has now been received or the specified time out has elapsed 2 A write request was initiated previously and transm
97. F E1 E2 F t 7i C Negated Coil A negated coil sets a discrete reference ON when it does not receive power flow It is not retentive so it cannot be used with system status references SA SB PSC or G Example In the example coil E3 is ON when reference E1 is OFF E1 E O E2 E Retentive Coil Like a normally open coil the retentive coil sets a discrete reference ON while it receives power flow The state of the retentive coil is retained across power failure Therefore it cannot be used with references from strictly nonretentive memory T Negated Retentive Coil The negated retentive coil sets a discrete reference ON when it does not receive power flow The state of the negated retentive coil is retained across power failure Therefore it cannot be used with references from strictly nonretentive memory T Chapter 10 Instruction Set Reference 10 65 Relay Functions Coils Positive Transition Coil If the reference associated with a positive transition coil was OFF when the coil receives power flow it is set to ON until the next time the coil is executed If the rung containing the coil is skipped on subsequent sweeps it will remain ON This coil can be used as a oneshot Do not write from external devices e g PCM programmer ADS etc to references used on positive transition coils since it will destroy the oneshot nature of these coils Transitional coils can be used with ref
98. FANUC GE Fanuc Automation Programmable Control Products VersaMax PLC User s Manual GFK 1503C March 2001 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness suff
99. I format each digit of the time and date items is an ASCII formatted byte Spaces and colons are embedded into the data to format it for printing or display ASCII format requires 12 words in the parameter block 13 words for 4 digit year 2 Digit Year Parameter Block Format High Byte Low Byte 1 change or O read 3 ASCII format year year month space space month day of month day of month hours Space hours minutes minutes seconds space seconds day of week day of week 4 Digit Year Parameter Block Format High Byte Low Byte 1 change or O read 83h ASCII 4 digit year hundreds year thousands year ones year tens month tens space space month ones day of month ones day of month tens hours tens space colon hours ones minutes ones minutes tens seconds tens colon space seconds ones day of week day of week tens ones Example Read Date and Time in Packed ASCII Format Mon Oct 5 1998 at 11 13 00pm address address 1 address 2 address 3 address 4 address 5 address 6 address 7 address 8 address 9 address 10 address 11 0 read 3 ASCII format 38 8 39 9 31 1 20 Space 20 Space 30 0 35 5 30 leading 0 31 1 20 space 3A 31 1 33 3 31 1
100. IN Length must be from 1 to 256 for all types except BIT If IN is a constant and Q is type BIT the length must be between 1 and 16 If IN is type Bit the length must be between 1 and 256 bits IN 1 Q M 1 G R Al AQ IN contains the value to be moved For MOVE_BOOL any constant discrete reference may be used it does not need to be byte For bit or word data only aligned However 16 bits beginning with the reference S address specified are displayed online For real data R Al AQ ok flow none The OK output is energized whenever the function is enabled Q 1 Q M T G R Al AQ When the move is performed the value at IN is written to Q For bit word data SA SB For MOVE_BOOL any discrete reference may be used it does SC not need to be byte aligned However 16 bits beginning with For real data R AI AQ the reference address specified are displayed online Example 1 When enabling input Q0014 is ON 48 bits are moved from memory location M0001 to memory location M0033 MO0001 and M0003 are defined as WORD types if length 3 Q0014 t MOVE WORD M0001 IN QF M0033 Even though the destination overlaps the source for 16 bits the move is done correctly Before using the Move function After using the Move function INPUT M0001 through M0048 INPUT M0033 through
101. LSB RO101 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 R0102 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 MSB Overlapping input and output reference address ranges in multiword functions is not recommended it can produce unexpected results 10 2 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Logical AND Logical OR Each scan that power is received a Logical AND or Logical OR function examines each bit in bit string I1 and the corresponding bit in bit string I2 beginning at the least significant bit in each A string length of 256 words can be selected Logical AND If both bits examined by the Logical AND function are 1 a 1 is placed in the corresponding location in output string Q If either or both bits are 0 a 0 is placed in string Q in that location The Logical AND function can be used to build masks or screens where only certain bits are passed through bits opposite a in the mask and all other bits are set to 0 The Logical AND function can also be used to clear an area of word memory by ANDing the bits with another bit string known to contain all Os The I1 and I2 bit strings specified may overlap Logical OR If either or both bits examined by the Logical OR function is 1 a 1 is placed in the corresponding location in output string Q If both bits are 0
102. M T G This optional bit reference is set if the dwell time for the current step has expired Timeout none Timeout Q M T G This optional bit reference is set if the drum has been in a particular step longer than Fault none the step s specified Fault Timeout First Q M T G This optional array of bits has one element for each step of the Drum Sequencer No Follower none more than one bit in the array is On at any time and that bit corresponds to the value of the Active Step VersaMax PLC User s Manual March 2001 GFK 1503C Control Functions Drum Sequencer GFK 1503C Parameter Block for the Drum Sequencer Function The parameter block control block for the Drum Sequencer function contains information needed to operate the Drum Sequencer address Active Step address 1 Preset Step address 2 Step Control address 3 Timer Control Active Step The active step value specifies the element in the Pattern array to copy to the Out output memory location This is used as the array index into the Pattern Dwell Time Fault Timeout and First Follower arrays Preset Step A word input that is copied to the Active Step output when the Reset is On Step Control A word that is used to detect Off to On transitions on both the Step input and the Enable input The Step Control word is reserved for use by the function block and must not be written to Timer Control Two words of data that hold values n
103. M capable Server slave or as a master and slave simultaneously For information about the DeviceNet Network Control Module refer to the VersaMax System DeviceNet Network Communications User s Manual GFK 1533 Chapter I Introduction 1 15 Chapter CPU Module Datasheets CPUOOI CPU002 2 CPU005 This chapter describes the appearance features and functionality of the following VersaMax PLC CPU modules C200CPU001 CPU with 34kB Configurable Memory C200CPU002 CPU with 42kB Configurable Memory C200CPU00S CPU with 64kB Configurable Memory GFK 1503C 2 1 IC200CPU001 CPU with 34kB Configurable Memory IC200CPU002 CPU with 42kB Configurable Memory IC200CPU005 CPU with 64kB Configurable Memory VersaMax PLC CPUs IC200CPU001 CPU002 and CPU00S provide powerful PLC functionality in a small versatile system They are designed to serve as the system controller for up to 64 modules with up to 2048 I O points Two serial ports provide RS 232 and RS 485 interfaces for SNP slave and RTU slave
104. M0080 1 MO0016 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 M0048 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 M0032 0 0 0 0 1 2 1 1 0 0 00 1 1 1 1 M0064 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 MO0048 1 1 1 1 1 2 2 1 1717272 1 1 171 M0080 1 1 17271 1 1 1 1 1 1 1 1 1 1 1 33 10 34 VersaMax PLC User s Manual March 2001 GFK 1503C Data Move Functions Block Move GFK 1503C The Block Move function copies a block of seven constants to a specified location When the Block Move function receives power flow it copies the constant values into consecutive locations beginning at the destination specified in output Q The function passes power to the right whenever power is received Enable BLKMVF oK INT Constant value Constant value Constant value Constant value Constant value Constant value Constant value l1 2 3 14 5 6 17 QJ Output Parameters of the Block Move Function Input Choices Description Output enable flow When the function is enabled the block move is performed 11 to 17 constant 11 through 17 contain seven constant values ok flow none The OK output is energized whenever the function is enabled Q Q M T G R Al AQ Output Q contains the first element of the moved For Word data SA SB SC array 11 is moved to Q For Real data R Al AQ Example In the example when the enabling input represented by the nickname FST_S
105. N Rigg MOD INT PALLETS L n Qf NT FULL 00017 Vee BOXES 2 0006 GFK 1503C Chapter 10 Instruction Set Reference 10 51 Math and Numerical Functions Scaling The Scaling function scales an input parameter and places the result in an output location For integer type data all parameters must be integer based signed For word type data all parameters must be word based unsigned Enable SCALE_ OK INT Max Input Value IHI OUT F Output Min Input Value ILO Max Output Value 4 OHI Min Output Value 4 OLO Input IN Parameters of the Scaling Function Input Choices Description Output enable flow When the function is enabled the operation is performed IHI R Al AQ IHI and ILO contain a constant or reference for the upper and lower limits of the ILO constant unscaled data These limits together with the values for OHI and OLO are used to calculate the scaling factor that will be applied to the input value IN OHI R Al AQ OHI and OLO contain a constant or reference for the upper and lower limits of OLO constant the scaled data IN R Al AQ IN contains a constant or reference for the actual value to be scaled constant ok flow none The OK output is energized when the function is performed without overflow OUT R Al AQ Output OUTcontains the scaled equivalent of the input value Example In the example the registers RO120 through
106. N t BLK_ CLR WORD Q0001 IN 10 36 VersaMax PLC User s Manual March 2001 GFK 1503C Data Move Functions Shift Register The Shift Register function shifts one or more data words or data bits from a reference location into a specified area of memory For example one word might be shifted into an area of memory with a specified length of five words As a result of this shift another word of data would be shifted out of the end of the memory area The reset input R takes precedence over the function enable input When the reset is active all references beginning at the shift register ST up to the length specified for LEN are filled with zeros If the function receives power flow and reset is not active each bit or word of the shift register is moved to the next highest reference The last element in the shift register is shifted into Q The highest reference of the shift register element of IN is shifted into the vacated element starting at ST The contents of the shift register are accessible throughout the program because they are overlaid on absolute locations in logic addressable memory Enable SHFR_F OK WORD Reset R QF Output Value to be shifted 7 N first bit or word ST Parameters of the Shift Register Function Input Choices Description Output enable flow When enable is energized and R is not the shiftis performed Length 1 to 256 bits or The length
107. N inputs have power flow the Manual Command word is incremented or decremented by one CV count every PID solution For faster manual changes of the output Control Variable it is also possible to add or subtract any CV count value directly to from the Manual Command word The PID block uses the CV Upper and CV Lower Clamp parameters to limit the CV output If a positive Minimum Slew Time is defined it is used to limit the rate of change of the CV output If either the CV amplitude or rate limit is exceeded the value stored in the integrator is adjusted so that CV is at the limit This anti reset windup feature means that even if the error tried to drive CV above or below the clamps for a long period of time the CV output will move off the clamp as soon as the error term changes sign This operation with the Manual Command tracking CV in Automatic mode and setting CV in Manual mode provides a bumpless transfer between Automatic and Manual modes The CV Upper and Lower Clamps and the Minimum Slew Time still apply to the CV output in Manual mode and the internal value stored in the integrator is updated This means that if you were to step the Manual Command in Manual mode the CV output will not change any faster that the Minimum Slew Time Inverse rate limit and will not go above or below the CV Upper or CV Lower Clamp limits VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Time Interval for the PID Function The PID wi
108. OVE SVC_ WORD REQ CONST IN Q R0051 CONST _ ENC 0006 00003 R00517 PARM GFK 1503C Chapter 11 The Service Request Function 11 7 SVCREQ 4 Change System Communications Window Mode Use SVCREQ 4 to change the system communications window mode Limited or Run to Completion The change occurs during the next CPU sweep after the function is called The time of the window cannot be changed it is always 6ms SVCREQ 4 passes power flow to the right unless a mode other than 0 Limited or 2 Run to Completion is selected The parameter block has a length of one word Changing the System Communications Window Mode To change the programmer window enter SVCREQ 4 with this parameter block High Byte Low Byte Example of SVCREQ 4 In the following example when enabling input 10003 is ON the system communications window is changed to Run to Completion mode The parameter block is at location R0025 10003 MOVE SVC_ WORD REQ CONST IN Q R0025 CONST FNC 0200 0004 ail R0025 PARM 11 8 VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 6 Change Read Number of Words to Checksum Use SVCREQ 6 to read or change the number of words in the program to be checksummed The function is successful unless some number other than 0 or 1 is entered as the requested operation Parameter Block Formats for SVCREQ 6 The parameter block has a length of 2 words
109. On Delay Timer Function a42933 ensste_ a a A B Cc D E ENABLE goes high timer begins accumulating time Current value reaches preset value PV Q goes high and timer continues accumulating time ENABLE goes low Q goes low timer stops accumulating time and current time is cleared ENABLE goes high timer starts accumulating time ENABLE goes low before current value reaches preset value PV Q remains low timer stops accumulating time and is cleared to zero CV 0 moO S Example In the example a delay timer with address TMRID is used to control the length of time that coil is on This coil has been assigned the Nickname DWELL When the normally open momentary contact with the Nickname DO_DWL is on coil DWELL is energized The contact of coil DWELL keeps coil DWELL energized when contact DO_DWL is released and also starts the timer TMRID When TMRID reaches its preset value of onehalf second coil REL energizes interrupting the latchedon condition of coil DWELL The contact DWELL interrupts power flow to TMRID resetting its current value and deenergizing coil REL The circuit is then ready for another momentary activation of contact DO_DWL DO_DWL REL DWELL C DWELL DWELL TMR REL 0 15 C CONST 00005 _PY TMRID VersaMax PLC User s Manual March 2001 GFK 1503C Timer and Counter Functions Off Delay Timer The Off Delay Timer increments while
110. RM T0001 l0017 AND ADD_ WOR INT R0303 11 QF R0303 R0303 7 11 QF R0303 CONST 7 12 NOON 4 12 OOFF T0001 l0017 ed MOVE MOVE SVC_ INT INT REQ MIN_SEC IN QF R0304 CONST IN Q R0300 CONST FNC 00001 00007 R0300 gt PARM VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 8 Reset Watchdog Timer GFK 1503C Use SVCREQ 8 to reset the watchdog timer during the sweep Ordinarily when the watchdog timer expires the PLC shuts down without warning SVCREQ 8 allows the timer to keep going during a time consuming task for example while waiting for a response from a communications line Caution Be sure that resetting the watchdog timer does not adversely affect the controlled process Parameter Block Format for SVCREQ 8 This function has no associated parameter block Example of SVCREQ 8 In this example power flow through enabling output Q0027 or input 11476 or internal coil M00010 causes the watchdog timer to be reset Q0127 11476 CONST 0008 M0010 Chapter 11 The Service Request Function 11 15 11 16 SVCREQ 9 Read Sweep Time from Beginning of Sweep Use SVCREQ 9 to read the time in milliseconds since the start of the sweep The data format is unsigned 16 bit integer Output Parameter Block Format for SVCREQ 9 The parameter block is an output parameter block only it has a length of one word
111. RO123 are used to store the high and low scaling values The input value to be scaled is analog input AI0017 The scaled output data is used to control analog output AQ0017 The scaling is performed whenever I0001 is ON 0001 SCALE_ oK INT R0120 IHI OUT AQ0017 RO0121 ILO R0122 4 OHI R0123 OLO AIO017 5 IN 10 52 VersaMax PLC User s Manual March 2001 GFK 1503C Math and Numerical Functions Square Root The Square Root function finds the square root of a value When the function receives power flow the value of output Q is set to the integer portion of the square root of the input IN The output Q must be the same data type as IN The Square Root function operates on these types of data INT Signed integer DINT Double precision signed integer REAL Floating Point OK is set ON if the function is performed without overflow unless one of these invalid REAL operations occurs IN lt 0O INis NaN Not a Number Otherwise OK is set OFF Enable SQROOT ok INT Input N Q Output Parameters of the Square Root Function Input Choices Description Output enable flow When the function is enabled the operation is performed IN All data types R Al A constant or reference for the value whose square root is to AQ constant be calculated IfIN is less than zero the function will not pass power flow Range for constants
112. Step by step instructions for using the configuration software are provided in the VersaPro Software User s Manual GFK 1670 Additional information is available in the online help GFK 1503C Chapter 5 CPU Configuration 5 5 Configuring CPU and Expansion Parameters The table below lists configurable parameters for VersaMax PLC CPUs and for expansion racks Parameter Description Default Choices Scan Parameters Sweep Mode Normal sweep runs until it is complete Normal Normal Constant sweep runs for time specified in Sweep Tmr Constant Sweep Sweep Times If Constant Sweep mode was selected a Constant Sweep 100mS mSecs Time in milliseconds can be specified Settings Parameters I O Scan Stop Determines whether I O is to be scanned while the PLC is No Yes No in STOP mode Powerup Mode Selects powerup mode Logic Configura Source a program and configuration when the PLC is a Flash tion From powered up Selects source of register data when PLC is powered up RAM Flash Passwords Determines whether the password feature is enabled or an Enabled disabled If passwords are disabled the ony way to Disabled enable them is to clear the PLC memory Checksum The number words in the application program to be 8 to 32 Words per checksummed each sweep Sweep Default Modem Modem turnaround time 10ms unit This is the time 0 255mS Turnaround required for the modem to start data transmission after Time rece
113. TE WORD SA SB SC SNX 1 Q M T G R Al AQ constant SNX contains the index of the source array DNX 1 Q M T G R Al AQ constant DNX contains the index of the destination array N 1 Q M T G R Al AQ constant N provides a count indicator ok flow none OK is energized whenever enable is energized DS For all SA SB SC R Al AQ The starting address of the destination array For For INT BIT BYTE WORD 1 Q M T G ARRAY_MOVE_BOOL any reference may be used it pa mer does not need to be byte aligned length The number of elements starting at SR and DS that make up each array It is defined as the length of SR DS GFK 1503C Chapter 10 Instruction Set Reference 10 69 Table Functions Array Move Example 1 In this example if R100 3 then RO003 R0007 of the array ROOO 1 ROO16 is read and is written into RO104 RO108 of the array RO100 ROL1S ROO1 and RO100 are declared as type WORD of length 16 10001 Io R0001 R DSF R0100 R0100 SNX CONST 00005 DNX CONST _ 00005 N Example 2 Using bit memory for SR and DS MO0011 M0017 of the array M0009 M0024 is read and then written to Q0026 Q0032 of the array Q0022 Q0037 M009 and Q0022 are declared as type BOOL of length 16 10001 f pray MOVE_ BOOL Mo009 SR DS Q0022 CONST 00003 SNX CONST _ 00005 DNX CONST _ 00007 N Example 3 Using word memory for SR and DS t
114. UN X 8 RUNS Transmitter Expansion oo 9 RUN 9 RUN ate or o o Receiver eoe 2 RERR X ea eae 202 Expansion 02 S Module Zog 16 10DT X lt 16 10DT S08 Receiver versity 89 S o n fen E S Mo o k o E4 por 20 21 RSEL XX 21 RSEL 208 Receiving 24 JOCLK X 24 loclK Port 25 IOCLK 25 locLK 7 ov 7 lov 23 ov X 23 Jov 1 SHIELD x 1 SHIELD VARIABLE SEE 26 PIN 26 PIN TEXT 26 PIN 26 PIN FEMALE MALE MALE FEMALE Building a Custom Expansion Cable Custom expansion cables can be built using Connector Kit IC200ACC202 Crimper AMP 90800 1 and Belden 8138 Manhattan CDT M2483 Alpha 3498C or equivalent AWG 28 0 089mm cable GFK 1503C Chapter 4 Installation 4 7 4 8 Connecting the Expansion Cable Single ended For a system with one non isolated expansion rack IC200ERM002 and NO Expansion Transmitter connect the expansion cable from the serial port on the VersaMax CPU to the Expansion Receiver as shown below The maximum cable length is one meter Cables cannot be fabricated for this type of installation cable IC200CBL600 must be ordered separately VersaMax PLC or NIU I O Station Main Rack z l PS j 1M CPU NIU VersaMax Expansion Rack PS No Terminator Plug is needed in a single ended installation however it will not
115. VCREQ 15 Read Last Logged Fault Table Entry Use SVCREQ 15 to read the last entry logged in either the PLC fault table or the TO fault table The SVCREQ output is set ON unless some number other than 0 or 1 is entered as the requested operation or the fault table is empty Input Parameter Block for SVCREQ 15 For this function the parameter block has a length of 22 words The input parameter block has this format address 2 Digit Year Format 4 Digit Year Format 0 Read PLC fault table 1 Read I O fault table 9 Read 8 Read PLC fault table O fault table The format of the output parameter block depends on whether the function reads data from the PLC fault table or the I O fault table 2 Digit Year Format or 4 Digit Year Format GFK 1503C PLC Fault Table Output Format High Byte Low Byte 0 Spare long short Spare Spare Slot rack task fault action fault group error code fault specific data minutes seconds day of month hour year month Spare month year address 1 address 2 address 3 address 4 address 5 address 6 address 7 address 8 to address 18 address 19 address 20 address 21 address 21 address 22 Chapter 11 The Service Request Function 1 0 Fault Table Output Format High Byte Low Byte 1 memory type long short offset Slot rack block bus point fault a
116. Watchdog timer If the PLC is in Constant Sweep Time mode the sweep is delayed until the required sweep time elapses If the required time has already elapsed the OV_SWP SA0002 contactis set and the sweep continues without delay Next the CPU updates timer values hundredths tenths and seconds When the sweep starts the CPU first scans inputs from input modules and option modules that provide input type data Modules are scanned in ascending reference address order Discrete input modules are scanned before analog input modules The CPU stores this new input data in the appropriate memories If the CPU has been configured to not scan I O in Stop mode the input scan is skipped when the CPU is in Stop mode For CPUE05 if the CPU is in run mode and the consumer period of an Ethernet Global Data exchange has expired the CPU copies the data for that exchange from the Ethernet interface to the appropriate reference memory Next the CPU solves the application program logic It always starts with the first instruction in the program Itends when the END instruction is executed Solving the logic creates a new set of output data Immediately after the logic solution the CPU scans all output modules in ascending reference address order The output scan is completed when all output data has been sent If the CPU has been configured to not scan 1 0 in Stop mode the output scan is also skipped when the CPU is in Stop mode For CPUE0S if I O is enabled an
117. When the block is switched to Manual mode this value is used to set the CV output and the internal value of the integrator within the Upper and Lower Clamp and Slew Time limits VersaMax PLC User s Manual March 2001 GFK 1503C Address 14 Address 15 Address 16 Address 17 Address 18 Address 19 Address 20 Address 21 Address 22 Address 23 to Address 25 Address 26 Address 27 Address 28 Address 29 to Address 39 GFK 1503C Control Word Maintained by PLC maintained the PLC unless unless set Bit 1 is set otherwise low bit sets Override if 1 Intemal SP Set and Non configurable maintained by the PLC Intemal CV Intemal PV Output Diff Term Storage Int Term Storage Slew Term Storage Y Remainder Storage SP PV Lower PV Counts 32000 to 32000 and Upper Range Reserved Non configurable Chapter 14 The PID Function If the Override low bit is set to 1 this word and other internal SP PV and CV parameters must be used for remote operation of this PID block see below This allows remote operator interface devices such as a computer to take control away from the PLC program Caution if you do not want this to happen make sure the Control Word is set to 0 If the low bitis 0 the next 4 bits can be read to track the status of the PID input contacts as long as the PID Enable contact has power A discrete data structure with the first five bit positi
118. a narrow range of input values where 1 lt IN lt 1 Given a valid value for the IN parameter the Inverse Sine Real function produces a result Q such that ASIN IN Mo 2 Oi ge eM 2 2 The Inverse Cosine Real function produces a result Q such that ACOS IN cia The Inverse Tangent function accepts the broadest range of input values where lt IN lt o Given a valid value for the IN parameter the Inverse Tangent Real function produces a result Q such that ATAN IN MoA eM 2 2 10 54 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Parameters of the Trigonometric Functions Input Choices Description Output enable flow When the function is enabled the operation is performed IN R Al AQ constant IN contains the constant or reference real value to be operated on ok flow none OK is energized when the function is performed without overflow unless an invalid operation occurs and or IN is NaN Q R Al AQ Output Q contains the trigonometric value of IN Example In the example the Cosine of the value in RO001 is placed in RO0033 COS _ REAL R0001 7 IN Q 3 141500 Chapter 10 Instruction Set Reference R0033 1 000000 Math and Numerical Functions Trigonometric Functions 10 55 Math and Numerical Functions Logarithmic Exponential Functions When a Logarithmic or Exponential function receives power flow it performs the
119. acteristics cesscseseccseeceseccesseecseessneeesseeeesaes 14 14 Setting Parameters Including Tuning Loop Gains ceeeeeseeeeeeeeneeeeneeeeneers 14 15 Sample PID Callers reesei e re EEDE So EEEren ste stetsaivorstawtlecee su veees sues 14 17 The EZ Program Store Device ccccssssssssssscsssssssseccssssssssssssscsssessees 15 1 Read Write Verify Data with a Programmer Present s eeeeeeeeeeereeereereerrerreeee 15 3 Update a PLC CPU without a Programmer Present seceseceeseeseeeesneeeeneees 15 6 Performance Data sis lecsisscteveoustniuastnshontaavasevaptuataveriucassesacstecsdeasdousdausdacseas A 1 Function Block Timing eeeccceessscceeesecceeeeceeeeseaeeeceenaeeecssneeesseaeeeeeseaeeeeneanees A 2 TO Module Scan Times s ievecdts save das avecdeastucecevt suedeetinkedovbinne depideee fevtarectevttvealetins A 8 Ethernet Global Data Sweep Impact ceeceeeseceeseeesseeceeecsaeeceseeeenaeeesaeessaeers A 13 Contents v Chapter Introduction l Guide to the VersaMax Document Set This manual contains general information about CPU operation and program content It also provides detailed descriptions of specific programming requirements Chapter 1 is a general introduction to the VersaMax family of products CPU Modules are described in detail in chapters 2 and 3 Installation procedures are described in Chapter 4 PLC Configuration is described in chapter 5 Configuration determines certai
120. ad operations 3 Write operations Operating Notes This function does not update the status of words of the cancelled COMMREQs Caution If this COMMREQ is sent in either Cancel All or Cancel Write mode when a Write Bytes 4401 COMMREQ is transmitting a string from a serial port transmission is halted The position within the string where the transmission is halted is indeterminate In addition the final character received by the device the CPU is sending to is also indeterminate 12 20 VersaMax PLC User s Manual March 2001 GFK 1503C Autodial Function 4400 This feature allows the VersaMax CPU to automatically dial a modem and send a specified byte string To implement this feature the port must be configured for Serial I O For example pager enunciation can be implemented by three commands requiring three COMMREQ command blocks Autodial 04400 1130h Dials the modem Write Bytes 04401 1131h Specifies an ASCII string from 1 to 250 bytes in length to send from the serial port Autodial 04400 1130h It is the responsibility of the PLC application program to hang up the phone connection This is accomplished by reissuing the autodial command and sending the hang up command string Autodial Command Block The Autodial command automatically transmits an Escape sequence that follows the Hayes convention If you are using a modem that does not support the Hayes convention you may be able to use the Write Bytes
121. adder Diagram format The transitions between steps are also programmed as Ladder Diagram logic Trans1 Transition 1 1 Trans2 Transition 2 Chapter 8 Elements of an Application Program 8 5 8 6 Ladder Diagram This traditional PLC programming language with its rung like structure executes from top to bottom The logic execution is thought of as power flow which proceeds down along the left rail of the ladder and from left to right along each rung in sequence Relay Power Z Power flow into function Power flow out of function Rail 10001 Q0001 MUL_ INT R0123 77 11 Qr R0124 ip inlicati Coil CONST 12 gar Multiplication function 00002 The flow of logical power through each rung is controlled by a set of simple program functions that work like mechanical relays and output coils Whether or not a relay passes logical power flow along the rung depends on the content of a memory location with which the relay has been associated in the program For instance a relay might pass power flow if its associated memory location contained the value 1 The same relay would not pass power flow if the memory location contained the value 0 If a relay or other function in a rung does not pass logical power flow the rest of that rung is not executed Power then flows down along the left rail to the next rung Within a rung there are many complex functions that can be used
122. age Pushbutton initiates update from the device to a PLC Dual color status LED Configurable OEM key password protection Compatible with all VersaMax CPU models release 2 10 and later VersaMax PLC User s Manual March 2001 GFK 1503C EZ Program Store Device IC200ACC003 Read Write Verify Data with a Programmer Present GFK 1503C With a programmer present the PLC CPU can read write or verify a program configuration and tables in the EZ Program Store device When reading or verifying data it is possible to select hardware configuration logic and or reference tables data However when writing data to the EZ Program Store device all three data types must be written If the hardware configuration includes Ethernet Global Data and or a file of Advanced User Parameters for Ethernet communications they will also be included The programmer must be using version 1 5 or later of the VersaPro programming software WARNING Do not use the pushbutton on the EZ Program Store device to invoke an update while 1 Loading program logic configuration data and or reference tables from the PLC to the programmer 2 Verifying program logic configuration data and or reference tables in the PLC with the programmer Doing so may corrupt the data being loaded or verified and produce unexpected results You should power cycle the PLC to restore normal operation Including All the Necessary Information When t
123. appropriate logarithmic exponential operation on the Real value in input IN and places the result in output Q For the Base 10 Logarithm LOG function the base 10 logarithm of IN is placed in Q For the Natural Logarithm LN function the natural logarithm of IN is placed in Q For the Power of E EXP function e is raised to the power specified by IN and the result is placed in Q For the Power of X EXPT function the value of input I1 is raised to the power specified by the value I2 and the result is placed in output Q The EXPT function has three input parameters and two output parameters The OK output receives power flow unless the input is NaN Not a Number or is negative Enable LOG_ REAL Input IN Q F OK Enable EXPT_ REAL Output Input1 11 QT Input 2 12 Parameters of the Logarithmic Exponential Functions OK Output Input Choices Description Output enable flow When the function is enabled the operation is performed IN or R Al AQ ForEXP LOG and LN IN contains the real value to be operated on 11 12 constant The EXPT function has two inputs I1 and 12 For EXPT 11 is the base value and 12 is the exponent ok flow none OK is energized when the function is performed without overflow unless an invalid operation occurs and or IN is NaN or is negative Q R Al AQ Output Q contains the logarithmic exponential value of IN
124. arameter For example a constant value of 2 in this parameter indicates to the CPU that it is to execute the Do T O function block for the module in location 2 The start and end references must be either I or Q These references specify the first and last reference the module is configured for Example Do I O for One Module In this example the Do I O function is executed only to a 16 point input module which is configured at I0001 through 10016 in location 2 Ssh Q0001 TF DO_IO 10001 ST 10016 END CONST ALT 00002 GFK 1503C Chapter 10 Instruction Set Reference 10 21 Control Functions Call The Call function causes program execution to go to a specified subroutine block CALL subroutine When the Call function receives power flow it causes the scan to go immediately to the designated subroutine block and execute it After the subroutine block execution is complete control returns to the point in the logic immediately following the Call instruction Example 10004 ts a 10006 CALL subroutine 10003 0010 GQO0Q10 VS 10001 10 22 VersaMax PLC User s Manual March 2001 GFK 1503C Control Functions End of Logic The End of Logic function provides a temporary end of logic The program executes from the first rung to the last rung or the End of Logic function whichever is encountered first The End of Logic function unconditio
125. arch 2001 GFK 1503C Diagnostic Message Summary addition of A module is present at powerup but not configured It is added to the configuration module Autoconfiguration is enabled and the module is capable of being autoconfigured addition of A previously configured module is inserted after powerup The CPU resumes module scanning of the module configuration A module was found at or after powerup that does not match the configuration for mismatch that slot extra module 1 A module is present at powerup but not configured 2 Autoconfiguration is not enabled 3 A previously unconfigured module is inserted after powerup loss of module A configured module is missing during powerup or normal operation addition of rack An Expansion Receiver Module that was not previously configured is present during configuration During normal operation communication is restored with a previously missing or failed Expansion Receiver Module The CPU starts scanning 1 0 for the modules in that rack Addition of Module faults are not generated when scanning resumes However if communications cannot be restored with any modules in the rack Loss of Module faults are generated A previously configured Expansion Receiver Module is not present during configuration _ During normal operation a previously working Expansion Receiver Module stops working Modules in the same expansion rack are terminated A previously unconfigured Expansion Receive
126. asked Compare Word function executes It compares M0001 16 with M0017 32 M0033 48 contain the mask The value in R0001 determines the bit position in the two input strings where the comparison starts FST_SCN MASK_ COMP _ WORD Q0001 MO0001 11 MC S M0017 12 Ql MO0033 M0033 M BN R0001 R0001 BIT Before the function block is executed the contents of the above references are 11 M0001 ecech Oli liol hi To o loli i o i o0 12 M0017 606Fh 0 1 1 o 1 1 o 1 lofi 1 o 4 1 4 1 M Q M0033 000Fh o oJolofofofolo fofofofo 1 1 1 1 BIT BN R0001 0 MC Q0001 OFF The contents of these references after the function block is executed are 11 M0001 same 0 4 1 o 1 1 o Jo oi 4 oli 1 Jo o 12 M0017 same o 4 1 o 1 1 o 1 of4 4 o 4 1 4 4 o oo o Jo o o 1 o Jo fo Jo 4 4 4 1 M Q M0033 BIT BN R0001 MC Q0001 uu 8 ON In this example contact T1 and coil M100 force one and only one execution otherwise the function would repeat with possibly unexpected results 10 14 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Bit Position GFK 1503C The Bit Position function locates a bit set to 1 in a bit string Each sweep that power is rec
127. at 32 17 16 1 is 1 401298E 45 to 3 402823E 38 8 bit exponent 23 bit mantissa See the next page for more information Two s Complement Values INT Signed Signed integer data uses 16 bit memory Word 1 Integer locations Signed integers are 16 bit positions represented in 2 s complement notation 16 1 Bit 16 is the sign bit 0 positive 1 negative Their range is Two s Complement Values 32 768 to 32 767 DINT Double Double precision signed integers data Word 2 Word 1 Precision uses two consecutive 16 bit memory Signed locations They are represented in 2 s 17 46 1 Integer complement notation Bit 32 is the sign Ja bit 0 positive 1 negative Their range is 2 147 483 648 to 2 147 483 867 GFK 1503C Chapter 9 Program Data l 9 9 Real Numbers The REAL data type which can be used for some Math functions and Numerical functions is actually floating point data Floatingpoint numbers are stored in single precision IEEEstandard format This format requires 32 bits which occupy two adjacent 16bit PLC words Mest Significant Register gt Least Significant Register gt Mm _ Bits 17 32 ___ ___5 ____ _ Bits 1 16 _5 s IITTI bzh IT LITI 1 23 bit mantissa lt gt 8 bit exponent 1 b it sign Bit 32 For example if the floatingpoint n
128. ation If the PLC CPU has not had a configuration stored from the programmer it automatically creates its own configuration at powerup To create the Autoconfiguration the CPU reads configuration data from each module and from the Ethernet interface This includes an Advanced User Parameter file for the Ethernet interface When an Autoconfiguration is present in the PLC CPU it is possible to edit some of the Ethernet configuration parameters from the Station Manager This changes the parameters that are stored in the Ethernet interface itself If the PLC is power cycled or cleared the edited configuration will be retrieved by the CPU from the Ethernet interface 6 2 VersaMax PLC User s Manual March 2001 GFK 1503C iG Configuring the Ethernet Interface The CPU s fundamental Ethernet operating characteristics must be correctly configured for proper operation over an Ethernet network The default configuration cannot supply valid network address data Configuration This is fixed as TCP IP It cannot be changed Mode IP Address The IP Address is the unique address of the Ethernet interface as a node on the network Subnet Mask and On a large network a subnet mask can be used to identify a section of the overall Gateway IP network A gateway address can be used to identify a gateway that joins one network with Address another These parameters must be correct or the Ethernet interface may be unable to communicate on the ne
129. ator tab tr Lithium Battery Replacement To replace the battery use a small screwdriver to gently pry open the battery holder Replace battery only with one of the following GE Fanuc IC200ACCO001 Panasonic BR2032 Use of another battery may present a risk of fire or explosion Battery may explode if mistreated Do not recharge disassemble heat above 100 deg C 212 deg F or incinerate Chapter 4 Installation 4 11 4 12 Serial Port Connections PORT1 ail H 0000p OOOO RS232 PORT2 ae PULL O O O O O O O O O O O O O s RS485 Providing Power to an External Device from Port 2 If either port is set up for communications with a serial device that requires 100mA or less at 5VDC the device can obtain power from Port 2 Cable Lengths and Baud Rates Maximum cable lengths the total number of feet from the CPU to the last device attached to the cable are Port 1 RS 232 15 meters 50 ft Port 2 RS 485 1200 meters 4000 ft Both ports support configurable baud rates as listed in the CPU descriptions in this manual The following pre assembled cables are available IC200CBL001 CPU Programming Cable RS232 IC200CBL002 Expansion Firmware Upgrade Cable
130. ault is entered in the PLC fault table and the PLC goes to Stop mode If the checksum calculation fails the programmer communications window is not affected Each sweep the CPU verifies the physical configuration of one module against its programmed configuration A missing additional or mismatched module causes a fault to be generated Standard CPU Sweep Operation Standard Sweep operation is the normal operating mode of the PLC CPU In Standard Sweep operation the CPU repeatedly executes the application program updates I O and performs communications and other tasks shown in the diagram The CPU performs its startofsweep housekeeping tasks It reads inputs It executes the application program It updates outputs If a programming device is present the CPU communicates with it It communicates with other devices It performs diagnostics Dae ONE Aiea oe Except for communicating with a programmer all these steps execute every sweep Programmer communications occur only when needed In this mode the CPU performs all parts of its sweep normally Each sweep executes as quickly as possible with a different amount of time consumed each sweep The Sweep Windows The programmer communications window and the system communications window have two operating modes Limited Mode The execution time of the window is 6ms The window terminates when it has no more tasks to complete or when 6ms has elapsed Run to Completion Mo
131. automatically set to either 80 bits for and Q Status address locations or 5 words for R Al and AQ Status address locations Network Time IP addresses of up to 3 NTP time servers used to synchronize timestamps in produced Servers Ethernet Global Data exchanges If no NTP time servers are configured here the Ethernet interface is initialized from the clock in the CPU instead See Timestamping of Ethernet Global Data Exchanges in chapter 13 for more information GFK 1503C Chapter 6 Ethernet Configuration 6 3 sl Configuring Ethernet Global Data VersaMax CPU IC200CPUE0S can be configured for up to 32 Ethernet Global Data exchanges any combination of produced and consumed See Ethernet Global Data in chapter 13 for a discussion of this feature Configuration defines both the content of an exchange its data ranges and its operational characteristics Each Ethernet Global Data produced or consumed exchange must be configured individually for each PLC You can configure Up to 1200 data ranges for all Ethernet Global Data exchanges for one CPUEO0S Up to 100 data ranges per exchange A data length of 1 byte to 1400 bytes per exchange The total size of an exchange is the sum of the lengths of all of the data ranges configured for that exchange Different exchanges may have different data ranges Multiple exchanges can also share some or all of the same data ranges even if the exchanges are produc
132. ax PLC User s Manual March 2001 GFK 1503C Software Configuration The configuration software makes it possible to create a customized configuration for the VersaMax PLC system For CPUE0S it is also used to configure Ethernet Global Data When you enter Hardware Configuration for VersaMax equipment folders the default view is the Rack Main A new configuration already includes a default power supply PWROO1 and CPU CPU001 Both can easily be changed to match the actual hardware in the PLC system To configure the PLC you will Configure the rack type non expanded single ended expanded or multi rack expanded Configure the power supply type and any booster power supplies and carriers Note that CPU005 and CPUE0S both require an expanded 3 3V supply Configure the CPU This includes changing the CPU type if necessary and assigning its parameters as described in this chapter Configure the parameters of the CPU serial ports as explained in this chapter For CPUE0S configure its Ethernet parameters as explained in chapter 6 Configure the expansion modules if the system has expansion racks Add module carriers and define wiring assignments Place modules on carriers and select their parameters Configurable parameters of I O modules are described in the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 Save the configuration file so that it can be stored to the PLC
133. ay Contact Passes Power to Right Normally Open When reference is ON Normally Closed When reference is OFF Continuation Contact lt t gt If the preceding continuation coil is set ON Normally Open Contact A normally open contact acts as a switch that passes power flow if the associated reference is ON 1 Normally Closed Contact A normally closed contact acts as a switch that passes power flow if the associated reference is OFF 0 Example The example shows a rung with 10 elements having nicknames from E1 to E10 Coil E10 is ON when reference E1 E2 E5 E6 and E9 are ON and references E3 m foe E4 E7 and E8 are OFF E9 10 FES E1 E2 E E4 E5 1 E6 E7 tol Z t f D Continuation Coils and Contacts Continuation coils and continuation contacts are used to continue relay ladder rung logic beyond the last column The state of the last executed continuation coil is the flow state used on the next executed continuation contact If the flow of logic does not execute a continuation coil before it executes a continuation contact the state of the contact is no flow There can be only one continuation coil and contact per rung the continuation contact must be in column 1 and the continuation coil must be in the last column Chapter 10 Instruction Set Reference 10 63 10 64 Relay Functions Coils Coils are used to control discrete references Conditional
134. below If all the Expansion Receivers are the Isolated type IC200ERM001 the maximum overall cable length is 750 meters If the expansion bus includes any non isolated Expansion Receivers IC200ERM002 the maximum overall cable length is 15 meters VersaMax PLC or I O Station Main Rack 0 i ETM PS D C All CPU NIU VersaMax ExpansionRack 1 PS 15M with any IC200ERM002 ERMs m 750M with all IC200ERM001 ERMs ERM VersaMax ExpansionRack 7 PS i D Cy Terminator Plug ERM Install the Terminator Plug supplied with the Expansion Transmitter module into the lower port on the last Expansion Receiver Spare Terminator Plugs can be purchased separately as part number IC200ACC201 Qty 2 VersaMax PLC User s Manual March 2001 GFK 1503C RS 485 Differential Inter Rack Connection IC200CBL601 602 615 PIN PIN 2 FRAME N XCX m 2 FRAME 3 FRAME 3 FRAME Expansion 5 RIRQ X 5 RIRQ Espana 6 RIRQ 6 RIRO Transmitter or 8 R
135. bled the Producer ID remains configured but production and consumption stops The samples of the consumed exchanges received while the PLC is stopped continue to be processed by the Ethernet interface The latest received data from the network will be available to the application when the PLC returns to an I O enabled state The table below summarizes what happens to the configuration and operation of Ethernet Global Data in different PLC modes Exchanges continue to be PLC Mode or Action Produced RUN Outputs Enabled Consumed STOP I O Enabled STOP I O Disabled The latest data from the network is available to the application when the PLC transitions from Stop to Run mode GFK 1503C Chapter 13 Ethernet Communications 13 11 EGD Synchronization Ethernet Global Data attempts to provide the most up to date process data consistent with the configured schedule The Ethernet interface maintains a timer for each produced exchange When the timer for the exchange expires the Ethernet interface requests that the data for the exchange be transferred from reference memory during the output scan portion of the next CPU sweep Once the data has been transferred by the CPU sweep the Ethernet interface immediately formulates a sample and transfers the sample on the network As soon as a sample for a consumed exchange is received it is transferred to the CPU during the next input scan portion of the CPU sweep T
136. bled Serial I O CPU Run Stop switch disabled Serial I O Disabled CPU Run Stop switch disabled Serial I O Serial I O CPU Run Stop switch disabled CPU Run Stop switch disabled Station Manager Disabled Station Manager Serial I O CPU Run Stop switch disabled Chapter 12 Serial I O SNP RTU Protocols 12 5 RTU Slave SNP Slave Operation With Programmer Attached A programmer an SNP SNPX device can be attached to port 1 or port 2 while RTU Slave mode is active on the port For multi drop connections the CPU must have been configured to use an appropriate PLC ID Note that for a multi drop SNP connection with the port currently configured for RTU the SNP ID associated with the CPU settings must match the multi drop ID The programmer must use the same serial communications parameters baud rate parity stop bits etc as the currently active RTU Slave protocol for it to be recognized When the CPU recognizes the programmer the CPU removes the RTU Slave protocol from the port and installs SNP Slave as the currently active protocol The SNP ID modem turnaround time and default idletime for this new SNP Slave session are obtained from the configured CPU settings not the port or port 2 configurations Connection should be established within 12 seconds When the programmer connection has been enabled normal programmer communications can take place Failure of the programmer to establish communications within 12 seconds is t
137. called references The reference s letter prefix identifies the memory area The numerical value is the offset within that memory area Word Memory References Each word memory address reference is on a 16 bit word boundary The PLC uses three types of references for data stored in word memory AI Normally used for analog inputs AQ Normally used for analog outputs PR Registers are normally used to store program data in word format Word memory is represented below The example below shows ten addresses Each has 16 bits that together contain one value The PLC cannot access individual bits in word memory 12467 12004 231 359 addresses 1 2 3 4 5 14 6 7 8 9 882 24 771 735 10 000 9 2 VersaMax PLC User s Manual March 2001 GFK 1503C Bit Memory References GFK 1503C Le Each bit memory address reference is on a bit boundary Data is stored in bit memory as represented below The illustration shows 160 individuallyaddressed bits with address 1 in the upper left and address 160 in the lower right addresses 123 45 67 8 0 Oj 1 1 0 Of O O Of O O Of 1 O OO 0 0 1 1 0 0 O 0 O O 1 0 1 0 0 0 1 1 1 1 0 0 O 1 1 0 O 1 0 0 0 0 1 1 0 0 O 0 O 1 1 1 0 0 1 0 1 0 O 1 0 1 0 0 Oj 1 0 110 1 0 0 0 0 1 1 0 0 0 8 Beas AN ek GG at oe 178 1 1 0 1 0 0 0 1 1 1 0 1 0 0 0 0 1 1
138. can be used Only the new form supports the new parameters Timing If a port configuration COMMREQ is sent to a serial port that currently has an SNP SNPX master for example the programmer connected to it the serial port configuration specified by the COMMREQ does not take effect until the CPU detects a loss of the SNP SNPX master This occurs the configured T3 time after the master disconnects The COMMREQ status word for the port configuration COMMREQ is updated as soon as the CPU verifies that the specified configuration is valid That means a COMMREQ Successful value may be returned by the Port Configuration COMMREQ before the specified configuration is actually installed Sending Another COMMREQ to the Same Port The application program must wait at least 2 seconds plus the configured T3 time after a new serial port protocol is installed before sending any COMMREQs specific to that protocol to the port This applies to a new protocol installed by Storing a new hardware configuration or by a port configuration COMMREQ If the port is configured for Serial I O this waiting period must also follow any Stop to Run mode transition of the CPU 12 4 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Invalid Port Configuration Combinations The configurations of both ports must be compatible One port must be available for PLC programmer connection The CPU rejects the following combinations Disabled Disabled Disa
139. causes characters to be read from the specified port until a specified terminating character is received The characters are read from the internal input buffer and placed in the specified input data area The function returns both the number of characters retrieved and the number of unprocessed characters still in the input buffer If zero characters of input are requested only the number of unprocessed characters in the input buffer are returned If the terminating character is not in the input buffer the status of the operation is not complete until either the terminating character has been received or the time out interval expires In either of those conditions the port status indicates the reason for completion of the read operation If the time out interval is set to zero the COMMREQ remains pending until it has received the requested string terminated by the specified end character If this COMMREQ fails for any reason no data is returned to the buffer Any data that was already in the buffer remains and can be retrieved with a subsequent read request Example Command Block for the Read String Function decimal hexadecimal address address 1 NOWAIT mode address 2 Status word memory type R address 3 Status word address minus 1 R 0001 address 4 address 5 address 6 address 7 Read time out 30 seconds address 8 0013 000D Terminating character carriage return must be between 0 and 255 OxFF inclusive addre
140. ce 10 9 Bit Operation Functions Rotate Bits Right Rotate Bits Left The Rotate Left function rotates all the bits in a string a specified number of places to the left When rotation occurs the specified number of bits is rotated out of the input string to the left and back into the string on the right The Rotate Right function rotates the bits in the string to the right When rotation occurs the specified number of bits is rotated out of the input string to the right and back into the string on the left A length of 1 to 256 words can be selected for either function The number of places to rotate must be more than zero and less than the number of bits in the string The Rotate Bits function passes power flow to the right unless the number of bits specified to be rotated is greater than the total length of the string or is less than zero The result is placed in output string Q If you want the input string to be rotated the output parameter Q must use the same memory location as the input parameter IN The entire rotated string is written on each scan that power is received Enable ROL F OK WORD Word to be rotated IN Q Output Number of bits N Parameters of the Rotate Bits Right Left Functions Input Choices Description Output enable flow When the function is enabled the rotation is performed IN 1 Q M T G R Al AQ IN contains the first word to be rotated N 1 Q M T G R Al
141. ce array to a destination array When the function receives power flow it copies the number of elements specified from the input array starting at the indexed location The function then writes the copied elements to the output array starting with the indexed location For bit data when word oriented memory is selected for the parameters of the source array and or destination array starting address the least significant bit of the specified word is the first bit of the array The indices in an Array Move instruction are based In using an Array Move no element outside either the source or destination arrays as specified by their starting address and length may be referenced The OK output receives power flow unless one of the following occurs Enable is OFF N SNX 1 is greater than length N DNX 1 is greater than length Enable ARRAY MOVE_ BOOL SR DS Source array address Source array index Destination array index elements to transfer N OK Destination array address Parameters for the Array Move Function Input Choices Description Output enable flow When the function is enabled the operation is performed SR For all R Al AQ SR contains the starting address of the source array For For INT BIT BYTE WORD I Q M T ARRAY_MOVE_ BOOL any reference may be used it G does not need to be byte aligned For BIT BY
142. ced User Parameter values Note that changing this timeout value does not reduce the actual time for the PLC to process the requests 13 22 VersaMax PLC User s Manual March 2001 GFK 1503C Unexpected Ethernet Restart or Runtime Errors Sustained heavy EGD and or SRTP operation can exceed the data transfer and processing capacity of the CPUEOS This can result in missed EGD exchanges unexpected automatic restarts of the Ethernet interface within the CPUEOS or runtime fatal errors at the Ethernet interface Restart errors are indicated in the PLC Fault Table as one or more of the following Loss of daughterboard no exception Event Reset of daughterboard no exception Event LAN system software fault restarted LAN I F with exception Event 3 Entry 2 1 Entry 3 5f0fH After any of the above errors the Ethernet interface restarts itself automatically without manual intervention The above Ethernet restarts may be accompanied by one or more of the following in the PLC Fault Table Backplane communications with PC fault lost request no exception event LAN system software fault resuming with exception Event 28 Entry 2 1 SCode 95255037H Runtime errors suspend normal operation and a blink fatal error code in amber at the STAT LED To recover manually restart the Ethernet interface Runtime error codes 31 and 33 have been observed under heavy load See Checking the E
143. ced in the configured output memory locations After completing the end of the application program the CPU writes the output data to modules in the system Read Inputs Execute Application Program Write Outputs 8 2 VersaMax PLC User s Manual March 2001 GFK 1503C Subroutines GFK 1503C The program can consist of one Main program that executes completely during each CPU sweep Main Program Or a program can be divided into subroutines The maximum size of a main program or subroutine block is 64kB The program can contain up to 255 subroutines Subroutines can simplify programming and reduce the overall amount of logic Each subroutine can be called as needed The main program might serve primarily to sequence the subroutine blocks gt subroutine Program e Subroutine gt Subroutine 4 A subroutine block can be called many times as the program executes Logic that should be repeated can be placed in a subroutine block reducing total program size Subroutine Program gt 2 In addition to being called from the program subroutine blocks can also be called by other subroutine blocks A subroutine block can even call itself i Subroutine i aea ae aln Subroutine Program 4 Subroutine Se _ 3 The main program is level 1 The program can include up to eight additio
144. change exchange definitions are of definitions at the producer and at the different size consumer Change the incorrect exchange definition so that produced and consumed definitions are the same size If the consumer wishes to ignore certain portions of a consumed exchange be sure that the length of the ignored portions is correct The ignored portion is specified as a byte count Receive Resource Exhaustion Errors Heavy network traffic can exhaust available memory in the Ethernet interface used for network communications This most often occurs under heavy Ethernet Global Data EGD traffic on a busy network Since the traffic on the network is unpredictable this error condition may always occur This error is indicated in the PLC Fault Table as LAN system software fault resuming with exception Event 28 Entry 2 1 Cause Corrective Action Heavy EGD traffic exhausts Modify the application to reduce the network data buffers number size or frequency of produced and consumed EGD exchanges Bursts of heavy network traffic are Analyze the broadcast and multicast received at the CPUEO5 network traffic received at the CPUEO5 Reduce such traffic if possible 13 24 VersaMax PLC User s Manual March 2001 GFK 1503C Station Manager Lockout under Heavy Load Sustained heavy EGD and or SRTP Server load can utilize all processing resources within the Ethernet interface effectively lock
145. character in the least significant byte of the word For example if the first two characters are A and B the Address 18 will contain the hex value 4241 Chapter 12 Serial I O SNP RTU Protocols 12 7 12 8 Example COMMREQ Data Block for Configuring RTU Protocol First 6 words Address 6 Address 7 Address 8 Address 9 Address 10 Address 11 Address 12 Address 13 Address 14 Address 15 Address 16 Address 17 Address 18 Address 19 21 Address 22 Address 22 Notes Values Meaning Reserved for COMMREQ use FFFOH Command 0003 Protocol 0003 RTU 0000 Port Mode 0000 Slave 2 1200 3 2400 4 4800 5 9600 Data Rate 6 19200 7 38400 8 57600 CPU models IC200C PU005 and CPUE05 only 0 None 1 Odd 2 Even Parity 0 Hardware 1 None Flow Control 0 255 units of 10ms e g 10 100ms Turnaround d elay not used Timeout not used Bits per Character not used Stop Bits not used Interface 0 2 wire 1 4 wire Duplex Mode Station Address 1 247 Device Identifier not used Device Identifier 0 255 units of 10ms e g 10 100ms Receive to transmit delay 0 255 units of 10ms e g 10 100ms RTS drop delay The data block length Address 0 for a COMMREQ that includes the Receive to transmit delay and RTS drop delay should be 12H not 10H Both forms Length 10H and 12H are supported If RTU
146. command to dial the modem Examples of commonly used command strings for Hayes compatible modems are listed below ATDP 15035559999 lt CR gt 16 10h Pulse dial the number 1 503 555 9999 ATDT15035559999 lt CR gt 16 10h Tone dial the number 1 503 555 9999 ATDT9 15035559999 lt CR gt 18 12h Tone dial using outside line with pause ATHO lt CR gt 5 05h Hang up the phone T ATZ lt CR gt 4 04h Restore modem configuration to internally saved values GFK 1503C Chapter 12 Serial I O SNP RTU Protocols 12 21 12 22 Example Autodial Command Block This example COMMREQ command block dials the number 234 5678 using a Hayes compatible modem Word Definition Values 1 0009h CUSTOM data block length includes command string 2 0000h NOWAIT mode 3 0008h Status word memory type R 4 0000h Status word address minus 1 Register 1 5 0000h not used 6 0000h not used 7 04400 1130h Autodial command number 8 00030 001Eh Modem response timeout 30 seconds 9 0012 000Ch Number of bytes in command string 10 5441h A 41h T 54h 11 5444h D 44h T 54h 12 3332h Phone number 2 32h 3 33h 13 3534h 4 34h 5 35h 14 3736h 6 36h 7 37h 15 0D38h 8 38h lt CR gt 0Dh VersaMax PLC User s Manual March 2001 GFK 1503C Write Bytes Function 4401 GFK 1503C This operation can be used to transmit one or more characters to the remote d
147. complete To avoid possible disconnect errors or read write errors adjust the request timeouts in the configuration to 30 63 seconds 30 000 63 000mS Writing Data to RAM or Flash Folder data is stored from the programmer to the EZ Program Store device in the same way data is stored to Flash memory Writing to either Flash or to the EZ Program Store device always writes all folder data regardless of what types are selected Data stored to the EZ Program Store device is verified in the same manner as data stored in Flash memory is verified Data can also be read from the device in the same manner as reading from Flash The EZ Program Store device can be used to update data in a PLC s RAM memory only or in both RAM and Flash memory In the configuration data stored to the EZ Program Store device be sure to specify which type of memory should be updated Select RAM only to update only RAM memory in the target PLC Select RAM amp FLASH to update both VersaMax PLC User s Manual March 2001 GFK 1503C IC200ACC003 EZ Program Store Device Using the EZ Program Store Device with the Programmer or a Programmer FR CPUE05 o TOIT eee E sono EZ Program r Store Device
148. contains the first word of the bit sequencer Optional R Al AQ none ok flow none The OK output is energized whenever the function is enabled Example In the example the Bit Sequencer operates on register memory RO001 Its static data is stored in registers R0010 12 When CLEAR is active the sequencer is reset and the current step is set to step number 3 The first 8 bits of R0001 are set to zero When NXT_SEQ is active and CLEAR is not active the bit for step number 3 is cleared and the bit for step number 2 or 4 depending on whether DIR is energized is set NXT_CYC BIT_ CLEAR SEQ 7 R R DIRECT DIR CONST STEP 00003 R0001 ST R0010 Chapter 10 Instruction Set Reference 10 17 Control Functions This section describes the control functions which may be used to limit program execution and to change the way the CPU executes the application program Service specified 1 0 DO 10 Go to a subroutine block CALL Temporary program end END Execute a group of logic rungs without power flow MCR Go to a specified location in the program J UMP LABEL Place a text explanation in the program logic COMMENT Provide predefined On Off patterns to a set of 16 discrete outputs in the manner of a mechanical DRUM SEQUENCER The more complex Control Functions Service Request and the PID algorithms are described in other chapters of this manual 10 18 VersaMax PL
149. ction fault group fault type fault category faultspecific data fault description minutes seconds day of month hour year month Spare month year 11 21 Long Short Value The first byte of word address 1 contains a number that indicates the length of the fault specific data in the fault entry These possible values are PLC fault table 00 8 bytes short 01 24 bytes long I O fault table 02 5 bytes short 03 21 bytes long Example of SVCREQ 15 When inputs 10250 and 10251 are both on the first Move function places a zero read PLC fault table into the parameter block for SVCREQ 15 When input 10250 is on and input 10251 is off the Move instruction instead places a one read I O fault table in the SVCREQ parameter block The parameter block is located at location R0600 10250 10251 I MOVE INT CONST IN Q R0600 00000 LEN 00001 10250 10251 MOVE INT CONST IN QF R0600 00001 LEN 00001 ALW_ON svc REQ CONST FNC 00015 RO600 PARM 11 22 VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 16 Read Elapsed Time Clock GFK 1503C Use SVCREQ 16 to read the system s elapsed time clock The elapsed time clock measures the time in seconds since the PLC was powered on Output Parameter Block for SVCREQ 16 This function has an output parameter block only Its length is 3 words
150. d Constant Sweep Timer 2 Read Window Times 3 Change Programmer Communications Window Mode and Time 4 Change System Communications Window Mode and Time 5 reserved 6 Change Read Number of Words to Checksum 7 Change Read Time of Day Clock 8 Reset Watchdog Timer 9 Read Sweep Time from Beginning of Sweep 10 Read Folder Name 11 Read PLC ID 12 reserved 13 Shut Down the PLC 14 Clear Fault Tables 15 Read Last Logged Fault Table Entry 16 Read Elapsed Time Clock 17 reserved 18 Read I O Override Status 19 22 reserved 23 Read Master Checksum 26 30 Interrogate I O 27 28 reserved 29 Read Elapsed Power Down Time 31 255 reserved 11 2 VersaMax PLC User s Manual March 2001 GFK 1503C Format of the SVCREQ Function The SVCREQ function has three inputs and one output enable 7 OK Function number gt FNC Beginning reference PARM When the SVCREQ receives power flow the PLC is requested to perform the function number FNC indicated Parameters for the function are located beginning at the reference given for PARM This is the beginning of the parameter block for the function The number of 16 bit references required depends on the SVCREQ function being used Parameter blocks may be used as both inputs for the function and the location where data may be output after the function executes Therefore data returned by the function is accessed at the same location specified for PARM The SVCREQ function passes p
151. d Ki gains are found try adding Kd to get quicker responses to input changes providing it doesn t cause oscillations Kd is often not needed and will not work with noisy PV 6 Check gains over different SP operating points and add Dead Band and Minimum Slew Time if needed Some Reverse Acting processes may need setting Config Word Error Sign or Polarity bits Chapter 14 The PID Function 14 15 14 16 Setting Loop Gains Using the Ziegler and Nichols Tuning Approach Once the three process model parameters K Tp and Tc are determined they can be used to estimate initial PID loop gains The following approach provides good response to system disturbances with gains producing an amplitude ratio of 1 4 The amplitude ratio is the ratio of the second peak over the first peak in the closed loop response 1 Calculate the Reaction rate R K Tc 2 For Proportional control only calculate Kp as Kp 1 R Tp Tc K Tp For Proportional and Integral control use Kp 0 9 R Tp 0 9 Tc K Tp Ki 0 3 Kp Tp For Proportional Integral and Derivative control use Kp G R Tp where G is from 1 2 to 2 0 Ki 0 5 Kp Tp Kd 0 5 Kp Tp 3 Check that the Sample Period is in the range Tp Tc 10 to Tp Tc 1000 The Ideal Tuning Method The Ideal Tuning procedure provides the best response to SP changes delayed only by the Tp process delay or dead time Kp 2 Tc 3 K Tp Ki Tc Kd Ki 4 if Deri
152. d RTU slave Errors are returned if they are attempted for a port configured for one of those protocols 12 10 VersaMax PLC User s Manual March 2001 GFK 1503C Status Word for Serial I O COMMREQs A value of is returned in the COMMREQ status word upon successful completion of the COMMREQ Any other value returned is an error code where the low byte is a major error code and the high byte is a minor error code Major Error Code Description 1 01h Successful Completion this is the expected completion value in the COMMREQ status word 12 0Ch Local error E rror processing a local command The minor error code identifies the specific error 1 01h Wait type command is not permitted Use No Wait command 13 00 requested to write is zero or greater than 250 bytes 48 30h Serial output timeout The serial port was unable to transmit the string Could be due to missing CTS signal when the serial port is configured to use hardware flow control 50 32h COMMREQ timeout The COMMREQ did not complete within a 20 second time limit 14 OEh Autodial Error An error occurred while attempting to send a command string to an attached external modem The minor error code identifies the specific error 1 01h 2 02h The modem command string length exceeds end of reference memory type 3 03h COMMREQ Data Block Length too small Output command string data missing or incomplete Modem responded with BUSY Modem is unable to
153. d the producer period of an Ethernet Global Data exchange has expired the CPU copies the data for that exchange from the appropriate reference memory to the Ethernet interface f there is a programming device attached the CPU next executes the programmer communications window The programmer communications window will not execute if there is no programmer attached n the default limited window mode each sweep the CPU honors one service request The time limit for programmer communications is 6 milliseconds If the programmer makes a request that requires more than 6 milliseconds to process the processing is spread out over multiple sweeps ext the CPU processes communications requests from intelligent option modules The modules are polled in roundrobin fashion so no module has priority n default Run to Completion mode the length of the system communications window is limited to 400 milliseconds If a module makes a request that requires more than 400 milliseconds to process the request is spread out over multiple sweeps n Limited mode option modules that communicate with the PLC using the system window have less impact on sweep time but response to their requests is slower A checksum calculation is performed on the application program at the end of every sweep You can specify from 0 to 32 words to be checksummed If the calculated checksum does not match the reference checksum the program checksum failure exception flag is raised A f
154. d to the PLC Both Produced and Consumed exchanges may be configured CPUEOS supports up to 1200 variables across all Ethernet Global Data exchanges and supports selective consumption of Ethernet Global Data exchanges See chapter 13for information about Ethernet Global Data Station Manager Functionality CPUEOS has built in Station Manager functionality This permits on line diagnostic and supervisory access through either the Station Manager port or via the Ethernet network Station Manager services include An interactive set of commands for interrogating and controlling the station Unrestricted access to observe internal statistics an exception log and configuration parameters Password security for commands that change station parameters or operation Use of the Station Manager function requires a separate computer terminal or terminal emulator See GFK 1876 for information about Station Manager operation Chapter 3 CPU Module Datasheet CPUEO5S 3 11 Chapter 4 GFK 1503C Installation This chapter describes Installing the CPU Installing the power supply Installing additional modules Activating or replacing the backup battery Serial port connections Installing expansion modules Ethernet connection for CPUEOS CE Mark installation requirements System installation instructions which give guidelines for carrier power supply and module installation as well as information about field wiring and gro
155. de Regardless of the time assigned to a particular window the window runs until all tasks within that window are completed up to 400ms SVCREQ 2 can be used in the application program to obtain the current times for each window The Watchdog Timer When the CPU is in Standard Sweep mode the Watchdog Timer catches failure conditions that could cause an unusually long sweep The length of the Watchdog Timer is 500 milliseconds It restarts from zero at the beginning of each sweep If the sweep takes longer than 500mS the OK LED on the CPU module goes off The CPU resets executes its powerup logic generates a watchdog failure fault and goes to Stop mode Communications are temporarily interrupted 7 4 VersaMax PLC User s Manual March 2001 GFK 1503C Constant Sweep Time Operation GFK 1503C If the application requires that each CPU sweep take the same amount of time the CPU can be configured to operate in Constant Sweep Time mode This operating mode assures that the inputs and outputs in the system are updated at constant intervals This mode can also be used to implement a longer sweep time to assure that inputs have time to settle after receiving output data from the program Changing the Configured Default for Constant Sweep Mode If the PLC is in STOP mode its Configured Constant Sweep mode can be edited After this is done the configuration must be Stored to the CPU for the change to take effect Once stored Constant S
156. ds The consumer s timeout period should be greater than the producer s repetition period GE Fanuc recommends that the consumer timeout be set to no lower than twice the production period 13 6 VersaMax PLC User s Manual March 2001 GFK 1503C Ethernet Global Data Groups GFK 1503C If more than one device on the network should consume a Global Data exchange those devices can be set up as a group The network can include up to 32 numbered groups Groups allow each sample from the producer to be seen simultaneously by all consumers in the group A device can belong to more than one group as illustrated below 10 0 0 4 10 0 0 8 Group 2 Group 1 10 0 0 1 10 0 0 2 10 0 0 3 mm 2 10 0 0 7 Each device in a group responds to the group s assigned ID number For CPUE0S the Group IDs are 1 to 32 Each Group ID corresponds to a Multicast Class D IP address reserved by the Internet authorities The default Multicast IP addresses used by Ethernet Global Data are Group ID IP Address 1 224 0 7 1 2 224 0 7 2 32 224 0 7 32 Group Multicast IP Addresses used by Ethernet Global Data should not be changed unless the defaults would cause a network conflict If necessary they can be changed within the reserved range of multicast IP addresses 224 0 0 0 through 239 255 255 255 The change must be made using an Advanced User Parameter File Chapter 13 Ethernet Communica
157. e bitclr Sets one bit within a string to false bitpos Bit Position Locates a bit set to true within a bit string mskemp Masked Compare Performs a masked compare of two arrays GFK 1503C Chapter 8 Elements of an Application Program 8 9 8 10 Data Move Functions move Move Moves one or more bits of data blkmov Block Move Moves a block of up to 7 constants blkelr Block Clear Clears to zero one or more bytes words of memory shfreg Shift Register Shifts one or more words or bits of data through a block of memory bitseq Bit Sequencer Sequences a 1 through a group of bits in PLC memory comreq Communication Request Sends a communications request Table Functions arrmov Array Move Copies a specified number of data elements from a source array to a destination array srh eq Search Equal Searches array for values equal to a specified value srh ne Search Not Equal Searches array for values not equal to a specified value srh gt Search Greater Than Searches array for values greater than a specified value srh ge Search Greater Than or Equal Searches array for values greater than or equal to a specified value sth It Search Less Than Searches array for values less than a specified value srh le Search Less Than or Equal Searches array for values less than or equal to a specified value Conversion Functions bed 4 Convert to BCD4 From INT Converts a number to 4digit BCD format Convert to Word Fro
158. e Hardware is SNP Control from None to CPUE05 in Local Station a e Manager mode None Hardware Timeout Specifies the set of timeout Long Long Medium Short None If Port Mode values to be used by is SNP Protocol op Bits Number of stop bits used in 1 1 2 If Port Mode transmission Most serial is SNP or devices use one stop bit Serial 1 0 slower devices use two SNP ID 8 byte ID for Port 1 Editable 0 Delay between receiving SNP Not available last character of a message RTU and Serial 10 0 255 units to asserting RTS of 10ms e g 10 100ms Turnaround Delay between asserting SNP none SNP Long Medium Short none delay RTS and transmitting a RTU amp Serial 10 0 RTU amp Serial 10 0 255 units of message 10ms e g 10 100ms d RTS drop Delay between when the SNP Not Available elay last character of a message RTU and Serial 10 0 255 units is transmitted and when 3i RTS is dropped of 10ms e g 10 100ms The VersaPro software allows configuration of RTU and Serial I O at 115 2K baud However these baud rates are not supported by the CPU If a configuration using these baud rates is stored to the PLC 1 For RTU an Unsupported Feature in Configuration fault is logged and the PLC transitions to Stop Faulted mode 2 For Serial I O the same fault is logged when the transition to Run mode occurs The PLC will immediately transition to Stop Faulted mode 5 8 Ve
159. e If all the SRTP connections in the CPUE0S are in use or otherwise unavailable anew SRTP client connection must wait until the TCP reconnect time expires on an existing connection The SRTP connection timeout is normal expected behavior and is consistent with other GE Fanuc PLC products GFK 1503C Chapter 13 Ethernet Communications 13 25 Chapter 14 GFK 1503C This chapter describes the PID Proportional plus Integral plus Derivative function The PID Function which is used for closed loop process control The PID function compares feedback from a process variable with a desired process Set Point and updates a Control Variable based on the error Format of the PID Function Operation of the PID Function Parameter Block for the PID Function PID Algorithm Selection Determining the Process Characteristics Setting Parameters Including Tuning Loop Gains Sample PID Call 14 1 Format of the PID Function The PID function uses PID loop gains and other parameters stored in an array of 40 16 bit words to solve the PID algorithm at the desired time interval All parameters are 16 bit integer words This allows AI memory to be used for input Process Variables and AQ to be used for output Control Variables le PID Ok enable IND 0 Set Point SP CVF Control Variable Process Variable py logic MAN logic UP logic DN Reference Array Address The PID function does not pass power flow if ther
160. e default sizes storing a hardware configuration to the PLC in the future will clear memory contents If you want to retain memory contents first load memory contents from the PLC to the programmer Then re store memory when you store the hardware configuration from the programmer to the PLC Chapter 5 CPU Configuration 5 7 Configuring Serial Port Parameters Both ports on a VersaMax PLC CPU are configurable for SNP slave or RTU slave operation 4 wire and 2 wire RTU are supported For CPUE0S only port 1 can also be configured on another tab for Local Station Manager operation The Local Station Manager parameters may differ from the Port A parameters Description Default Choices PortMode Defines the protocol SNP NP Serial I O RTU Disabled PUE05 can also be configured s a Local Station Manager Parity Determines whether parity Odd For CPUE05 when Port Odd Even None is added to words Mode is Local Station Manager default is None e Data Rate Data transmission rate in Serial comms modes 19200 SNP 4800 9600 19200 38400 bps bits per second RTU 1200 2400 4800 9600 19200 38400 57600 Serial I O 4800 9600 19200 38400 57600 CPUE05 in Local Station Local Station Manager mode Manager mode 9600 1200 2400 4800 9600 19200 38400 57600 11520 fen ae apne the method of flow None RTU mode None Hardware not required control to use i Port Mode When changing Flow ae mode Non
161. e for the bit number where the next comparison should start MC flow none User logic to determine if a miscompare has occurred Q R Al AQ Output copy of the mask M bit string For WORD only I Q M T SA SB SC G BN 1 Q M T S G R Al AQ Bit number where the last miscompare occurred length Constant The number of words in the bit string Max is 4095 for WORD and 2047 for DWORD GFK 1503C Chapter 10 Instruction Set Reference 10 13 Bit Operation Functions Masked Compare Operation of the Masked Compare If all corresponding bits in strings I1 and I2 match the function sets the miscompare output MC to 0 and BN to the highest bit number in the input strings The comparison then stops On the next invocation of a Masked Compare Word it is reset to 0 When the two bits currently being compared are not the same the function checks the correspondingly numbered bit in string M the mask If the mask bit is a the comparison continues until it reaches another miscompare or the end of the input strings If a miscompare is detected and the corresponding mask bit is a 0 the function does the following 1 Sets the corresponding mask bit in M to 1 2 Sets the miscompare MC output to 1 3 Updates the output bit string Q to match the new content of mask string M 4 Sets the bit number output BN to the number of the miscompared bit 5 Stops the comparison Example In the example after first scan the M
162. e function is enabled it compares the value of input IN against the range specified by limits L1 and L2 Either L1 or L2 can be the high or low limit When the value is within the range specified by L1 and L2 inclusive output parameter Q is set ON 1 Otherwise Q is set OFF 0 RANGE Enabl nable INT Limit1 L1 Q Output Limit 2 L2 Value to be compared IN Parameters for the Range Function Input Choices Description Output enable flow When the function is enabled the operation is performed L1 R Al AQ constant L1 contains the start point of the range T and WORD only Constants must be integer values for double precision signed Q M T G integer operations L2 R Al AQ constant L2 contains the end point of the range T and WORD only Constants must be integer values for double precision signed Q M T G integer operations N R Al AQ N contains the value to be compared against the range T and WORD only specified by L1 and L2 Q M T G Q flow none Output Q is energized when the value in IN is within the range specified by L1 and L2 inclusive 10 60 VersaMax PLC User s Manual March 2001 GFK 1503C Range Example Relational Functions In this example when the Range function receives power flow from relay 10001 the function determines whether the value in AT001 is within the range 0 to 100 ROOO1 contains the
163. e input IN can be either a reference for the data to be moved or a constant Ifa constant is specified then the constant value is placed in the location specified by the output reference For example if a constant value of 4 is specified for IN then 4 is placed in the memory location specified by Q If the length is greater than 1 and a constant is specified then the constant is placed in the memory location specified by Q and the locations following up to the length specified Do not allow overlapping of IN and Q parameters The result of the Move depends on the data type selected for the function as shown below For example if the constant value 9 is specified for IN and the length is 4 then 9 is placed in the bit memory location specified by Q and the three locations following MOVE_BOOL MOVE_INT Enable OK Enable OK 9 IN Qf Output msb Isb 977 IN QI Output 121010 1 Length 4 bits ko ko ko ko Length 4 words The function passes power to the right whenever power is received GFK 1503C Chapter 10 Instruction Set Reference 10 33 Data Move Functions Move Data Parameters for the Move Data Function Input Choices Description Output enable flow When the function is enabled the move is performed Length The number of bits words or double words of data to be copied This is the length of
164. e is an error in the configurable parameters It can be monitored using a temporary coil while modifying data 14 2 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Parameters of the PID Function Input Choices Description Output When enabled through a contact the PID algorithm is performed 1 Q M T G R Al The control loop or process SetPoint Set using Process AQ constant Variable counts the PID function adjusts the output Control Variable so that the Process Variable matches the Set Point zero error 1 Q M T G R Al AQ Process Variable input from the process being controlled often a Al input flow When energized to 1 through a contact the PID block is in manual mode If the PID block is on manual off the PID block is in automatic mode UP flow If energized along with MAN it adjusts the Control Variable up by 1 CV per solution flow If energized along with MAN it adjusts the Control Variable down by 1 CV per solution Address Location of the PID control block information user and internal parameters Uses 40 R words that cannot be shared ok flow none OK is energized when the function is performed without error It is Off if errors exist cm l Q M T G R Al AQ The Control Variable output to the process often a AQ output Incremented UP parameter or decremented DN parameter by one 1 per access of the PID function As scaled 16 integer numbers many parameters must be d
165. e not updated This allows the current values of inputs to be compared with their values at the beginning of the scan 10001 I po_10 10001 4 ST 210064 END MO0001 ALT Q0001 i Do I O for Outputs If output references are specified when the function receives power flow the PLC writes the latest output values from the starting reference ST to the END reference to the output modules If outputs should be written to the output modules from internal memory other than Q or AQ the beginning reference can be specified for ALT Example Do I O For Outputs In the next example when the function receives power flow the PLC writes values from references R0001 0004 to analog output channels AQO0 1 004 and QO0001 is turned on Because a reference is entered for ALT the values at AQO01 004 are not written to output modules 10001 Q0001 DO_10 AQ001 7 ST AQ004 END RO0001 5 ALT If no reference were specified for ALT the PLC would write values at references AQ001 004 to analog output channels VersaMax PLC User s Manual March 2001 GFK 1503C Control Functions Do I O Do I O to One Module Enhanced Do I O The Do I O function can be used on a single discrete input or discrete output module located in the main PLC Execution of the function is much faster when just one module is read or written to The module to be read written is specified in the ALT p
166. e of this feature is configurable The default configuration enables Run Stop mode selection and disables memory protection RUN ON STOP OFF L a CPU LEDs The seven CPU LEDs visible through the module door indicate the presence of power and show the operating mode and diagnostic status of the CPU They also indicate the presence of faults forces and communications on the CPU s two ports CPUEDS POWER ON when the CPU is receiving 5V power from the power supply Does not indicate the status of the 3 3V power output OK ON indicates the CPU has passed its powerup diagnostics and is functioning properly OFF indicates a CPU problem Fast blinking indicates that the CPU roa iS running its powerup diagnostics Slow blinking indicates the CPU is configuring I O modules Simultaneous blinking of this LED and the green Run LED indicates that the CPU is in boot mode and is waiting for a firmware update through port 1 RUN Green when the CPU is in Run mode Amber when the CPU is in Stop lO Scan mode If this LED is OFF but OK is ON the CPU is in Stop No IO Scan mode If this LED is flashing green and the Fault LED is ON the module switch was moved from Stop to Run mode while a fatal fault existed Toggling the switch will continue to Run mode FAULT ON if the CPU is in Stop F aulted mode because a fatal fault has occurred To turn off the Fault LED clear both the I O Fault Table and the PLC Fau
167. ed at different rates Note The programming software will not permit consumed exchanges to share data ranges The Ethernet Global Data configuration screens are reached via the rack configuration not the CPU configuration Before You Configure EGD Exchanges Before configuring Ethernet Global Data exchanges you will need to collect information about the PLCs that will be exchanging the data Note that this information will be needed for each PLC s configuration See chapter 13 for details Determine for each PLC what data needs to be produced and consumed Make a list of the IP addresses of the Ethernet Interfaces in the PLCs that are being used to produce or consume the exchanges Identify the members of up to 32 groups of devices that will share Ethernet Global Data exchanges Decide on appropriate repetition rates and timeout periods for the exchanges Identify the content of each exchange in the producer and identify appropriate data ranges in the consumers to receive the data It is not necessary to consume all of the data from a produced exchange in each consumer A consumed exchange may be configured to ignore specified data ranges 6 4 VersaMax PLC User s Manual March 2001 GFK 1503C iG Configuring a Global Data Exchange for a Producer Each Global Data exchange must be configured in the producer as defined below The exchange must also be configured in each consumer as explained next Descr
168. eeded to run the timer These values are reserved for use by the function block and must not be written to Notes on Using the Drum Sequencer Function 1 The Dwell Timeout Output bit is cleared the first time the drum is in a new step This is true Whether the drum is introduced to a new step by changing the Active Step or by using the Step Input Regardless of the Dwell Time Array value associated with the step even if it is 0 During the first sweep the Active Step is initialized 2 The Active and Preset Step of the Drum Sequencer s control block must be initialized for the Drum Sequencer to work or to pass power flow Even if the Active Step is in the correct range between 1 and length of the Pattern array and the Preset Step is not used the drum will not function if the Preset Step is not in the proper range Chapter 10 Instruction Set Reference 10 31 10 32 Data Move Functions The Data Move functions of the Instruction Set provide basic data move capabilities Move Data This function copies data as individual bits so the new location does not have to be the same data type Block Move This function places constants into seven specified memory locations Block Clear This function fills an area of memory with zeros Shift Register This function shifts one or more data words or data bits from a reference location into a specified area of memory Data already in the area is shifted out
169. eeens 11 25 SVCREQ 26 30 Interrogate I O oe eeeeeeecesseecsneeceseeceseeeesseecsaeecseeseneeeesaes 11 26 SVCREQ 29 Read Elapsed Power Down Time eceesceesseeesseeeseeeeseeeeeneers 11 27 Serial I O SNP RTU Protocol icc cicscitecicscacessnscscassassocssecncsensivsosencasus 12 1 Format of the Communication Request Function eeseeeeeeeereeereeereerreererrresre 12 2 Configuring Serial Ports Using the COMMREQ Function 12 4 Calling Serial YO COMMREQs from the PLC Sweep 12 10 Serial O COMMREQ Command5s cccesscceeeseseeeeeeeneeccsseeeesseeecessaeeeeseanees 12 12 Ethernet Communications oc scicscicscicesesscececicztinssanidscactenssconscssnonenssemsosnses 13 1 Overview of the Ethernet Interface ccecesccceeeenceeeeeeeeeeeaeeceesteeeceseneeeesenees 13 2 IP Addressin os s 2cssceesiitsss tt iiestety hig eng ties Hide a a eo ee 13 4 ROULETS E E A TT E A eymeaunecess 13 5 Ethernet Global Datas e R A S a 13 6 Didenostic Tools soan ae ei on T T ee ee 13 14 The PID Hume Gh Gis sessen 14 1 Format of the PID Function ccceeccceeessececeeseeeeeesceceeenaeeeceseeeeeseeeeesenees 14 2 Operation of the PID Function cee ceeseeceseecesseeeseecseecsaeesseeceeecesaeeesaeessaeers 14 4 Parameter Block for the PID Function ccccccessscceeeseeceeeeeeceeeesnneeeeesneeeeeanes 14 6 PID Algorithm Selection PIDISA or PIDIND and Gains cesceeeeeeeeeee 14 10 Determining the Process Char
170. efined in either Process Variable PV counts or units or Control Variable CV counts or units For example the Set Point SP input must be scaled over the same range as the Process Variable as the PID block calculates the error by subtracting these two inputs The Process Variable and Control Variable Counts may be 32000 or 0 to 32000 matching analog scaling or from 0 to 10000 to display variables as 0 00 to 100 00 The Process Variable and Control Variable Counts do not have to have the same scaling in which case there will be scale factors included in the PID gains Chapter 14 The PID Function 14 3 14 4 Operation of the PID Function Automatic Operation The PID function can be called every sweep by providing power flow to Enable and no power flow to Manual input contacts The block compares the current PLC elapsed time clock with the last PID solution time stored in the internal RefArray If the difference is greater than the sample period defined in the third word Ref 2 of the RefArray the PID algorithm is solved using the time difference Both the last solution time and Control Variable output are updated In Automatic mode the output Control Variable is placed in the Manual Command parameter Ref 13 Manual Operation The PID block is placed in Manual mode by providing power flow to both the Enable and Manual input contacts The output Control Variable is set from the Manual Command parameter Ref 13 If either the UP or D
171. egal range Memory Required for a Bit Sequencer Each bit sequencer uses three words registers of R memory to store the information word 1 current step number word 2 length of sequence in bits word 3 control word VersaMax PLC User s Manual March 2001 GFK 1503C Bit Operation Functions Bit Sequencer Word 3 the control word stores the state of the boolean inputs and outputs of its associated function block in the following format hs ha 13 12 h1 ho 9 8 7 Je s Ja 3 2 1 Jo od STC Reserved OK status output EN enable input Parameters for the Bit Sequencer Function Input Choices Description Output address R Address is the location of the bit sequencer s current step length and the last enable and OK status enable flow When the function is enabled if it was not enabled on the previous sweep and if R is not energized the bit sequence shift is performed R flow When R is energized the bit sequencer s step number is set to the value in STEP default 1 and the bit sequencer is filled with zeros except for the current step number bit DIR flow When DIR is energized the bit sequencer s step number is incremented prior to the shift Otherwise it is decremented STEP 1 Q M T G R Al AQ When R is energized the step number is set to this value constant none ST l Q M T SA SB SC G ST
172. eived the function scans the bit string starting at IN When the function stops scanning either a bit equal to 1 has been found or the entire length of the string has been scanned POS is set to the position within the bit string of the first nonzero bit POS is set to zero if no nonzero bit is found A string length of 1 to 256 words can be selected The function passes power flow to the right whenever enable is ON Enable 1 BIT_ F OK POS_ WORD First word 7 IN POS Position of non zero bit or 0 Parameters for the Bit Position Function Input Choices Description Output enable flow When the function is enabled a bit search operation is performed IN Q M T S G R IN contains the first word of the data to be operated on ok flow none The OK output is energized whenever enable is energized POS Q M T G R Al The position of the first nonzero bit found or zero if a AQ nonzero bit is not found Example In the example if I0001 is set the bit string starting at M0001 is searched until a bit equal to 1 is found Coil QO001 is turned on If a bit equal to 1 is found its location within the bit string is written to ZAQOO1 If 10001 is set bit M0001 is 0 and bit MO0002 is 1 then the value written to AQOO is 2 0001 Q0001 1 BIT_ POS WORD M00017 IN Q POS AQ0001 Chapter 10 Instruction Set Reference 10 15 Bit Operation Functions
173. elational Functions The size of a function is the number of bytes consumed in user logic space for each instance of the function in a ladder diagram application program Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Exponential Power of e 592 12 393 10 11 Power of X 365 12 249 10 17 Radian Convert RAD to DEG 328 12 214 10 11 Conversion Convert DEG to RAD 106 12 70 10 11 Relational Equal INT 43 12 30 10 10 Equal DINT 50 12 37 10 16 Equal REAL 60 12 41 10 14 Not Equal INT 40 12 30 10 10 Not Equal DINT 45 12 30 10 16 Not Equal REAL 60 12 40 10 14 Greater Than INT 40 12 30 10 10 Greater Than DINT 45 12 30 10 16 Greater Than REAL 60 12 40 10 14 Greater Than E qual INT 40 12 30 10 10 Greater Than E qual DINT 46 12 30 10 10 Greater Than E qual REAL 60 12 40 10 14 Less Than INT 40 12 30 10 10 Less Than DINT 46 12 30 10 16 Less Than REAL 60 12 40 10 14 Less Than Equal INT 40 12 30 10 10 Less Than E qual DINT 46 12 30 10 16 Less Than E qual REAL 60 12 40 10 14 Range INT 50 12 33 10 13 Range DINT 55 12 40 10 22 Range WORD 50 12 33 10 13 VersaMax PLC User s Manual March 2001 GFK 1503C Sizes of Bit Operations Data Move Functions The size of a function is the number of bytes consumed
174. elay you may want to use SVC_REQ 16 to load the current PLC elapsed time clock into Ref 23 to update the last PID solution time to avoid a step change on the integrator If you have set the Override low bit of the Control Word Ref 14 to 1 the next four bits of the Control Word must be set to control the PID block input contacts and the Internal SP and PV must be set as you have taken control of the PID block away from the ladder logic Loop Number Integer 0 to 255 Optional number of the PID block It provides a common identification in the PLC with the loop number defined by an anz interface device Set by the PLC ISA algorithm independent algorithm Sample Period 10ms 0 every sweep to The shortest time in 10mS increments between solutions of 65535 10 9 Min the PID algorithm For example use a 10 fora 100mS At least 10ms sample period Dead Band PV Counts 0 to 32000 INT values defining the upper and lower Dead Band and never negative limits in PV Counts If no Dead Band is required these Dead Band never positive values must be 0 Ifthe PID Error SP PV or PV SP is above the value and below the value the PID calculations are solved with an Error of 0 If non zero the value must greater than 0 and the value less than 0 or the PID block will not function Leave these at 0 until the PID loop gains are set up or tuned A Dead Band might be added to avoid small CV output cha
175. ementary power supply carriers The power supply on the CPU or Expansion Receiver Module supplies 5V and 3 3V to downstream modules through the mating connector The number of modules that can be supported depends on the power requirements of the modules Additional booster power supplies can be used as needed to meet the power needs of all modules If the rack includes any Power Supply Booster Carrier and additional rack Power Supply it must be tied to the same source as the Power Supply on the CPU The configuration software provides power calculations with a valid hardware configuration Power Supply installation instructions are given below 1 The latch on the power supply must be in sll the unlocked position 2 Align the connectors and the latch post and press the power supply module down firmly until the two tabs on the bottom of the power supply click into place Be sure the tabs are fully inserted in the holes in bottom edge of the CPU ERM or carrier Pf 3 Turn the latch to the locked position to A secure the power supply as Removing the Power Supply Exercise care when working around operating equipment Devices may become very hot and could cause injury f A 1 Remove power f fA 2 Turn the latch to the unlocked position as illustrated 3 Press the flexible panel on the lower edge of the power supply to disengage the tabs on the power supply from the holes in the carr
176. empty slot or faulted module and continues with the next rack For example if there are modules physically present in slots 1 2 3 5 and 6 the modules in slots 5 and 6 are not autoconfigured To autoconfigure a system with expansion racks either all racks must be powered from the same source or the expansion racks must be powered up before the main rack Autoconfiguration Assigns Reference Addresses Modules are automatically assigned reference addresses in ascending order For example if the system contains a 16 point input module an 8 point input module a 16 point output module and another 16 point input module in that order the input modules are assigned reference addresses of I0001 10017 and I0025 respectively For modules that utilize multiple data types for example mixed I O modules each data type is assigned reference addresses individually GFK 1503C Chapter 5 CPU Configuration 5 11 5 12 Autoconfiguration Diagnostics Module Present But Non Working During Autoconfiguration If a module is physically present but not working during autoconfiguration the module is not configured and the CPU generates an extra module diagnostic Empty Slot During Autoconfiguration Autoconfiguration of a rack stops at the first empty slot Modules located after the empty slot are not autoconfigured The CPU generates an extra module diagnostic for each of them Previously Configured Modules Present During Autoconfiguration Pre
177. er 6 The IP address is 32 bits long and has a netid part and a hostid part The format of the IP address depends on the network class 8 16 24 34 Class A 0 netid hostid 8 16 24 31 Class B 1 0 netid hostid 8 16 4 31 Class C il Al netid f hostid Each IP address on a network has The same class Each network is a Class A Class B or Class C network A Class A network can support 16 777 214 hosts Class B 65 534 hosts and Class C 254 hosts The same netid which is generally assigned by the Internet authorities A different hostid giving it a unique IP address The hostid is generally assigned by your local network administrator IP addresses are written in dotted decimal format as four decimal integers 0 255 separated by periods Each integer represents one byte of the IP address For example the 32 bit IP address 00001010 00000000 00000000 00000001 is written as 10 0 0 1 The class of an IP address is indicated by the first decimal integer Range of first integer Class 0 127 A 128 191 B 192 223 C 224 239 D Reserved for Multicast Use 240 255 E Reserved for Experimental Use RFC 1918 reserves IP addresses in the following ranges for private networks 10 0 0 0 10 255 255 255 Class A 172 16 0 0 172 31 255 255 Class B 192 168 0 0 192 168 255 255 Class C X y Z 1 is reserved for gateways x y z 255 is reserved for subnet broadcast Ve
178. er flow to the Reset input or to the Step input selects the reference to be copied The Control Block input is the beginning reference for the Drum Sequencer function s parameter block which includes information used by the function Chapter 10 Instruction Set Reference 10 29 10 30 Control Functions Drum Sequencer Parameters of the Drum Sequencer Function Input Choices Description Output enable flow The Enable input controls execution of the function Step flow The Step input can be used to go one step forward in the sequence When the Enable input receives power flow and the Step input makes an Off to On transition the Drum Sequencer moves one step When Reset is active the function ignores the Step input Reset flow The Reset input can be used to select a specific step in the sequence When Enable and Reset both receive power flow the function copies the Preset Step value in the Control Block to the Active Step reference also in the Control Block Then the function block copies the value in the Preset Step reference to the Out reference bits When Reset is active the function ignores the Step input Pattern R Al AQ The starting address of an array of words each representing one step of the Drum Sequencer The value of each word represents the desired combination of outputs for a particular value of Active Step The number of elements in the array is eq
179. erences from either retentive or nonretentive memory Q M T G WSA SB or SC Negative Transition Coil If the reference associated with this coil is OFF when the coil stops receiving power flow the reference is set to ON until the next time the coil is executed Do not write from external devices to references used on negative transition coils since it will destroy the oneshot nature of these coils Transitional coils can be used with references from either retentive or nonretentive memory Q M T G WSA SB or SC Example In the example when reference E1 goes from OFF to ON coils E2 and E3 receive power flow turning E2 ON for one logic sweep When E2 goes from ON to OFF power flow is removed from E2 and E3 turning coil E3 ON for one sweep E1 E2 P E2 E3 N 10 66 VersaMax PLC User s Manual March 2001 GFK 1503C Relay Functions Coils GFK 1503C SET Coil SET and RESET are nonretentive coils that can be used to keep latch the state of a reference either ON or OFF When a SET coil receives power flow its reference stays ON whether or not the coil itself receives power flow until the reference is reset by another coil RESET Coil The RESET coil sets a discrete reference OFF if the coil receives power flow The reference remains OFF until the reference is set by another coil The lastsolved SET coil or RESET coil of a pair takes precedence Example In the example
180. erface s built in clock is periodically synchronized to the clock from one to three NTP servers on the network The Ethernet interface periodically requests time from the servers and uses the time from the most accurate server based on NTP stratum number CPUE05 CPU Ethernet interface ie NTP Time lock Server on Network pme timestamp EGD with ii tamp All Ethernet interfaces that have been configured to use Network Time Protocol will have updated synchronized timestamps because they are all controlled by the NTP server clock Therefore accurate timing comparisons between exchanged data can be made For example if several PLCs sent alarm data it might be helpful to know the order in which the alarms occurred Multiple NTP servers can be used to improve the availability of time servers When the time is obtained from an NTP server dates from January 1 1970 are supported by the Ethernet Interface Configuring NTP for the CPUE05 Ethernet Interface GFK 1503C To implement Network Time Protocol in the Ethernet interface in CPUEOS the IP address of one to three NTP Time Servers are specified in the PLC Ethernet configuration See Configuring the Ethernet Interface in chapter 6 for details CPUEO5 does not support multicast NTP operation multiple NTP servers may be specified individually The Ethernet interface in CPUEOS always operates in client mode It will synchro
181. erface with the network with PLC backplane communication or with your application The LOG TALLY and STAT Station Manager commands are especially useful Refer to the VersaMax PLC Ethernet Station Manager Manual for information on how to access and use the Station Manager What to do if you Cannot Solve the Problem If you still cannot solve your problem call GE Fanuc Automation NA 1 800 GE FANUC Please have the following information available when you call The Name and Catalog Number marked on the product Description of symptoms of problem Depending on the problem you may also be asked for the following information 1 The ladder logic application program and the PLC sweep length at the time the problem occurred 2 A listing of the configuration parameters for the Ethernet Interface that failed 3 A description of the network configuration This should include the number of PLCs and host computers accessing the network the type of network cable used e g twisted pair fiber optic etc length of network cable and the number and manufacturer of transceivers hubs and network switches used 13 14 VersaMax PLC User s Manual March 2001 GFK 1503C Checking the Ethernet LEDs After configuring the Interface follow the steps below to verify that the Ethernet Interface is operating correctly 1 Turn power OFF to the PLC for 3 5 seconds then turn the power back ON This starts a series of diagnostic t
182. erformed ST 1 Q Al AQ The starting address of the I O to be serviced END 1 Q Al AQ The ending address of the I O to be serviced ALT 1 Q M T G R Al Forthe input scan ALT specifies the address to store AQ constant none scanned input point word values For the output scan ALT Specifies the address to get output point word values from to send to the 1 0 modules ok flow none OK is energized when the scan completes normally Chapter 10 Instruction Set Reference 10 19 10 20 Control Functions Do I O Do I O for Inputs If input references are specified when the function receives power flow the PLC scans input points from the starting reference ST to the END reference If a reference is specified for ALT copies of the new input values are placed in memory beginning at that reference and the real input values are not updated ALT must be the same size as the reference type scanned If a discrete reference is used for ST and END ALT must also be discrete If no reference is specified for ALT the real input values are updated This allows inputs to be scanned one or more times during the program execution portion of the CPU sweep Example Do I O for Inputs In this example when the function receives power flow the PLC scans references 10001 64 and QOO001 is turned on Copies of the scanned inputs are placed in internal memory from M0001 64 Because a reference is specified for ALT the real inputs ar
183. ergized when 100 parts have been counted When M0001 is ON the accumulated count is reset to zero 10012 M0001 CTU gt M0001 R CONST 00100 PY PRT_CNT Chapter 10 Instruction Set Reference 10 81 Timer and Counter Functions Down Counter The Down Counter function counts down from a preset value The minimum Preset Value is zero the maximum present value is 32 767 counts The minimum Current Value is 32 768 When reset the Current Value of the counter is set to the Preset Value PV When the enable input transitions from OFF to ON the Current Value is decremented by one The output is ON whenever the Current Value is less than or equal to zero The Current Value of the Down Counter is retentive on power failure no automatic initialization occurs at powerup Enable CTD Q Reset p Preset Value 3 Address Parameters of the Down Counter Function Input Choices Description Output address R The function uses three consecutive words registers of R memory to store the following e Current value CV word 1 Preset value PV word 2 e Control word word 3 Do not use this address with another down counter up counter or any other instruction or improper operation will result Careful Overlapping references will resultin erratic counter operation enable flow Ona positive transition of enable the Current Value is decremented by one R flow When R receives power flow it
184. ests During powerup diagnostics after a brief delay the STAT LED on the Ethernet side of the CPU module blinks Both the LAN and PORT1 LEDs are off If a fatal diagnostic failure occurs the failure is indicated by a two digit pattern in amber on the STAT LED 2 After successful power up all three LEDs on the Ethernet side turn on briefly Then the STAT and LAN LEDs should be green The LAN LED blinks when there is traffic 3 Ifthe STAT LED is amber check the PLC Fault Table With the Station Manager feature you can also use the LOG command as explained in GFK 1876 The VersaMax PLC Ethernet Station Manager Manual If a problem occurs during power up the Ethernet interface may not begin operating Check the Ethernet LEDs as explained below Ethernet LEDs Indications Actions Off Make sure the PLC has power Look in the PLC Fault Table for problems AN O o Ane stat O o Recheck configuration Pri o Check module installation Ifthe problem persists replace PLC CPU Performing powerup diagnostics No action necessary diagnostics will complete ian O o within 3 to 10 seconds STAT e Fastblink green PorT O o Hardware failure mode STAT Blinks 2 digit Note error code wO g error code l Power cycle or restart Ethernet interface i 1 2 unexpected interrupt f problem persists replace the PLC STAT Blinking amber 1 3 timer failure hardware Porti O 0 1 4
185. ete Mixed I O Modules ixed 24VDC Positive Logic Input Grouped 20 Point Output Relay 2 0A per Point C200MDD840 Grouped 12 Point Module ixed 24VDC Positive Logic Input 20 Point Output 12 Point 4 High Speed Counter IC200MDD841 PWM or Pulse Train Configurable Points ixed 16 Point Grouped Input 24VDC Pos Neg Logic 16 Pt Grouped Output 24VDC C200MDD842 Pos Logic 0 54 w ESCP ixed 24VDC Positive Logic Input Grouped 10 Point Output Relay 2 0A per Point 6 C200MDD843 Point Module ixed 24 VDC Pos Neg Logic Input Grouped 16 Point Output 12 24VDC Pos Logic C200MDD844 0 5A 16 Point Module ixed 16 Point Grouped Input 24VDC Pos Neg Logic 8 Pt Relay Output 2 0A per Pt C200MDD845 solated Form A ixed 120VAC Input 8 Point Output Relay 2 0A per Point 8 Point Module C200MDD846 ixed 240VAC Input 8 Point Output Relay 2 0A per Point 8 Point Module C200MDD847 ixed 120VAC Input 8 Point Output 120VAC 0 5A per Point Isolated 8 P oint Module C200MDD848 ixed 120VAC In Isolated 8 Point Output Relay 2 0A Isolated 8 Point Module C200MDD849 ixed 240VAC In Isolated 4 Point Output Relay 2 0A Isolated 8 Point Module C200MDD850 Analog Input Modules Analog Input Module 12 Bit Voltage Current 4 Channels C200ALG230 Analog Input Module 16 Bit Voltage Current 1500VAC Isolation 8 Channels C200ALG240 Analog Input Module 12 Bit Voltage Current 8 Channels C200ALG 260 Analog Input Module 15 Bit Differential Voltage 8 Channels C200ALG261 Analog Input Module
186. etwork usage set the Producer Period to the same value as the Consumer Period Do not produce data faster than is required by your application For example it is usually not useful to produce data faster than the scan time of the producer or consumer PLCs This reduces the load on the network and on the devices providing capacity for other transfers Reply Rate Currently not used Status Word A data range that identifies the memory location where the status value for the produced exchange will be placed See Checking the Status of an Exchange in chapter 13 for details Note that the Status Word address must be unique itis not automatically assigned the next highest address example High Pai Status R Status Where the PLC will place the status data Exchange A list of 1 to100 data ranges that will be sent in the exchange Data is sent as a Data Ranges contiguous set of bytes See Checking the Status of an Exchange in chapter 13 for details The total size can be up to 1400 bytes The list of data ranges to be sentin an exchange specifies example High Point 00 f r f 100 105 Conveyor in PLC Conveyor limit switch in PLC1 GFK 1503C Chapter 6 Ethernet Configuration 6 5 sl Configuring a Global Data Exchange for a Consumer To receive a Global Data Exchange configure the following information Local Producer The address that uniquely identifies the CPUE05 as an Ethernet Global Data device ID across the ne
187. evice through the specified serial port The character s to be transmitted must be in a word reference memory They should not be changed until the operation is complete Up to 250 characters can be transmitted with a single invocation of this operation The status of the operation is not complete until all of the characters have been transmitted or until a timeout occurs for example if hardware flow control is being used and the remote device never enables the transmission Example Command Block for the Write Bytes Function decimal hexadecimal address address 1 address 2 Status word memory type R address 3 Status word address minus 1 R0001 address 4 address 5 address 6 Write bytes command address 7 address 8 address 9 h 68h e 65h address 10 27756 6C 6C 6Ch 6Ch address 11 0111 006F o 6Fh Although printable ASCII characters are used in this example there is no restriction on the values of the characters which can be transmitted Operating Notes Note Specifying zero as the Transmit time out sets the time out value to the amount of time actually needed to transmit the data plus 4 seconds Caution If an Initialize Port 4300 COMMEQ is sent or a Cancel Operation 4399 COMMREQ is sent in either Cancel All or Cancel Write mode while this COMMREQ is transmitting a string from a serial port transmission is halted The position within the string where the transmission
188. evices Class A 8KV Air 4KV Contact 10V___ m 80Mhz to 1000Mhz 80 AM rms 10Vims m 900MHz 5MHZ 100 AM with 200Hz square wave 2KV power supplies 1KV 1 0 communication Damped Oscillatory Wave 2 5KV power supplies 1 0 12V 240V 1KV communication Damped Oscillatory Wave Class Il power supplies I O 12V 240V 2 kV cm P S 1 kV cm I O and communication modules 10V___ 0 15 to 80Mhz 80 AM rms 1 5KV During Operation Dips to 30 and 100 Variation for AC 10 Variation for DC 20 GFK 1503C IC200CPUE05 CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory Serial Ports The two serial ports are software configurable for SNP slave or RTU slave operation 4 wire and 2 wire RTU are supported If a port is being used for RTU it automatically switches to SNP slave mode if necessary Port 1 can also be configured for Local Station Manager operation to provide access to diagnostic information about the Ethernet interface Both ports default to SNP slave and both automatically revert to SNP slave when the CPU is in Stop mode if configured for Serial I O Either port can be software configured to set up communications between the CPU and various serial devices An external device can obtain power from Port 2 if it requires 100mA or less at SVDC PORTL 00000 WLLL RS232 PORT2 Q e e O e fe O O O fe fe ie O O ie
189. f Consumed only The data has been refreshed since the previous a Data after refresh timeout consumption but was not refreshed within the timeout period 10 IP connection not available Produced and Consumed The IP network connection is not available 1 Produced and Consumed Local resources are not available to establish y Lack of resource error the exchange Look in the PLC Fault Table for details 14 Length error Consumed only The packet received did not match the length expected Produced and Consumed The Ethernet interface is not communicating with the CPU A loss of module or reset of module PLC Fault Table entry 18 Loss 0 ae interface may also be present If the failure is transient in nature the status of the exchange may change ata later time That indicates subsequent transfers on the exchange were successful 22 EGD not supported This error cannot occur with CPUE05 26 0 response Produced and Consumed Ethernet interface failed to establish exchange 28 Other error Produced and Consumed Error other than 12 14 18 or 26 when establishing an exchange Look in the PLC Fault Table for information Produced And Consumed Exchange has been deleted and will no longer 30 Exchange deleted be scanned VersaMax PLC User s Manual March 2001 GFK 1503C Using the Ethernet Station Manager Function GFK 1503C CPUEOS provides local Station Manager operation via Port 1 This port can be configured for either CPU serial communica
190. face LAN indicates the status and activity of the Ethernet network connection ON flickering green indicates Ethernet interface is online ON amber indicates Ethernet interface is offline STAT indicates the general status of the Ethernet interface ON green indicates no exception detected ON amber indicates an exception Blinking amber indicates error code Blinking green indicates waiting for configuration or waiting for IP address PORT1 indicates when the Ethernet interface is controlling the RS 232 serial port It also indicates when the Ethernet Restart pushbutton has been used to override configured RS 232 port usage for Local Station Manager operation ON amber indicates P ort 1 is available for Local Station Manager use either by configuration or forced OF F indicates PLC CPU is controlling Port 1 Does not blink to indicate traffic The Ethernet LEDs turn ON briefly first amber then green whenever a restart is performed in the Operational state by pressing and releasing the Restart pushbutton This allows you to verify that the Ethernet LEDs are operational All three LEDs blink green in unison when a software load is in progress GFK 1503C Chapter 3 CPU Module Datasheet CPUEO5S 3 9 3 10 IC200CPUE05 CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory Configurable Memory CPUEOS provides a total of 64K bytes of configurable user memory This 64K of memory is use for the application
191. fore the sweep impact will vary based on the number of exchanges that are scheduled to be transferred during the sweep However at some point during the operation of the PLC all of the exchanges will be scheduled to transfer data during the same sweep Therefore all exchanges must be considered when computing the worst case sweep impact The Ethernet Global Data EGD sweep impact has two parts Consumption Scan and Production Scan EGD Sweep Impact Consumption Scan Time Production Scan Time Where the Consumption and Production Scans consist of two parts exchange overhead and byte transfer time Scan Time Exchange Overhead Byte Transfer Time Exchange Overhead Exchange overhead includes the setup time for each exchange that will be transferred during the sweep This overhead varies depending on whether the exchange is consumed or produced and if the time stamp for the exchange originates from the PLC itself or from a remote Network Time Protocol NTP server When computing the sweep impact include overhead time for each exchange Consumed Exchange Produced Exchange Exchange Overhead a ee 110 304 Times are in microseconds Represents overhead if the exchange is time stamped with the PLC clock instead of a remote NTP server Byte Transfer Time This is the time required to transfer data between the PLC CPU module and the Ethernet module The byte transfer time is slightly greater if the PLC memory being writ
192. functions Enabled Sweep impact time in microseconds when a function block has been enabled power flow to the function block Disabled Sweep impact time in microseconds when a function block has been disabled no power flow to function block and or power flow to reset of function block Increment Incremental time in microseconds input unit to add to the base function time for each addition to the length of an input parameter Only applies to table functions that can have varying input lengths i e Search Array Moves etc All timings represent typical execution time Timings may vary with input and error conditions Each timing includes the time to execute one contact and normal overhead including a connection with a programmer Note timings listed in previous versions of this manual did not include this overhead A 2 For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microseconds number of bits or words For functions that have an increment value multiply the increment by Length 1 and add that value to the base time to get total instruction time VersaMax PLC User s Manual March 2001 GFK 1503C Sizes of Timers Counters Math Functions Trig Functions Log Functions The size of a function is the number of bytes consumed in user logic space for each instance of the function in a ladder diagram application program
193. g Output 2 Channels Network Communications Modules NCM Scan Impact Times vary depending upon the network configuration GFK 1503C Appendix A Performance Data A 11 Modules Located in Single ended Isolated Expansion Rack The table below shows timing for modules located in an expansion rack in a single ended expansion system that has an Isolated Expansion Receiver Module IC200ERMO001 in the expansion rack and an Expansion Transmitter module IC200ETMO001 in the CPU rack CPU005 CPUE05 CPU001 CPU002 Module Type 9 ok iscrete Output Type 1 iscrete Output Type 2 Discrete Output w ESCP Per Point Fault Reporting ntelligent Discrete Input 20 P oints 4050 ntelligent Discrete Output 12 P oints fF e D D D D iscrete Input Type 2 75 Aralo Output2 chames Analog Output chames __ ralog Ouput Chane Analog Output 12 Charnes S DeviceNet Network Master Slave Mixed modules have both and input and output scan time values PLC Network Comm Profibus DP lave j Network Communications Modules NCM Scan Impact Times vary depending upon the network configuration A 12 VersaMax PLC User s Manual March 2001 GFK 1503C Ethernet Global Data Sweep Impact GFK 1503C Depending on the relationship between the CPU sweep time and Ethernet Global Data EGD exchange s period the exchange data may be transferred every sweep or periodically after some number of sweeps There
194. g table compares the functions of Port 1 and Port 2 Port 1 Port 2 CPU Protocols SNP slave RTU Defaults to SNP slave Defaults to SNP slave Slave Serial I O Firmware Upgrade PLC in Stop No I O mode no Smart module firmware upgrade PLC in Stop No I O mode PLC in Stop No lO mode Cable Lengths Maximum cable lengths the total number of feet from the CPU to the last device attached to the cable are Port 1 RS 232 15 meters 50 ft Port 2 RS 485 1200 meters 4000 ft Chapter 2 CPU Module Datasheets CPU001 CPU002 CPU005 2 5 CPU with 34kB Configurable Memory IC200CPU001 CPU with 42kB Configurable Memory IC200CPU002 CPU with 64kB Configurable Memory IC200CPU005 Serial Port Baud Rates CPU001 CPU002 CPU005 RTU protocol 1200 2400 4800 9600 19 2K 1200 2400 4800 9600 19 2K 38 4K 57 6K Serial I O protocol 4800 9600 19 2K 4800 9600 19 2K 38 4K 57 6K SNP protocol 4800 9600 19 2K 38 4K 4800 9600 19 2K 38 4K 2 6 Firmware Upgrade via 2400 4800 9600 19 2K 38 4K na WInloader Only available on one port at a time The VersaPro software allows configuration of RTU and Serial I O at 115 2K baud However these baud rates are not supported by the CPU If a configuration using these baud rates is stored to the PLC 1 For RTU an Unsupported Feature in Configuration fault is logged and the PLC transit
195. gorithms work a43646 PROPORTIONAL BIAS TERM ky SP Error Sign p DEAD INTEGRAL Ki SLEW UPPER LOWER POLARITY c a gt CV C gt BAND a A TIME LIMIT gt CLAMP oft PV Deriv Action 5 VALUE DERIVATIVE A TIME TERM Kd The ISA Algorithm PIDISA is similar except the Kp gain is factored out of Ki and Kd so that the integral gain is Kp Ki and derivative gain is Kp Kd The Error sign DerivAction and Polarity are set by bits in the Config Word user parameter GFK 1503C Chapter 14 The PID Function 14 11 CV Amplitude and Rate Limits The block does not send the calculated PID Output directly to CV Both PID algorithms can impose amplitude and rate of change limits on the output Control Variable The maximum rate of change is determined by dividing the maximum 100 CV value 32000 by the Minimum Slew Time if specified as greater than 0 For example if the Minimum Slew Time is 100 seconds the rate limit will be 320 CV counts per second If the dt solution time was 50 milliseconds the new CV output can not change more than 320 50 1000 or 16 CV counts from the previous CV output The CV output is then compared to the CV Upper and CV Lower Clamp values If either limit is exceeded the CV output is set to the clamped value If either rate or amplitude limits are exceeded modifying CV the internal integrator value is adjusted to match the limited value to avo
196. gured on the master device as the PLC slave scan time increases It is not necessary to change the configuration of the VersaMax CPU itself however Chapter 5 CPU Configuration 5 9 Storing a Configuration from a Programmer Ordinarily a VersaMax PLC system is configured by creating a configuration file on the programmer computer then transferring the file from the programmer to the PLC CPU via the CPU port The CPU stores the configuration file in its non volatile RAM memory The configuration is stored whether I O scanning is enabled or not After the configuration is stored I O scanning is enabled or disabled according to the newly stored configuration parameters Autoconfiguration and Storing a Configuration Clearing a configuration from the programmer causes a new autoconfiguration to be generated Autoconfiguration remains enabled until the configuration is stored from the programmer again Storing a configuration disables autoconfiguration Storing a Configuration with Non default Memory Allocation If you reconfigure reference tables from the default sizes storing a hardware configuration to the PLC in the future will clear memory contents If you want to retain memory contents first load reference memory contents from the PLC to the programmer Then re store reference memory when you store the hardware configuration from the programmer to the PLC Default Serial Port Parameters When a programmer is first connected the PL
197. he EZ Program Store device updates a PLC it writes over existing configuration program files and data in the target PLC Therefore it is important to be sure that the information placed on the EZ Program Store device is complete for proper operation of the PLC system For example if the EZ Program Store device contains an application program but instead of a customized hardware configuration it contains the default PLC configuration the update will overwrite any existing configuration data in a PLC being updated If that happens the modules in the PLC system will then use their default configuration which may cause unexpected operation Chapter 15 The EZ Program Store Device 15 3 EZ Program Store Device IC200ACC003 15 4 Matching OEM Protection If the PLC s that will be updated by the EZ Program Store device are protected by an OEM key password be sure the same OEM key password is present in the configuration stored to the EZ Program Store device otherwise no update will be possible If the PLC s being updated had no OEM key password assigned the EZ Program Store device must also not have an OEM key password The device does not use other system passwords See chapter 7 CPU Operation for information about passwords and the OEM key Adjusting the Configuration Timeouts Reading and writing large programs hardware configurations and reference tables to or from the EZ Program Store device may take 30 seconds or more to
198. he result of this scheduling method for Ethernet Global Data is a variability of up to one producer CPU sweep time in the interval between samples produced on the network This variability in the time between samples is present to assure that the most up to date data is being transferred In general it is not useful or necessary to configure the production period to be less than the CPU sweep time If the producer period for an exchange is set lower than the CPU sweep time the Ethernet interface will send a stale sample a sample containing the same data as previously sent at the configured interval When the fresh CPU data becomes available at the end of the sweep the Ethernet interface will immediately send another sample with the fresh data The timer of the produced exchange is not reset when this sample is sent This can result in more samples in the network than would be expected from the configured period 13 12 VersaMax PLC User s Manual March 2001 GFK 1503C Timing Examples The following illustrations show the relationship between the PLC output scan time the produced exchange timer and data samples on the network Example 1 Only one sample is produced on the network per producer period expiration The variability between samples can be up to producer CPU sweep time Producer Period 1 5 Times CPU Sweep Producer PLC Output Scan Pa WN a We Ie Ethernet Global Data Production Timer Expires Sample on Networ
199. he third least significant bit of ROOO1 through the second least significant bit of R0002 of the array containing all 16 bits of ROOO1 and four bits of R0002 is read and then written into the fifth least significant bit of RO100 through the fourth least significant bit of RO101 of the array containing all 16 bits of RO100 and four bits of RO101 0001 and RO100 are declared as type BOOL of length 20 10001 ARRAY MOVE_ BOOL R0001 SR DS R0100 CONST 00003 SNX CONST 00005 DNX CONST _ 00016 N 10 70 VersaMax PLC User s Manual March 2001 GFK 1503C Table Functions Search for Array Values GFK 1503C Use the Search functions listed below to search for values in an array Search Equal Search Not Equal Search Greater Than Search Greater Than or Equal Search Less Than Search Less Than or Equal Equal to a specified value Not equal to a specified value Greater than a specified value Greater than or equal to a specified value Less than a specified value Less than or equal to a specified value When the Search function receives power it searches the specified array Searching begins at the starting address AR plus the index value NX enable Starting address Input index Object of search SRCH_ EQ_ INT AR FD M Found indication NX NX Output index N The search continues until the array element of the search object IN i
200. ication program and hardware configuration are automatically determined by the actual program and configuration entered from the programmer The rest of the configurable memory can be easily allocated to suit the application Configurable memory CPU001 34K bytes maximum CPU002 42K bytes maximum CPU005 64K bytes maximum Application program size not configurable 128 bytes minimum CPU001 for rel 1 50 compatibility 12K bytes CPU002 for rel 1 50 compatibility 20K bytes Hardware configuration size not configurable Registers R 256 bytes minimum CPU001 002 for rel 1 50 compatibility 4 096 bytes Analog Inputs Al 256 bytes minimum Analog Outputs AQ 256 bytes minimum 2 8 VersaMax PLC User s Manual March 2001 GFK 1503C Chapter CPU Module Datasheet CPUEO5 3 This chapter describes the appearance features and functionality of the following VersaMax PLC CPU module JC200CPUEO0S CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory GFK 1503C 3 3 2 IC200CPUE05 CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory VersaMax PLC CPU IC200CPUE0S shares the basic features of the other VersaMax PLC CPUs It provides powerful PLC functionality in a small versatile system CPUEOS can serve as the system controller for up to 64 modules with up to 2048 I O points Two serial ports provide RS 232 and RS 485 interfaces for serial communicatio
201. iciency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply The following are trademarks of GE Fanuc Automation North America Inc Alarm Master Genius PowerTRAC Series Six CIMPLICITY Helpmate ProLoop Series Three CIMPLICITY 90 ADS Logicmaster PROMACRO VersaMax CIMSTAR Modelmaster Series Five VersaPro Field Control Motion Mate Series 90 VuMaster GEnet PowerMotion Series One Workmaster Copyright 2001 GE Fanuc Automation North America Inc All Rights Reserved Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 GFK 1503C Contents IMPOMU LION sc iscsescsiscscsstesiserasercoandeiciesedcdedesetatecntesntedsstdsdosesedeseieonteantasuauss 1 1 The VersaMax Family of Products ceseeseseecsseecsseeceseeeseeceseeeesaeessaeesseeeees 1 3 CPU Modules for VersaMax PLCS 00 ceecesccceseeceseecseecencecseecesaeeesaeecseesseeeee 1 4 Power Supplies ienesa naa ie cata ieee as aa ea ieee 1 6 VO Modules ciate dis Ae Aisi Monn And S apna aes 1 7 Caiet Seaan E E E ET AA E atneestls Woes iatana elses tara a 1 10 Expansion M odU ES a a a A E E S R 1 12 Communications Modules sscccesecceseeceseeceseeeeseecsaeecssecsseecseecesaeeesaeessaeers 1 14 CPU Module Datasheets CPU001 CPU002 CPU006 sssssseeees 2 1 CPU Module Datasheet CPUEOS ssccsscsssssssssssssssssssscsesssesssscseeess 3 1 Install tio nsciis 4 1 M
202. id reset windup Finally the block checks the Output Polarity 2nd bit of the Config Word Ref 12 and changes the sign of the output if the bit is 1 CV Clamped PID Output or Clamped PID Output if Output Polarity bit set If the block is in Automatic mode the final CV is placed in the Manual Command Ref 13 If the block is in Manual mode the PID equation is skipped as CV is set by the Manual Command but all the rate and amplitude limits are still checked That means that the Manual Command can not change the output above the CV Upper Clamp or below the CV Lower Clamps and the output can not change faster than the Minimum Slew Time allowed 14 12 VersaMax PLC User s Manual March 2001 GFK 1503C Sample Period and PID Block Scheduling The PID block is a digital implementation of an analog control function so the dt sample time in the PID Output equation is not the infinitesimally small sample time available with analog controls The majority of processes being controlled can be approximated as a gain with a first or second order lag possibly with a pure time delay The PID block sets a CV output to the process and uses the process feedback PV to determine an Error to adjust the next CV output A key process parameter is the total time constant which is how fast does the PV respond when the CV is changed As discussed in the Setting Loop Gains section below the total time constant Tp Tc for a first order system is the time requ
203. ier 4 Pull the power supply straight off Chapter 4 Installation 4 9 4 10 Installing Additional Modules A CPU or Expansion Receiver Module can serve up to 8 additional I O and option modules on the same section of DIN rail Power must be off before adding a carrier to the rack Before joining carriers to the CPU or ERM remove the connector cover on the righthand side of the CPU ERM Do not discard this cover you will need to install it on the last carrier It protects the connector pins from damage and ESD during handling and use Do not remove the connector cover on the lefthand side N Connector Cover Connector Cover Install each carrier close to the previously installed carrier then slide the properly aligned carriers together to join the mating connectors To avoid damaging the connector pins do not force or slam carriers together DIN rail clamps available as part number IC200ACC313 should be installed at both ends of the station to lock the modules in position VersaMax PLC User s Manual March 2001 GFK 1503C Activating or Replacing the Backup Battery GFK 1503C The CPU module is shipped with a battery already installed The battery holder is located in the top side of the CPU module Before the first use activate the battery by pulling and removing the insul
204. ill the hole in the panel Install the module using an M3 5 6 screw in the panel mount hole C fe Note 1 Tolerances on all dimensions are 0 13mm 0 005in non cumulative Note 2 1 1 to 1 4Nm 10 to 12 in Ibs of torque should be applied to M3 5 6 32 steel screw threaded into material containing internal threads and having a minimum thickness of 2 4mm 0 093in SEE NOTE 2 4 3mm M3 5 6 SCREW 0 170in SPLIT LOCK t WASHER FLAT WASHER m I 4 3mm a 0 170in chy 15 9mm 0 62in REF 5 1mm LY 0 200in 4 TAPPED l HOLE IN CPU PANEL GFK 1503C Chapter 4 Installation 4 3 Installing an Expansion Transmitter Module If the VersaMax PLC will have more than one expansion rack or one expansion rack that uses an Isolated Expansion Receiver Module IC200ERMO001 as its interface to the expansion bus an Expansion Transmitter Module must be installed to the left of the CPU The Expansion Transmitter Module must be installed on the same section of DIN rail as the rest of the modules in the main rack rack 0 Ne D C SS aaa SS Make sure rack power is off Attach the Expansion Transmitter to DIN rail to the left of the CPU position In
205. ing out the Station Manager function The Station Manager appears inoperative under either local or remote operation The Ethernet interface always gives higher priority to data communication functions than to the Station Manager When the processing load is reduced the Station Manager becomes operative once again This condition is not reported to the PLC Fault Table or Ethernet exception log PING Restrictions To conserve network data buffer resources the CPUE0S process only one ICMP control message at a time An ICMP Echo ping request that arrives while the CPUEDS is processing another ICMP control message is discarded When multiple remote hosts attempt to ping the CPUEOS at the same time some individual ping requests may be ignored depending upon the timing of the ping requests on the network The CPUEOS may initiate ping requests to another host on the network via the ping Station Manager command The ping request sequence is restricted to one remote host at a time Discarded ping requests are not reported to the PLC Fault Table or Ethernet exception log SRTP Connection Timeout When a remote SRTP client is abruptly disconnected from a CPUE0S for example by disconnecting the Ethernet cable the underlying TCP connection attempts to re establish communication The SRTP connection in the CPUEOS remains open for approximately 5 minutes while TCP attempt to reconnect during this interval the SRTP connection is unavailabl
206. ing package will help The CV step size should be large enough to cause an observable change in PV but not so large that it disrupts the process being measured A good size may be from 2 to 10 of the difference between the CV Upper and CV Lower Clamp values 14 14 VersaMax PLC User s Manual March 2001 GFK 1503C Setting Parameters Including Tuning Loop Gains GFK 1503C As all PID parameters are totally dependent on the process being controlled there are no predetermined values that will work however it is usually simple to find acceptable loop gain 1 Set all the User Parameters to 0 then set the CV Upper and CV Lower Clamps to the highest and lowest CV expected Set the Sample Period to the estimated process time constant above 10 to 100 2 Put block in Manual mode and set Manual Command Ref 13 at different values to check if CV can be moved to Upper and Lower Clamp Record PV value at some CV point and load it into SP 3 Set a small gain such as 100 Maximum CV Maximum PV into Kp and turn off Manual mode Step SP by 2 to 10 of the Maximum PV range and observe PV response Increase Kp if PV step response is too slow or reduce Kp if PV overshoots and oscillates without reaching a steady value 4 Once a Kp is found start increasing Ki to get overshooting that dampens out to a steady value in 2 to 3 cycles This may required reducing Kp Also try different step sizes and CV operating points 5 After suitable Kp an
207. ion 7 5 CPU Stop Modes The PLC may also be in either of two Stop modes m Stop with I O Disabled mode m Stop with I O Enabled mode When the PLC is in Stop mode the CPU does not execute the application program logic You can configure whether or not the I O will scanned during Stop mode Communications with the programmer and intelligent option modules continue in Stop mode In addition faulted board polling and board reconfiguration execution continue in Stop mode SVCREQ 13 can be used in the application program to stop the PLC at the end of the next sweep All I O will go to their configured default states and a diagnostic message will be placed in the PLC Fault Table 7 6 VersaMax PLC User s Manual March 2001 GFK 1503C Controlling the Execution of a Program GFK 1503C The VersaMax CPU Instruction Set contains several powerful Control functions that can be included in an application program to limit or change the way the CPU executes the program and scans I O Calling a Subroutine Block The CALL function can be used to cause program execution to go to a specific subroutine Conditional logic placed before the Call function controls the circumstances under which the CPU performs the subroutine logic After the subroutine is finished program execution resumes at the point in the logic directly after the CALL instruction Creating a Temporary End of Logic The END function can be used to provide a temporary end of l
208. ions to Stop Faulted mode 2 For Serial I O the same fault is logged when the transition to Run mode occurs The PLC will immediately transition to Stop Faulted mode Mode Switch The CPU module has a convenient switch that can be used to place the PLC in Stop or Run mode The same switch can also be used to block accidental writing to CPU memory and forcing or overriding discrete data Use of this feature is configurable The default configuration enables Run Stop mode selection and disables memory protection RUN ON a STOP OFF VersaMax PLC User s Manual March 2001 GFK 1503C IC200CPU001 CPU with 34kB Configurable Memory IC200CPU002 CPU with 42kB Configurable Memory IC200CPU005 CPU with 64kB Configurable Memory CPU LEDs The seven CPU LEDs visible through the module door indicate the presence of power and show the operating mode and diagnostic status of the CPU They also GFK 1503C indicate the presence of faults forces and communications on the CPU s two ports CPU001 PURO xO aU FAULT ForcE PoRTIO PoR O POWER OK RUN FAULT FORCE PORT 1 PORT 2 ON when the CPU is receiving 5V power from the power supply Does not indicate the status of the 3 3V power output ON indicates the CPU has passed its powerup diagnostics and is functioning properly OFF indicates a CPU problem Fast blinking indicates thatthe CPU is running its powe
209. iption Local The address that uniquely identifies the CPUE05 as an Ethernet Global Data device Producer ID across the network It is a dotted decimal number The default is the same as the IP address of the CPUE05 The default can be changed Exchange ID A number that identifies a specific data exchange Adapter Name Always 0 0 for CPUE05 Consumer Select whether the data s destination will be a single device IP address or one of 32 Type predefined device groups Group ID See Ethernet Global Data Groups in chapter 13 for more information Consumer If the Consumer Type above is IP Address this is the IP address of a single device to Address receive the exchange If the Consumer Type is Group ID this is the group s ID number 1 32 See chapter 13 for more information about IP Addresses Send Type Currently fixed at always Ethernet Global Data will always be sent when the PLC s I O scan is enabled It will not be sent when the 1 0 scan is disabled Producer The scheduled repetition period for sending the data on the network The range is 10 Period 3 600 000 milliseconds 10 milliseconds to 1 hour The default is 200 milliseconds Round this value to the nearest 10 milliseconds before you enter it The producer period has a resolution of 10 milliseconds If you enter a value such as 12 milliseconds the actual producer period will be rounded up to 20 milliseconds For easier troubleshooting and efficient n
210. ired for PV to reach 63 of its final value when CV is stepped The PID block will not be able to control a process unless its Sample Period is well under half the total time constant Larger Sample Periods will make it unstable The Sample Period should be no bigger than the total time constant divided by 10 or down to 5 worst case For example if PV seems to reach about 2 3 of its final value in 2 seconds the Sample Period should be less than 0 2 seconds or 0 4 seconds worst case On the other hand the Sample Period should not be too small such as less than the total time constant divided by 1000 or the Ki Error dt term for the PID integrator will round down to 0 For example a very slow process that takes 10 hours or 36000 seconds to reach the 63 level should have a Sample Period of 40 seconds or longer Unless the process is very fast it is not usually necessary to use a Sample Period of 0 to solve the PID algorithm every PID sweep If many PID loops are used with a Sample Period greater than the sweep time there may be wide variations in PLC sweep time if many loops end up solving the algorithm at the same time The simple solution is to sequence a one or more bits through an array of bits set to O that is being used to enable power flow to individual PID blocks GFK 1503C Chapter 14 The PID Function 14 13 Determining the Process Characteristics The PID loop gains Kp Ki and Kd are determined by the characteristics of the
211. is minimum maximum er dale Ipe oie t DINT for double precision signed integer operations rly ok flow none The OK output is energized when the function is performed without overflow unless an invalid operation occurs Q All data types R Al Output Q contains the square root of IN AQ INT data type only Q rly Example In the example the square root of the integer number located at AIO01 is placed into the result located at RO003 whenever I0001 is ON l0001 SQROOT INT AI001 IN Q F RO0003 GFK 1503C Chapter 10 Instruction Set Reference 10 53 Math and Numerical Functions Trigonometric Functions There are six Trigonometric functions Sine Cosine Tangent Inverse Sine Inverse Cosine and Inverse Tangent Sine Cosine and Tangent When a Sine Cosine or Tangent function receives power flow it operates on IN whose units are radians and stores the result in output Q Both IN and Q are floatingpoint values Enable 7 SIN_ OK REAL Input IN Q Output The Sine Cosine and Tangent functions accept a broad range of input values where 263 lt IN lt 263 263 9 22x1018 Inverse Sine Cosine and Tangent When an Inverse Sine Cosine or Tangent function receives power flow it operates on IN and stores the result in output Q whose units are radians Both IN and Q are floatingpoint values The Inverse Sine and Cosine functions accept
212. is possible to clear logic configuration and references from the programmer with the CPU at any privilege level even with the OEM key locked Operators can clear logic configuration and references and store a new application program to the CPU without knowing passwords If passwords and or the OEM key have been set and written to flash a read from flash updates the protection level In this case it is not necessary to reenter the password to gain access to a particular level A Clear All does not clear user flash Chapter 7 CPU Operation 7 11 Chapter S GFK 1503C Elements of an Application Program This chapter provides basic information about the application program for a VersaMax PLC Structure of an application program Subroutines Program languages The Instruction Set 8 1 Structure of an Application Program The application program consists of all the logic needed to control the operations of the PLC CPU and the modules in the system Application programs are created using the programming software and transferred to the PLC Programs are stored in the CPU s non volatile memory During the CPU Sweep described in the previous chapter the CPU reads input data from the modules in the system and stores the data in its configured input memory locations The CPU then executes the entire application program once utilizing this fresh input data Executing the application program creates new output data that is pla
213. isabled or in Local Station Manager mode Smart module firmware PLC in Stop No I O mode Portl PLC must be in Stop No IO mode upgrade configured for CPU protocol EZ Program Store device No Read Write Verify and Update PLC must be in Stop No IO mode GFK 1503C Chapter 3 CPU Module Datasheet CPUEO5 3 5 CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory IC200CPUE05 Cable Lengths Maximum cable lengths the total number of feet from the CPU to the last device attached to the cable are Port 1 RS 232 15 meters 50 ft Port 2 RS 485 1200 meters 4000 ft Serial Port Baud Rates Port 1 Port 2 RTU protocol 1200 2400 4800 9600 19 2K 1200 2400 4800 9600 19 2K 38 4 K 57 6 K 38 4 K 57 6 K Serial I O protocol 4800 9600 19 2K 38 4K 57 6K 4800 9600 19 2K 38 4K 57 6K SNP protocol 4800 9600 19 2K 38 4K 4800 9600 19 2K 38 4K Local Station Manager 1200 2400 4800 9600 19 2K na this is independent of 38 4K 57 6K 115 2K serial protocol baud rate Firmware Upgrade via 2400 4800 9600 19 2K 38 4K na Winloader 57 6K 115 2K Only available on one port at a time The VersaPro software allows configuration of RTU and Serial I O at 115 2K baud However these baud rates are not supported by the CPU If a configuration using these baud rates is stored to the PLC 1 For RTU an Unsupported Feature in Configuratio
214. iscrete Input 20 P oints 43 ntelligent Discrete Output 12 P oints Analog Input 4 Channels 17 Analog Input 8 Channels 27 96 38 79 93 Xk Xk PLC Network Comm Profibus DP Slave DeviceNet Network Master S lave Analog Output 2 Channels 1 1 6 3 5 8 4 4 4 O Oo Es a 8 a Em Em Analog Input 15 Channels f 896 aa rae oe E Za Oom 493 sees CPU001 CPU002 Mixed modules have both and input and output scan time values Network Communications Modules NCM Scan Impact Times vary depending upon the network configuration VersaMax PLC User s Manual March 2001 GFK 1503C Modules Located in Multiple Remote Expansion Rack The table below shows timing for modules located in the expansion racks of a multiple rack expansion system that uses only Isolated Expansion Receiver Modules IC200ERMO001 In this type of system there is an Expansion Transmitter module IC200ETMO001 in the CPU rack CPU005 CPUE05 CPU001 CPU002 Module Type Multiple Remote Rack Multiple Remote Rack Discrete Output Type 1 Discrete Output Type 2 Discrete Output w ESCP Per Point Fault Reporting ntelligent Discrete Input 20 P oints ntelligent Discrete Output 12 P oints ee Analog Input 4 Channels Analog Input 8 Channels Analog Input 15 Channels PLC Network Comm Profibus DP Slave DeviceNet Network Master S lave Mixed modules have both and input and output scan time values Analo
215. ission of the specified number of characters is complete or a time out has elapsed The status returned by the function indicates the event or events that have completed More than one condition can occur simultaneously if both a read and a write were initiated previously Example Command Block for the Read Port Status Function decimal hexadecimal address address 1 address 2 Status word memory type R address 3 Status word address minus 1 R0001 address address 5 address 6 4303 10CF Read port status command address 7 adress 8 Chapter 12 Serial I O SNP RTU Protocols 12 17 12 18 Port Status The port status consists of a status word and the number of characters in the input buffer that have not been retrieved by the application characters which have been received and are available word 1 Port status word see below word 2 Characters available in the input buffer The Port Status Word can be Bit Name Definition Meaning i O 15 Read In progress Se Read Bytes or Read String invoked Cleared Previous Read bytes or String has timed out been canceled or finished 14 RS Read Success Se Read Bytes or Read String has successfully completed New Read Bytes or Read String invoked 1 RT Read Time out Se Receive timeout occurred during Read Bytes or Read String New Read Bytes or Read String invoked ite In progress New Write Bytes invoked Cleared Previously invoked Write By
216. isted pair cables must meet the applicable IEEE 802 standards Network Connection Connection of the CPUEOS to a 10BaseT network is shown below CPUE05 10BaseT Hub cone A f Twisted Pair Cable To Other Network Devices The cable between each node and a hub or repeater can be up to 100 meters in length Typical hubs or repeaters support 4 to 12 nodes connected in a star wiring topology Host Computer or Control Device VersaMax PLC with VersaMax PLC with Running a Host Communications CPUE05 CPUE05 Toolkit Application ll Series 90 70 PLC with Programmer Software Ethernet Interface running on a PC Series 90 30 PLC with Ethernet Interface Ethernet Cable 4 18 VersaMax PLC User s Manual March 2001 GFK 1503C CE Mark Installation Requirements GFK 1503C The following requirements for surge electrostatic discharge ESD and fast transient burst FTB protection must be met for applications that require CE Mark listing m The VersaMax PLC is considered to be open equipment and should therefore be installed in an enclosure IP54 m This equipment is intended for use in typical ind
217. iving the transmit request Default Idle Time in seconds the CPU waits to receive the next Time message from the programming device before it assumes that the programming device has failed and proceeds to its base state Communication with the programmer is terminated and will have to be reestablished he Timer Enables or disables viewing of SFC Timer faults Disabled eee Faults abled SCR Switch Determines whether the switch will control Run Stop mode Enabled Enabled Run Stop operation Disabled Switch Memory Determines whether the switch will control RAM memory Disabled Enabled Protect protection Disabled Diagnostics Unless your application requires unusually fast power up Enabled Enabled leave this setting ENABLED The DISABLED setting Disabled causes the PLC to power up without running diagnostics Fatal Fault Determines whether fatal faults will normally be Disabled Enabled Override overridden Disabled EZ Program Specifies where data that is read from the EZ Program RAM only RAM only Store Store device will be loaded RAM amp Flash 5 6 VersaMax PLC User s Manual March 2001 GFK 1503C Configuring CPU Memory Allocation CPUO001 and CPU002 release 2 0 or later CPU005 and CPUE0S5 have configurable user memory The configurable memory is equal to the sum of the application program hardware configuration registers R analog inputs AD and analog outputs AQ The amount of memory all
218. k Example 2 More than one sample can be produced per producer period expiration and stale samples are produced to the network Producer Period 2 3 Time of CPU Sweep Producer PLC Output Scan a E E ee Ee eS Ethernet Global Data Production Timer Expires Sample on Network Stale Data is Produced tae ea GFK 1503C Chapter 13 Ethernet Communications 13 13 Diagnostic Tools There are several tools to assist you in diagnosing problems that may occur with Ethernet operations and Ethernet Global Data Check the Ethernet LEDs as detailed on the following pages to troubleshoot a problem on power up of the Ethernet Interface The LEDs provide an immediate visual summary of the operating state of the Interface Use the PLC Fault Table also explained in this chapter The PLC Fault Table records exceptions logged by the PLC the Ethernet interface and other modules The PLC Fault Table is accessed through the PLC programming software The application program can use special status data to monitor Ethernet operations O The Ethernet interface status address selected during PLC configuration contains information about the operating status of the Ethernet interface O The Exchange Status words selected during Ethernet Global Data configuration contain information about the status of exchange operations Use the Station Manager function to troubleshoot a problem with the Ethernet Int
219. l GFK 1503C Values Meaning Address 10H Data Block Length Address 1 0 No Wait WAIT NOWAIT Flag Address 2 0008 R register memory Status Word Pointer Memory Type Address 3 Zero based number that gives the address Status Word Pointer Offset of the COMMREQ status word for example a value of 99 gives an address of 100 for the status word Address 4 0 Only used in Wait No Wait mode Idle Timeout Value Address 5 0 Only used in Wait No Wait mode Maximum Communication Time Address 6 FFFOH Command Word serial port setup Address 7 0001 Protocol 1 SNP Address 8 0000 Slave Port Mode Address 9 7 38400 6 19200 5 9600 4 4800 Data Rate Address 10 0 None 1 Odd 2 Even Parity Address 11 1 None Flow Control Address 12 0 None 1 10ms 2 100ms 3 500ms Turnaround Delay Address 13 0 Long 1 Medium 2 Short 3 None Timeout Address 14 1 8 bits Bits Per Character Address 15 0 1 Stop Bit 1 2 Stop bits Stop Bits Address 16 not used nterface Address 17 not used Duplex Mode Address 18 user provided Device identifier bytes 1 and 2 Address 19 user provided Device identifier bytes 3 and 4 Address 20 user provided Device identifier bytes 5 and 6 Address 21 user provided Device identifier bytes 7 and 8 The device identifier for SNP Slave ports is packed into words with the least significant
220. length of 1 to 256 words can be selected Enable BIT TEST WORD Bit to be tested IN Q F Output Bit number of IN B T Parameters of the Bit Test Function Input Choices Description Output enable flow When the function is enabled the bit test is performed IN 1 Q M T S G R Al AQ IN contains the first word of the data to be operated on BIT Q M T G R Al AQ BIT contains the bit number of IN that should be tested constant Valid range is 1 lt BIT lt 16 length Q flow none Output Q is energized if the bit tested was a 1 Example In the example whenever input I0001 is set the bit at the location contained in reference PICKBIT is tested The bit is part of string PRD_CDE If it is 1 output Q passes power flow and the coil QO001 is turned on 10001 e T TEST WORD Q0001 PRD_CDE IN Q PICKBIT 4 BIT GFK 1503C Chapter 10 Instruction Set Reference 10 11 Bit Operation Functions Bit Set and Bit Clear The Bit Set function sets a bit in a bit string to 1 The Bit Clear function sets a bit in a string to 0 Each sweep that power is received the function sets the specified bit If a variable register rather than a constant is used to specify the bit number the same function block can set different bits on successive sweeps A string length of 1 to 256 words can be selected The function passes power flow to the right unless the
221. ll not execute more often than once every 10 milliseconds If it is set up to execute every sweep and the sweep is under 10 milliseconds the PID function will not run until enough sweeps have occurred to accumulate an elapsed time of 10 milliseconds For example if the sweep time is 9 milliseconds the PID function executes every other sweep so the overall elapsed time between executions is 18 milliseconds A specific PID function should not be called more than once per sweep The longest possible interval between executions is 10 9 minutes The PID function compensates for the actual time elapsed since the last execution within 100 microseconds The PID algorithm is solved only if the current PLC elapsed time clock is at or later than the last PID solution time plus the sample period If the sample period is set to 0 the function executes each time it is enabled however it is restricted to a minimum of 10 milliseconds as noted above Scaling Input and Outputs All parameters of the PID function are 16 bit integer words for compatibility with 16 bit analog process variables Some parameters must be defined in either process variable counts or units or control variable counts or units The set point input must be scaled over the same range as process variable because the PID function calculates error by subtracting these two inputs The process variable and control variable counts do not have to use the same scaling Either may be 32
222. lock Q M T G R SYSID contains the rack number most significant byte and slot Al AQ number least significant byte of the target device For the CPU constant SYSID must specify rack slot 0 R Al AQ TASK specifies the port for which the operation is intended constant task 19 for port 1 task 20 for port 2 flow none FT is energized if an error is detected processing the COMMREQ e The specified target address is not present SYSID e The specified task is not valid for the device TASK e The data length is 0 e The device s status pointer address in the command block does not exist 12 2 VersaMax PLC User s Manual March 2001 GFK 1503C Command Block for the COMMREQ Function The Command Block starts at the reference specified in COMMREQ parameter IN The length of the Command Block depends on the amount of data sent to the device The Command Block contains the data to be communicated to the other device plus information related to the execution of the COMMREQ The Command Block has the following structure address Length in words address 1 Wait No Wait Flag address 2 Status Pointer Memory address 3 Status Pointer Offset address 4 Idle Timeout Value address 5 Maximum Communication Time address 6 to Data Block address 133 Example of the COMMREQ Function In the example when MO0021 is ON a Command Block located starting at R0032 is sent to port 2
223. logic must be used to control the flow of power to a coil Coils cause action directly they do not pass power flow to the right If additional logic in the program should be executed as a result of the coil condition an internal reference for the coil or a continuation coil contact combination may be used Coils are always located at the rightmost position of a line of logic References and Coil Checking When the level of coil checking is set to single you can use a specific M or Q reference with only one Coil but you can use it with one Set Coil and one Reset Coil simultaneously When the level of coil checking is warn multiple or multiple each reference can be used with multiple Coils Set Coils and Reset Coils With multiple usage a reference could be turned On by either a Set Coil or a normal Coil and could be turned Off by a Reset Coil or by a normal Coil Power Flow and Retentiveness The following table summarizes how power flow to different types of coils affects their reference The states of retentive coils are saved when power is cycled or when the PLC goes from Stop to Run mode The states of nonretentive coils are set to zero when power is cycled or the PLC goes from Stop to Run mode Type of Coil Symbol Power to Coil Result Normally Open ON Sets reference ON non retentive OFF Sets reference OFF non reten
224. low it performs the conversion making the result available via output Q The function passes power flow when power is received unless the specified conversion would result in a value that is outside the range 0 to FFFFh Enable REAL OK TO WORD Value to be converted 7 IN Q Output Parameters of the Convert to Word Function Input Choices Description Output enable flow When the function is enabled the conversion is performed IN R Al AQ constant IN contains a reference for the value to be converted to Word type ok flow none OK is energized when the function is performed without error Q Q M T G R Al AQ Contains the word form of the original value in IN Example l0002 REAL RANGE F TO WORD ue Q1001 R0001 IN Q R0003 HILIM L1 Q LOW LIM 7 L2 R0003 7 IN 10 46 VersaMax PLC User s Manual March 2001 GFK 1503C Data Type Conversion Functions Truncate Real Number The Truncate function copies a Real number and rounds the copied number down to an integer or double precision integer The original data is not changed by this function When the function receives power flow it performs the conversion making the result available via output Q The function passes power flow when power is received unless the specified conversion would result in a value that is out of range or unless IN is not a number Enable
225. lso be configured to prevent writing to program or configuration memory and forcing or overriding discrete data It defaults to enabled Run Stop mode selection and disabled memory protection Configurable Run Stop Mode Operation If Run Stop mode switch operation is enabled the switch can be used to place the CPU in Run mode m Ifthe CPU has non fatal faults and is not in Stop Fault mode placing the switch in Run position causes the CPU to go to Run mode Faults are NOT cleared m If the CPU has fatal faults and is in Stop Fault mode placing the switch in Run position causes the Run LED to blink for 5 seconds While the Run LED is blinking the CPU switch can be used to clear the fault table and put the CPU in Run mode After the switch has been in Run position for at least 1 2 second move it to Stop position for at least 2 second Then move it back to Run position The faults are cleared and the CPU goes to Run mode The LED stops blinking and stays on This can be repeated if necessary m Ifthe switch is not toggled as described after 5 seconds the Run LED goes off and the CPU remains in Stop Fault mode Faults stay in the fault table Configurable Memory Protection Operation of the switch can be configured to prevent writing to program memory and configuration and to prevent forcing or overriding discrete data Summary of CPU Switch Run Stop Operation Run Stop Mode 1 0 Scan Stop Switch Posi
226. lt Table If this LED is blinking and the OK LED is OFF a fatal fault was detected during PLC powerup diagnostics Contact PLC Field Service FORCE ON if an override is active ona bit reference PORT1 Blinking indicates activity on that port when controlled by the CPU PORT 2 3 8 VersaMax PLC User s Manual March 2001 GFK 1503C CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory IC200CPUE05 Ethernet Restart Pushbutton The Ethernet Restart pushbutton is located on the right side of the module IP Address IP ADDRESS Writable Area ETHERNET RESTART Pushbutton o pm Ethernet Restart O Ethernet ETHERNET un O _ LEDs 10 BASET port O The Ethernet Restart pushbutton has two functions When pressed for less than 5 seconds it resets the Ethernet hardware tests the Ethernet LEDs and restarts the Ethernet firmware This disrupts any Ethernet communications that are presently underway When pressed for at least 5 seconds it toggles the function of Port 1 between its configured operation and forced local Station Manager operation Note that if Port 1 is available for Local Station Manager operation Winloader cannot be used for a firmware upgrade Ethernet LEDs The three Ethernet LEDs indicate the status and activity of the Ethernet inter
227. lt and No Fault Contacts Alarm Contacts Table Functions Array Move Search Data Type Conversion Functions Convert to BCD 4 Convert to Signed Integer Convert to Double Precision Signed Integer Convert to Real Convert Real to Word Truncate Real Number PID see chapter 14 Timer and Counter Functions Time tick Contacts On Delay Stopwatch Timer On Delay Timer Off Delay Timer Up Counter Down Counter 10 1 Bit Operation Functions The Bit Operation functions perform comparison logical and move operations on bit strings The Bit Operation functions are Logical AND BitTest Logical OR BitSet Bit Clear Exclusive OR Masked Compare Logical Invert NOT Bit Position Shift Right S hift Left BitSequencer Rotate Right R otate Left Data Lengths for the Bit Operation Functions The Logical AND OR XOR and NOT Invert functions operate on a single word of data The other Bit Operation functions may operate on up to 256 words All Bit Operation functions require Word type data However they operate on data as a continuous string of bits with bit 1 of the first word being the Least Significant Bit LSB The last bit of the last word is the Most Significant Bit MSB For example if you specified three words of data beginning at reference RO100 it would be operated on as 48 contiguous bits RO0100 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 e bit 1
228. lue scale Scaling Scales an input constant or word value sqroot Square Root Finds the square root of an integer or real value Log Base 10 Logarithm Finds the base 10 logarithm of a real value In Natural Logarithm Finds the natural logarithm base of a real number exp Raises the natural logarithm base to the power specified by input 8 8 VersaMax PLC User s Manual March 2001 GFK 1503C Relational Functions Equal Tests for equality between two numbers ts for nonequality between two numbers gt Greater Than Tests whether one number is greater than another Passes power if the number is greater than the second ge Greater Than or Equal Tests whether one number is greater than or equal to another To Less Than Tests whether one number is less than another Less Than or Equal To Test whether one number is greater than or equal to another Test the input value against a range of two numbers Bit Operation Functions and Logical AND Performs Logical AND of two bit strings or Performs Logical OR of two bit strings xor performs Logical Exclusive OR of two bit strings not Logical Invert Performs a logical inversion of a bit string shl Shifts a bit string left shr shittright e Shifts a bit string right rol Rotates a bit string left ror Rotate Right Rotates a bit string right bittst Testa bit within a bit string bitset itset Sets one bit within a string to tru
229. lure to configure any ignored bytes in the consumed exchange will result in exchange exception log and fault table entries error status in the exchange status data and no data being transferred for the exchange VersaMax PLC User s Manual March 2001 GFK 1503C a Configuring Advanced User Parameters Advanced User Parameters are internal operating parameters used by the Ethernet interface For most applications the default Advanced User Parameters should not be changed If it is necessary to modify any of these parameters it must be done by creating an Advanced User Parameter file using any ASCII text editor This file must contain the names and values of only those parameters that are being changed The file must be named AUP_0_0 apf The completed file must be placed into the PLC folder that contains the PLC configuration When the entire hardware configuration is stored from the programmer to the PLC the programmer software also stores the parameters from the AUP_0_0 apf file Format of the Advanced User Parameters File GFK 1503C The Advanced User Parameters file must have this format AUP_0_0 lt parameter name gt lt parameter value gt lt parameter name gt lt parameter value gt lt parameter name gt lt parameter value gt All parameter names are lowercase The equal sign is required between the parameter name and parameter value Parameter values are converted to lowercase unless they are e
230. m REAL Converts a Real value to Word format Convert to INT From BCD4 Converts a number to signed integer format or REAL tdint Convert to DINT Converts a number to double precision integer format From BCD4 or REAL word int real Convert to Real Converts a value to real value format From INT DINT BCD4 or WORD int Truncate to INT from REAL Truncates to a 16bit signed number The range is 32 768 to 32 767 dint Truncate to Double Precision Truncates to a 32bit signed number The range is 2 147 483 648 to INT from REAL 2 147 483 647 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C bit output pattem from an array of stored patterns and sending it to a Chapter 8 Elements of an Application Program Control Functions call Causes a program execution to go to a specified subroutine block do io Do I O Services a specified range of inputs or outputs immediately all inputs or outputs on a module will be serviced if any addresses on that module are included in the function partial I O module updates are not performed pidind Independent PID Selects the noninteracting independent PID algorithm Algorithm pidisa ISA PID Algorithm Selects the ISA PID algorithm end Temporary End of Logic The program executes from the first rung to the last rung or the END instruction whichever is encountered first This instruction is useful for debugging purposes
231. mer to the PLC CPU Use the programming software to read write or verify the data When performing an update with the programmer present the pushbutton on the EZ Program Store device is not used 15 6 VersaMax PLC User s Manual March 2001 GFK 1503C IC200ACC003 EZ Program Store Device Update a PLC CPU without a Programmer Present With a program configuration tables Ethernet Global Data and Advanced User Parameters if any already stored in an EZ Program Store device it can be used to update one or more other PLC CPUs of the same type All the data stored in the EZ Program Store device will be updated in the PLC CPU To update all of the data in a VersaMax PLC CPU follow these steps 1 Plug the EZ Program Store device into port 2 of the VersaMax PLC CPU 9000000 EZ Program Store Device If the PLC is in Run mode when the EZ Program Store device is connected the Run LED on the PLC blinks at a 1 Hz rate This blinking indicates that the Run Stop switch is enabled regardless of the configuration of the switch Run LED i 2LED GFK 1503C Chapter 15 The EZ Program Store Device 15 7 EZ Program Store Device IC200ACC003 2 Ifthe PLC s Run LED is blinking and the LED on the device is green stop the PLC by moving the Run Stop switch from Run On to Stop Off position RUN ON u STOP OFF If the switch is already on the Sto
232. mit driver If the transmit driver is not enabled asserting RTS with the Write Port Control COMMREQ will not cause RTS to be asserted on the serial line The state of the transmit driver is controlled by the protocol and is dependent on the current Duplex Mode of the port For 2 wire and 4 wire Duplex Mode the transmit driver is only enabled during transmitting Therefore RTS on the serial line will only be seen active on port 2 configured for 2 wire or 4 wire Duplex Mode when data is being transmitted For point to point Duplex Mode the transmit driver is always enabled Therefore in point to point Duplex Mode RTS on the serial line will always reflect what is chosen with the Write Port Control COMMREQ Chapter 12 Serial I O SNP RTU Protocols 12 19 Cancel Commreq Function 4399 This function cancels the current operations in progress It can be used to cancel both read operations and write operations If a read operation is in progress and there are unprocessed characters in the input buffer those characters are left in the input buffer and available for future reads The serial port is not reset Example Command Block for the Cancel Operation Function VALUE VALUE MEANING decimal hexadecimal address Data block length 2 address 1 address 2 Status word memory type R address 3 Status word address minus 1 R0001 address address 5 address 6 address 7 0001 Transaction type to cancel 1 All operations 2 Re
233. n fault is logged and the PLC transitions to Stop Faulted mode 2 For Serial I O the same fault is logged when the transition to Run mode occurs The PLC will immediately transition to Stop Faulted mode 3 6 VersaMax PLC User s Manual March 2001 GFK 1503C CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory IC200CPUE05 Ethernet LAN Port The Ethernet LAN port supports SRTP Server and Ethernet Global Data This port connects directly to a 10BaseT twisted pair network without an external transceiver The 10BaseT twisted pair cables must meet applicable IEEE 802 standards CPUEOS5 automatically selects either half duplex of full duplex operation as sensed from the network connection A space is provided on the front of the CPUEO5 module where the configured IP Address can be written IP Address IP ADDRESS Writable Area M Ethernet RESTART LAN Port anit ETHERNET Lan 10 BASE T star roti O RJ 45 GFK 1503C Chapter 3 CPU Module Datasheet CPUE05 3 7 IC200CPUE05 CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory Mode Switch The Mode switch is located behind the module door It can be used to place the PLC in Stop or Run mode It can also be used to block accidental writing to CPU memory and forcing or overriding discrete data Us
234. n Functions explains how to convert data to a different type 10 48 VersaMax PLC User s Manual March 2001 GFK 1503C Math and Numerical Functions Add Subtract Multiply Divide The standard math functions are Addition Subtraction Multiplication and Division The Division function rounds down it does not round to the closest integer For example 24 DIV 5 4 When a math function receives power flow the operation is performed on input parameters I1 and I2 Parameters I1 I2 and output Q must be the same data type Enable ADD_ OK INT Input 1 1 Q Output Input 2 7 12 The math functions pass power if there is no math overflow If an overflow occurs the result is the largest value with the proper sign and no power flow Parameters of the Standard Math Functions Input Choices Description Output enable flow When the function is enabled the operation is performed 1 All data types R Al 11 contains a constant or reference for the first value used in the AQ constant operation 11 is on the left side of the mathematical expression as in INT data type only 1 Q 12 ET Range for constants in doubleprecision signed integer operations is minimum maximum DINT 12 All data types R Al 12 contains a constant or reference for the second value used in the AQ constant operation 12 is on the right side of the mathematical expression as in INT data type only
235. n characteristics of module operation and also establishes the program references used by each module in the system Ethernet Configuration for CPU model IC200CPUE0S is described in chapter 6 CPU Operation is described in chapter 7 Serial Communications are described in chapter 12 Ethernet Communications for CPU model IC200CPUEO0S5 is described in chapter 13 The rest of the manual describes many programming features Elements of an Application Program chapter 8 Program Data chapter 9 Instruction Set Reference chapter 10 The Service Request Function chapter 11 The PID Function chapter 14 Instruction Timing appendix A GFK 1503C 1 1 Other VersaMax Manuals VersaMax Modules Power Supplies Describes the many VersaMax I O and option and Carriers User s Manual catalog modules power supplies and carriers This number GFK 1504 manual also provides detailed system installation instructions VersaMax PLC Ethernet Station Describes the diagnostic interface to the Manager s Manual catalog number Ethernet functions of CPU module GFK 1876 IC200CPUE05 VersaMax Ethernet Network Interface Describes the installation and operation of the Unit User s Manual catalog number Ethernet Network Interface Unit module GFK 1860 VersaMax Genius NIU User s Manual Describes the installation and operation of the catalog number GFK 1535 Genius NIU VersaMax DeviceNet Describes the installation and operatio
236. n in a ladder diagram application program Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Table Array Move INT 110 12 90 10 5 50 22 DINT 100 12 80 10 2 76 22 BIT 129 12 92 10 1 08 22 BYTE 109 12 80 10 4 15 22 WORD 110 12 90 10 5 50 22 Search Equal INT 90 12 70 10 6 59 19 DINT 90 12 60 10 7 14 22 BYTE 81 12 60 10 2 58 19 WORD 90 12 70 10 6 59 19 Search Not Equal INT 100 12 78 10 6 66 19 DINT 110 12 81 10 7 14 22 BYTE 74 12 57 10 2 56 19 WORD 100 12 78 10 6 66 19 Search Greater Than INT 100 12 80 10 6 69 19 DINT 94 12 70 10 7 12 22 BYTE 90 12 69 10 2 58 19 WORD 100 12 76 10 6 69 19 Search Greater Than E qual INT 90 12 70 10 6 79 19 DINT 90 12 60 10 7 15 22 BYTE 81 12 60 10 2 56 19 WORD 90 12 70 10 6 79 19 Search Less Than INT 80 12 60 10 6 59 19 DINT 110 12 80 10 7 13 22 BYTE 73 12 56 10 2 58 19 WORD 80 12 60 10 6 66 19 Search Less Than E qual INT 80 12 60 10 6 66 19 DINT 90 12 60 10 7 13 22 BYTE 72 12 54 10 2 59 19 WORD 80 12 60 10 6 66 19 VersaMax PLC User s Manual March 2001 GFK 1503C Sizes of Conversion and Control Functions The size of a function is the number of bytes consumed in user logic space for each instance of the function in a ladder diagram application program
237. n of a Double Precision Integer 32 bit word The upper 16 bits or second word should be either a 0 positive or 1 negative value or the Double Precision Integer number will be too big to convert to 16 bits Example This example uses the Addition and Subtraction functions to keep track of the number of parts in a temporary storage area Each time a part enters the storage area power flows through relay 10004 to a positive transition coil with reference MO0001 Relay MO0001 then enables the Addition function adding the constant value 1 to the current total value in RO201 Each time a part leaves the storage area power flows through relay I0005 to a positive transition coil with reference MO0002 Relay M0002 then enables the Subtraction function subtracting the constant value from the current total value in RO201 I0004 MOQO1 f G 0005 mt 02 ee ADD_ INT R0201 11 Q R0201 CONST jo 00001 MO002 5 Sta INT R02017 11 QF RO0201 CONST 7 12 00001 VersaMax PLC User s Manual March 2001 GFK 1503C Math and Numerical Functions Modulo Division The Modulo Division function divides one value by another of the same data type to obtain the remainder The sign of the result is always the same as the sign of input parameter I1 The Modulo function operates on these types of data INT Signed integer DINT Double precision signed integer When the fu
238. n of the Communications Modules User s DeviceNet Network Interface Unit module and Manual catalog number GFK 1533 the DeviceNet Network Slave Module VersaMax Profibus Communications Describes the installation and operation of the Modules User s Manual catalog Profibus Network Interface Unit module and the number GFK 1534 Profibus Network Communications Module 1 2 VersaMax PLC User s Manual March 2001 GFK 1503C The VersaMax Family of Products The VersaMax family of products provides universally distributed I O that spans PLC and PC based architectures Designed for industrial and commercial automation VersaMax I O provides a common flexible I O structure for local and remote control applications The VersaMax PLC provides big PLC power with a full range of I O and option modules VersaMax I O Stations with Network Interface Modules make it possible to add the flexibility of VersaMax I O to other types of networks VersaMax meets UL CUL CE Class Zone 2 and Class I Division 2 requirements As a scaleable automation solution VersaMax I O combines compactness and modularity for greater ease of use The 70 mm depth and small footprint of VersaMax I O enables easy convenient mounting as well as space saving benefits Modules can accommodate up to 32 points of I O each The compact modular VersaMax products feature DIN rail mounting with up to eight I O and option modules per rack and up to 8 racks per VersaMax PLC
239. n the Jump and the Label are not executed and coils are not affected In the example when 10002 is ON the Jump is taken Since the logic between the Jump and the Label is skipped QO001 is unaffected if it was ON it remains ON if it was OFF it remains OFF 10001 gt gt TEST1 10001 Q0Q01 R00017 11 QF R0001 1 412 gt gt TEST1 Chapter 10 Instruction Set Reference 10 27 Control Functions Comment The Comment function is used to enter a comment rung explanation in the program A comment can have up to 2048 characters of text Longer text can be included in printouts using an annotation text file It is represented in the ladder logic like this COMMENT 10 28 VersaMax PLC User s Manual March 2001 GFK 1503C Control Functions Drum Sequencer GFK 1503C The Drum Sequencer function is a program instruction that operates like a mechanical drum sequencer The Drum Sequencer steps through a set of potential output bit patterns and selects one based on inputs to the function block The selected value is copied to a group of 16 discrete output references Enable 7 DRUM OK Step 7 Pern Out Reset Drum Coil Pattern 7 Dwell Timeout Dwell Time Timeout Fault Fault Timeout 7 m First Follower Power flow to the Enable input causes the Drum Sequencer to copy the content of a selected reference to the Out reference Pow
240. nal nested call levels Chapter 8 Elements of an Application Program 8 3 8 4 Declaring a Subroutine A subroutine must be declared through the block declaration editor of the programming software Calling a Subroutine A subroutine invoked in the program is using a CALL instruction Up to 64 subroutine block declarations and 64 CALL instructions are allowed for each block in the program 10004 wey 210006 CALL subroutine 10003 71001 0 Q0010 VersaMax PLC User s Manual March 2001 GFK 1503C Program Languages GFK 1503C Programs can be created in Ladder Diagram or Instruction List format The main program or subroutines within the program can also be created in Sequential Function Chart format The PLC programming software can be used to create both types of logic Sequential Function Chart Sequential Function Chart SFC is a graphic method of representing the functions of a sequential automated system as a sequence of steps and transitions Each step represents commands or actions that are either active or inactive The flow of control passes from one step to the next through a conditional transition that is either true 1 or false 0 If the transition condition is true 1 control passes from the current step which becomes inactive to the next step which then becomes active The logic associated with a step is executed when the step is active This logic is programmed in L
241. nally terminates program execution There can be nothing after the end function in the rung No logic beyond the End of Logic function is executed and control is transferred to the beginning of the program for the next sweep The End of Logic function is useful for debugging purposes because it prevents any logic which follows from being executed The programming software provides an END OF PROGRAM LOGIC marker to indicate the end of program execution This marker is used if no End of Logic function is programmed in the logic END Example In the example an End of Logic function is programmed to terminate the end of the current sweep STOP END GFK 1503C Chapter 10 Instruction Set Reference 10 23 Control Functions Master Control Relay MCR End MCR All rungs between an active Master Control Relay MCRN and its corresponding End Master Control Relay ENDMCRN function are executed without power flow to coils The ENDMCRN associated with the Master Control Relay is used to resume normal program execution Unlike Jump functions Master Control Relays can only move forward the ENDMCRN must appear after its corresponding Master Control Relay instruction in a program Nested MCR A Nested Master Control Relay function can be nested completely within another MCRN ENDMCRN pair There can be multiple Master Control Relay functions with a single ENDMCRN The Master Control Relay function has an enable input and a
242. name This name is used again with the ENDMCRN The Master Control Relay has no outputs there can be nothing after it in a rung name enable 47 MCR With a Master Control Relay function blocks within the scope of the Master Control Relay are executed without power flow and coils are turned off The ENDMCRN function must be tied to power rail there can be no logic before it in the rung The name of the ENDMCRN associates it with the corresponding Master Control Relay s The ENDMCRN function has no outputs there can be nothing after it in a rung name ENDMCRN 10 24 VersaMax PLC User s Manual March 2001 GFK 1503C Control Functions Master Control Relay MCR End MCR GFK 1503C Example Master Control Relay and ENDMCRN Functions In the example when I0002 is ON the Master Control Relay is enabled When the Master Control Relay is enabled even if I0001 is ON the Addition function block is executed without power flow i e it does not add 1 to RO001 and QO0001 is turned OFF If 10003 and 10004 are ON Q0003 is turned OFF and Q0004 remains ON Chapter 10 Instruction Set Reference 10002 ne MCRN 10001 Q0001 ADD_ C INT R00017 11 QF R0001 1712 10003 Q0003 gt 10004 Q0004 s FIRST ENDMCRN 10 25 Control Functions Jump Label The Nested Jump instruction causes a portion
243. nclosed in a pair of double quotes The format for the individual parameter values depends on the parameter Numeric parameters are entered in decimal or hexadecimal format hexadecimal values must end with an h or H character IP address parameters must be entered in standard dotted decimal format Character string values are case sensitive Uppercase parameter values must be enclosed within a pair of double quotes The enclosing quotes are not part of the data and are removed during processing Comments in the file must start with a semicolon character All characters in the same line following a semicolon are ignored Blank lines are also ignored The following example sets the station manager password to system and the IP time to live for point to point Ethernet Global Data exchanges to 4 Example Advanced User Parameter File AUP_0_0 stpasswd system set the password to system gucast_ttl 4 set the EGD unicast IP TTL to 4 Chapter 6 Ethernet Configuration 6 9 sl Advanced User Parameter Definitions The following Advanced User Parameters can be configured for the CPUE05 Ethernet interface Name Description Default Range staudp Remote Station Manager UDP port 18245 4745H 0 65535 ffffH stpasswd Station Manager password system 0 8 char case
244. nction receives power flow it divides input I1 by input I2 These parameters must be the same data type Output Q is calculated using the formula Q 11 11 DIV 12 12 The division produces an integer Q is the same data type as inputs I1 and I2 OK is always ON when the function receives power flow unless there is an attempt to divide by zero In that case it is set OFF Enable MOD F OK INT Input 1 11 QPF Output Input 2 7 12 Parameters of the Modulo Division Function Input Choices Description Output enable flow When the function is enabled the operation is performed 1 All data types R Al AQ 11 contains a constant or reference for the value to be constant divided by 12 Range for constants in double precision INT data type only Q M T G signed integer operations is minimum maximum DINT 12 All data types R Al AQ 12 contains a constant or reference for the value to be constant divided into 11 Range for constants in double precision INT data type only Q M T G signed integer operations is minimum maximum DINT ok flow none The OK output is energized when the function is performed without overflow Q All data types R Al AQ Output Q contains the result of dividing 11 by 12 to obtain a INT data type only 1 Q M T G remainder Example In the example the remainder of the integer division of BOXES into PALLETS is placed into NT_FULL whenever I0001 is O
245. nd 0 1 second 1 0 second and 1 minute The state of these contacts does not change during the execution of the sweep These contacts provide a pulse having an equal on and off time duration The contacts are referenced as T_10MS 0 01 second T_100MS 0 1 second T_SEC 1 0 second and T_MIN 1 minute The following timing diagram represents the on off time duration of these contacts T XXXXX e a ee E x 2 x 2 SEC SEC These time tick contacts represent specific locations in S memory Chapter 9 Program Data 9 11 Chapter 10 GFK 1503C Instruction Set Reference This section is a reference to the functions in the VersaMax PLC Instruction Set Bit Operation Functions Logical AND Logical OR Exclusive OR Logical Invert NOT Shift Right S hift Left Rotate Right R otate Left Bit Test Bit Set Bit Clear Masked Compare Bit Position Bit Sequencer Math and Numerical Functions Add Subtract Multiply Divide Modulo Division Scaling Square R oot Trigonometric Functions Logarithmic E xponential Functions Convert Radians Degrees Control Functions Do 1 0 Call End Comment Master Control Relay Drum Sequencer Service Request see chapter 11 PID see chapter 14 Relational Functions Equal Not Equal Greater Than Less Than Greater or Equal Less or Equal Range Data Move Functions Move Block Move Block Clear Shift Register Communication Request Relay Functions Contacts Coils Fau
246. nd LABEL are needed because the transition to Stop mode does not occur until the end of the sweep in which the function executes LOS_MD vores T0001 ane SVC_ gt gt END_PRG REQ CONST _ 00013 FNC PARM END_PRG Chapter 11 The Service Request Function 11 19 SVCREO 14 Clear Fault Use SVCREQ 14 to clear either the PLC fault table or the I O fault table The SVCREQ output is set ON unless some number other than 0 or 1 is entered as the requested operation Input Parameter Block for SVCREQ 14 For this function the parameter block has a length of 1 word It is an input parameter block only There is no output parameter block 0 clear PLC fault table 1 clear I O fault table Example of SVCREQ 14 In the example when input 10346 is on and input 10349 is on the PLC fault table is cleared When input 10347 is on and input 10349 is on the I O fault table is cleared When input 10348 is on and input 10349 is on both are cleared The parameter block for the PLC fault table is located at RO500 for the I O fault table the parameter block is located at RO550 Both parameter blocks are set up elsewhere in the program 10349 10346 SVC_ REQ 9 CONST _ 10348 00014 FNC R0500 PARM 10349 10347 t SVC_ REQ o CONST _ 10348 00014 FNC R0550 PARM 11 20 VersaMax PLC User s Manual March 2001 GFK 1503C S
247. nd update the configuration application program and reference tables data of a VersaMax PLC The update can include Ethernet Global Data and Advanced User Parameters for Ethernet A programmer and PLC CPU are used to initially write data to the device In addition to writing data to the device the programmer can read data already stored on an EZ Program Store device and compare that data with similar files already present in the programmer Once the data is written to the EZ Program Store device the data can be written to one or more other PLC CPUs of the same type with no programmer needed Side Pushbutton Top Connector j Green IC200ACC003 OK Amber 5 8cm Active PLC 1 7 in EZ PROGRAM STORE H Blink i Error l lt 6 6cm gt lt 1 8cm gt 2 6 in 0 7 in The EZ Program Store device and PLC must both have no OEM key password or the same OEM key password for an update to occur The EZ Program Store device does not perform special processing for other types of passwords The EZ Program Store device plugs directly into port 2 on a VersaMax PLC No cables or connectors are required Power for the device comes from port 2 Because the EZ Program Store device is not used during normal operation it does not need to be screwed down to the PLC The device can be hot inserted and hot removed without disrupting the system Features 2 Megabit Serial Data Flash for non volatile stor
248. nfiguration so the PLC will not overwrite the configuration during subsequent startups However actually clearing a configuration from the programmer does cause a new autoconfiguration to be generated In that case autoconfiguration is enabled until a configuration is stored from the programmer again One of the parameters that can be controlled by the software configuration is whether the CPU reads the configuration and program from Flash at powerup or from RAM If Flash is the configured choice the CPU will read a previously stored configuration from its Flash memory at powerup If RAM is the choice the CPU will read a configuration and application program from its RAM memory at powerup 5 2 VersaMax PLC User s Manual March 2001 GFK 1503C Configuring Racks and Slots GFK 1503C Even though a VersaMax PLC does not have a module rack both autoconfiguration and software configuration use the traditional convention of racks and slots to identify module locations in the system Each logical rack consists of the CPU or an Expansion Receiver module plus up to 8 additional I O and option modules mounted on the same DIN rail Each I O or option module occupies a slot The module next to the CPU or Expansion Receiver module is in slot 1 Booster power supplies do not count as occupying slots Main Rack rack 0 ey cu 0O O 0
249. nfiguration Overview ccescccescecesseeesseecsseecsseeceeecesaeeesaeecsaeeseneeeees 6 2 Configuring the Ethernet Interface cee ceeeeeeeeesneeceneeceneeceseeceseeeesaeecsaeesseeeees 6 3 Configuring Ethernet Global Data 0 cee eeeeeesecesseeceneeeeseceeeeceseeeesneecsaeersneeeees 6 4 Configuring a Global Data Exchange for a Producer sceescesseeeteeeeneereneeeeee 6 5 Configuring a Global Data Exchange for a Consumer eseceeeseeereeeeneeteneeeeee 6 6 Configuring Advanced User Parameters ssssscccsseecsseeeeseeeeseeeesaeecsaeeseneeenes 6 9 CRU Operation icicscccccicseccscissecssesssesesesosascsesssssosesssosesssesssccssesssesasesssaseses 7 1 Parts of the CPU Sweep yistcsics steers E E N ei eined a era 7 2 Standard CPU Sweep Operation eesceeseessseecsseecesseeseeeesaeessaeecsaeesseeesseeeesaes 7 4 iii Contents Chapter 8 Chapter 9 Chapter 10 Chapter 11 Constant Sweep Time Operation eeeeesscesseecsseceneecseecsseecesaeeesseessaeesseeeses 7 5 CPU Stop MGdes oe a e e eana an valde dis Stas ome NENES Aana 7 6 Controlling the Execution of a Program eseesseeseeesreereeeressreseresereseseresererereseres 7 7 Run Stop Mode Switch Operation eesseeeseesesesreeseeertssresereseresreressresereseresereseres 7 8 Pash Met ry cos saci scssishs Scsssued be cbintaccedansdlactechacestovebs suns cuuequterstute sess suneegsouuboeesacenss 7 9 Privilege Levels and Passwo
250. nges due to variations in error Proportional Gain 0 01 CV PV 0 to 327 67 Change in the Control Variable in CV Counts for a 100 PV Kp Count change in the Error term A Kp entered as 450 is Controller gain displayed as 4 50 and results in a Kp Error 100 or Kc in the ISA 450 E rror 100 contribution to the PID Output Kp is generally version the first gain set when adjusting a PID loop VersaMax PLC User s Manual March 2001 GFK 1503C Address 6 Address 7 Address 8 Address 9 Address 10 Address 11 GFK 1503C Derivative Gain Kd 0 01 seconds 0 to 327 67 sec Repeat 1000 0 to 32 767 Sec repeat sec Integral R ate Ki 32000 to 32000 add to integrator CV Bias Output CV Counts Offset output CV Upper and Lower Clamps CV Counts 32000 to 32000 gt R ef 10 Second F ull Travel Minimum Slew Time 0 none to 32000 sec to move 32000 CV Chapter 14 The PID Function Change in the Control Variable in CV Counts if the Error or PV changes 1 PV Count every 10ms Entered as a time with the low bit indicating 10ms For example a Kd entered as 120 is displayed as 1 20 Sec and results in a Kd delta Error delta time or 120 4 3 contribution to the PID Output if Error was changing by 4 PV Counts every 30ms Kd can be used to speed up a slow loop response but is very sensitive to PV input noise Change in the Control Variable in CV Counts if the Error were a constant 1 PV C
251. nize to an NTP time server but it will not synchronize other devices on the network Time synchronization takes multiple message exchanges to reach maximum precision Based on the default configuration of poll times NTP synchronization should occur approximately 2 minutes after a time server has been established Chapter 13 Ethernet Communications 13 9 The Content of an Ethernet Global Data Exchange Each Ethernet Global Data exchange is composed of one or more data ranges transmitted as a sequence of to 1400 bytes of data The content of the data is defined for both the producer and consumers of the data In this example a producer sends an 11 byte exchange consisting of the current contents of RO0100 through ROO104 followed by the current contents of 100257 through 100264 Address Length Type Description R00100 5 WORD Conveyorl in PLC1 100257 1 BYTE Conveyorl limit switch in PLC1 The same exchange can be configured for each consumer to suit the needs of the application The size of the exchange must be consistent on all nodes Data Types for Ethernet Global Data The table below lists memory types that can be configured for produced and or consumed Ethernet Global Data Type Description Producer Consumer R Register memory in word mode P C HAI Analog input memory in word mode P C AQ Analog output memory in word mode P C l Discrete input memory
252. ns CPUE0S also provides a built in Ethernet Interface The RS 232 serial port can be configured for Local Station manager operation to provide access to diagnostic information about the Ethernet interface CPUEOS5 has 64kB of configurable memory In addition CPUEOS is compatible with the EZ Program Store device which can be used to write read update and verify programs configuration and reference tables data without a programmer or programming software A i MAC XXXXXXXXXX i n J L IC200CPUE05 CPU 40K BYTES USER MEM 3 L 3 g g l r o O Solio sella 1 IP ADDRESS r 8 a P 7 i mi i RSD D 39 z a is PORT2 H ETHERNET 5 RESTART T q 7 E E g ae p H D ETHERNET NO g 10MBPS BASET stat T ori O R5485 L VI Features 64kB of configurable memory Programming in Ladder Diagram Sequential Function Chart and Instruction List Compatible with EZ Program Store device
253. o psoovoososoeoocosoe lssaenedsae9000080e Zs 2 1 10 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Available Carriers and Terminal Strips The following types of Carriers terminals and cables are available Terminal Style I O Carriers Barrier S tyle Terminal I O Carrier C200CHS001 Box Style Terminal I O Carrier C200CHS 002 Spring Style Terminal I O Carrier C200CHS 005 Compact Terminal Style I O Carriers Compact Box Style I O Carrier C200CHS022 Compact S pring Style 1 0 Carrier C200CHS025 Connector Style I O Carrier Connector Style 1 0 Carrier C200CHS 003 Interposing Terminals for use with Connector Style Carrier Barrier S tyle Interposing I O Terminals C200CHS011 Box Style Interposing I O Terminals C200CHS012 Thermocouple S tyle Interposing I O Terminals C200CHS014 Spring Style Interposing I O Terminals C200CHS015 Cables for use with Connector Style I O Carriers 2 connectors 0 5m with shield C200CBL305 2 connectors 1 0m with shield 200CBL310 2 connectors 2 0m with shield 200CBL320 1 connector 3 0m with shield C200CBL430 2 connectors 0 5m no shield C200CBL105 2 connectors 1 0m no shield C200CBL110 2 connectors 2 0m no shield C200CBL120 1 connector 3 0m no shield C200CBL230 Auxiliary I O Terminal Strips for use with Terminal style I O Car
254. o entries SC0015 SFT_FLT Set when a software fault occurs Cleared when both fault tables have no entries VersaMax PLC User s Manual March 2001 GFK 1503C How Program Functions Handle Numerical Data Regardless of where data is stored in memory in one of the bit memories or one of the word memories the application program can handle it as different data types Type Name Description Data Format BIT Bit A Bit data type is the smallest unit of memory Ithas two states 1 or 0 The programmer functions use the term BOOL for bit type data BYTE Byte A Byte data type has an 8 bit value The valid range is 0 to 255 0 to FF in hexadecimal WORD A Word data type uses 16 consecutive Word 1 bits of data memory but instead of the c Fr bits in the data location representing a es ca number the bits are independent of 16 1 each other Each bit represents its own binary state 1 or 0 The valid range of word values is 0 to 65 535 FFFF BCD 4 Four Digit Four digit BCD numbers use 16 bit data Word 1 Binary Coded memory locations Each BCD digit uses 4 BCD Digits Decimal four bits and can represent numbers HHH between 0 and 9 BCD coding of the 16 16 13 9 5 1 Bit Positions bits has a value range of 0 to 9999 REAL Floating Point Real numbers use two consecutive 16 bit Word 2 Word 1 memory locations The range of A O T numbers that can be stored in this form
255. ocated to the application program and hardware configuration are automatically determined by the actual program and configuration entered from the programmer The rest of the configurable memory can easily be configured to suit the application For example an application may have a relatively large program that uses only a small amount of registers and analog memory Similarly there might be a small logic program but a larger amount of memory needed for registers and analog inputs and outputs Configurable Memory for CPU Module IC200CPU001 CPU002 CPU005 Configurable memory CPU001 34K bytes maximum CPU002 42K bytes maximum CPU005 64K bytes maximum Application program size not configurable 128 bytes minimum CPU001 for rel 1 50 compatibility 12K bytes CPU002 for rel 1 50 compatibility 20K bytes Registers R 256 bytes 128 words minimum CPU001 002 for rel 1 50 compatibility 4 096 bytes 2048 words Analog Inputs Al 256 bytes 128 words minimum Analog Outputs AQ 256 bytes 128 words minimum Configurable Memory for CPU Module IC200CPUE05 GFK 1503C Configurable memory 64K bytes maximum Application program size not configurable 128 bytes minimum Hardware configuration size not configurable 528 bytes minimum Registers R 256 bytes 128 words minimum Analog Inputs Al 256 bytes 128 words minimum Analog Outputs AQ 256 bytes 128 words minimum If you reconfigure memory allocation from th
256. of the program logic to be bypassed Program execution continues at the Label specified When the Jump is active all coils within its scope are left at their previous states This includes coils associated with timers counters latches and relays The Nested Jump instruction has the form gt gt LABELO1 where LABELO1 is the name of the corresponding nested Label instruction A nested Jump can be placed anywhere in a program There can be multiple nested Jump instructions corresponding to a single nested Label Nested Jumps can be either forward or backward Jumps There can be nothing after the Jump instruction in the rung Power flow jumps directly from the instruction to the rung with the named label Caution To avoid creating an endless loop with forward and backward Jump instructions a backward Jump must contain a way to make it conditional Label The Label instruction is the target of a Jump Use the Label instruction to resume normal program execution There can be only one Label with a particular name in a program The Label instruction has no inputs and no outputs there can be nothing either before or after a Label in a rung 10 26 VersaMax PLC User s Manual March 2001 GFK 1503C Control Functions Jump Label GFK 1503C Example Jump and Label Instructions In the example whenever Jump TEST is active power flow is transferred to Label TESTI With a Jump any function blocks betwee
257. ogic It can be placed anywhere in a program No logic beyond the END function is executed and program execution goes directly back to the beginning This ability makes the END function useful for debugging a program The END function should not be placed in logic associated with or called by a Sequential Function Chart control structure If this occurs the PLC will be placed in STOP FAULT mode at the end of the current sweep and an SFC_END fault will be logged Executing Rungs of Logic without Logical Power Flow The nested Master Control Relay can be used to execute a portion of the program logic with no logical power flow Logic is executed in a forward direction and coils in that part of the program are executed with negative power flow Master Control Relay functions can be nested to 8 levels deep Jumping to Another Part of the Program The Jump function can be used to cause program execution to move either forward or backward in the logic When a nested Jump function is active the coils in the part of the program that is skipped are left in their previous states not executed with negative power flow as they are with a Master Control Relay Jump functions can also be nested Jumps cannot span blocks SFC actions SFC transitions or SFC pre or post processing logic Chapter 7 CPU Operation 7 7 7 8 Run Stop Mode Switch Operation The CPU Run Stop mode switch can be configured to place the CPU in Stop or Run mode It can a
258. ogram block that is not called every sweep it accumulates time between calls to the program block unless it is reset That means it functions like a timer in a program with a much slower sweep than the timer in the main program block For program blocks that are inactive for a long time the timer should be programmed to allow for this catchup For example if a timer in a program block is reset and the program block is inactive for four minutes when the program block is called four minutes of time will have accumulated This time is applied to the timer when enabled unless the timer is first reset Example In the example an Off Delay Timer is used to turn off an output Q00001 whenever an input 1I00001 turns on The output is turned on again 0 3 seconds after the input goes off 100001 Q00001 OFDT 0 10 CONST Pv cv 00003 R00019 GFK 1503C Chapter 10 Instruction Set Reference 10 79 Timer and Counter Functions Off Delay Timer Operation of the Off Delay Timer Function Steet EEE ES ABLE and Q both go high timer is reset CV 0 ABLE goes low timer starts accumulating time V reaches PV Q goes low and timer stops accumulating time ABLE goes high timer is reset CV 0 ABLE goes low timer starts accumulating time ABLE goes high timer is reset CV 0 ENABLE goes low timer begins accumulating time V reaches PV Q goes low and timer stops accumulating time Parameters of the Off
259. on Profibus NIU User s Manual 1 2 Program checksum 7 3 Program scan 7 3 Programmer communications 7 3 Programmer Communications Window change Protocol errors 12 10 R 422 point to point connections Index 3 Read Bytes Read String Real Numbers Reference address assignment References 9 2 Relational functions 8 9 Relay functions coils continuation coil continuation contact 10 63 normally closed contact normally open contact Resource problem bit 13 19 Retentiveness 10 64 Retentiveness of data ROL 10 10 ROR 10 10 Rotate left function RS 422 point to point connections RS 485 1 4 p 2 RTU slave Sequential Function Chart overview 8 5 Serial I O Cancel Operation function Flush Input Buffer functi Initialize Port function Input Buffer function Read Bytes function 12 24 Read Port Status function 12 17 Read String function Write Bytes function 12 21 12 23 Write Port Control function Serial port and cables appendix C multidrop connections 4 17 Service Request Change read time of day clock 11 11 Clear fault tables 11 20 function numbers Interrogate I O 11 26 Read elapsed power down time Read elapsed time clock Read I O override status Read last logged fault table entry 11 21 Read master checksum Shut down stop PLC Service Request function SET coil 10 67 Shift left function Shift right function
260. on has an output parameter block only The parameter block has a length of 3 words address Power Down Elapsed Seconds low order address 1 Power Down Elapsed Seconds high order address 2 zero The first two words are the power down elapsed time in seconds The last word is always 0 Example of SVCREQ 29 In the example when input 10251 is ON the Elapsed Power Down Time is placed into the parameter block that starts at ROO50 The output coil Q0001 is turned on 10251 Q0001 SVC _ REQ go029 FNC R0050 PARM Chapter 11 The Service Request Function 11 27 Chapter Serial I O SNP RTU Protocols 12 This chapter describes the VersaMax CPU s Serial I O feature which can be used to control the read write activities of one of the CPU ports directly from the application program This chapter also contains instructions for using COMMREQs to configure the CPU serial ports for SNP RTU or Serial I O protocol m Format of the COMMREQ Function m Configuring Serial Ports Using the COMMREQ Function O RTU Slave SNP Slave Operation with a Programmer Attached O COMMREQ Command Block for Configuring SNP Protocol O COMMREQ Data Block for Configuring RTU Protocol O COMMREQ Data Block for Configuring Serial I O m Serial YO COMMREQ Commands Initialize Port Set Up Input Buffer Flush Input Buffer Read Port Status Write Port Control Cancel Operation Autodial Write B
261. ons in the following format Bit Word Function Status or External Action if Override Value bit set to 1 1 Override If 0 monitor block contacts below If 1 set them externally 1 2 Manual If 1 block is in Manual mode other Auto numbers it is in Automatic mode 2 Enable Should normally be 1 otherwise block is never called 3 UP If 1 and Manual Bit 1 is 1 CV is Raise being incremented every solution 16 DN If 1 and Manual Bit 1 is 1 CV is Lower being incremented every solution Tracks SP in must be set externally if Override 1 Tracks CV out Tracks PV in must be set externally if Override bit 1 Signed word value representing the output of the function block before the optional inversion If no output inversion is configured and the output polarity bit in the control word is set to 0 this value equals the CV output If inversion is selected and the output polarity bit is set to 1 this value equals the negative of the CV output Used internally for storage of intermediate values Do not write to these locations Internal elapsed time storage time last PID executed Do not write to these locations Holds remainder for integrator division scaling for 0 steady state error Optional INT values in PV Counts that define high and low display values R ef 27 must be lower than Ref 28 29 34 are reserved for internal use 35 39 are reserved for extemal use Do not use these references 14 9 PID Algo
262. onstant Sweep Timer ceceeeeeeeseereeeeneeeeneeeeee 11 4 SVCREQ 2 Read Window Times c cccccccecssssssseceecssesseeeeeeceessessseeeeeeeeeees 11 6 SVCREQ 3 Change Programmer Communications Window Mode 11 7 SVCREQ 4 Change System Communications Window Mode cceeeee 11 8 SVCREQ 6 Change Read Number of Words to Checksum eseeseeeeseeeees 11 9 SVCREQ 7 Read or Change the Time of Day Clock ceeeeeeeesseeeneeeeeees 11 11 SVCREQ 8 Reset Watchdog Timet 00 ceeeeeceesseessseecsseeseecseeeeseeeesaeeesneers 11 15 SVCREQ 9 Read Sweep Time from Beginning of Sweep sceeseeeeeeeeeeeee 11 16 SVCREQ 10 Read Folder Name c ccccsssseseeecceeeeneeceeeeeeeeeeeeeeeeseeeeesenees 11 17 SVCREO Jt Read PEG ID cfs a Sah lhe ects ah es ate 11 18 SVCREQ 13 Shut Down Stop PLC 0 eeeeeeseceseecsseeeeseceseeseseeeesaeeesneers 11 19 SVCREQ 14 Clear Fault s scsi ch e endian EOS 11 20 SVCREQ 15 Read Last Logged Fault Table Entry eee eeeeeseeeeeneeeeeees 11 21 SVCREQ 16 Read Elapsed Time Clock eeeceeeceeseesseeeeeeceneeeeseeeesaeeseneers 11 23 SVCREQ 18 Read I O Override Status cceeesccceeeesceceeeeeeeeeneeeeeseneeeesenees 11 24 VersaMax PLC User s Manual March 2001 GFK 1503C Chapter 12 Chapter 13 Chapter 14 Chapter 15 Appendix A GFK 1503C Contents SVCREQ 23 Read Master Checksum ccccccccsssssccecccessssseeeceessessneeeeeee
263. onstant SweepTimer is read the timer is increased by two milliseconds and the new timer value is sent back to the PLC The parameter block is in local memory at location R0050 Because the MOVE and ADD functions require three horizontal contact positions the example logic uses discrete internal coil MO00001 as a temporary location to hold the successful result of the first rung line On any sweep in which OV_SWP is not set MO0001 is turned off OV_SWP M00001 _t MOVE SVC_ ADD_ WORD REQ INT CONST Jin QL CONST FNC R0051 11 Q R00051 00003 i a CONST _ R0050 PARM ANT ea M00001 l MOVE SVC_ WORD REQ CONST _ IN QH R00050 CONSTH FNC 00001 00001 R0005077 PARM Chapter 11 The Service Request Function SVCREQ 2 Read Window Times SVCREQ 2 can be used to read the times of the programmer communications window and the system communications window These windows can operate in Limited or Run to Completion Mode Mode Name Value Description Limited Mode 0 The execution time of the window is limited to 6ms The window terminates when it has no more tasks to complete or after 6ms elapses Run to Completion 2 Regardless of the time assigned to a window it runs until all tasks Mode within that window are completed up to 400ms A window is disabled when the time value is zero Output Parameter Block for SV
264. or host 1 The value 6 0006H 64 seconds 4 14 000eH specifies log 2 of the interval in seconds eg the 16 16384 sec value 3 means 8 secs 4 means 16 sec etc nmax_polll NTP maximum poll interval for host 1 in log 2 of 10 000aH 1024 sec seconds nmin_poll2 NTP min poll interval for host 2 in log 2 of 6 0006H 64 sec seconds nmax_poll2 NTP max poll interval for host 2 in log 2 of 10 000aH 1024 sec seconds nmin_poll3 NTP min poll interval for host 3 in log 2 of 6 0006H 64 sec seconds nmax_poll3 TP max poll interval for host 3 in log 2 of 10 000aH 1024 sec seconds nsync_tout NTP synchronization timeout period in seconds 300 012ch 150 65535 The max time between network time updates to 0096H ffffH remain synchronized 6 10 VersaMax PLC User s Manual March 2001 GFK 1503C Chapter CPU Operation This chapter describes the operating modes of the VersaMax PLC CPUs and shows the relationship between the application program execution and other tasks performed by the CPU CPU Operating Modes The application program in a PLC executes repeatedly In addition to executing the application program the PLC CPU regularly obtains data from input devices sends data to output devices performs internal housekeeping and performs communications tasks This sequence of operations is called the sweep m The basic operating mode of the PLC is called Standard Sweep mode
265. ound program check is active PLC_BAT Setto indicate a bad battery in the CPU The contact reference is updated once per sweep S0017 SNPXACT SNP X hostis actively attached to CPU port 1 Port 2 defaults to disabled and must be activated with a CRQ 5S0018 SNPX_RD SNP X hosthas read data from CPU port 1 50019 SNPX_WT SNP X hosthas written data to CPU port 1 50020 Set ON when a relational function using REAL data executes successfully Itis cleared when either input is NaN Nota Number 50021 FF_OVR Set to report a Fatal Fault Overide 50022 USR_SW_ Setto reflect the state of the CPU mode switch 1 Run On 0 Stop Off 9 6 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Le SA SB and SC References References in SA SB and SC memory can be both read and written to Reference Name Definition SA0001 PB SUM Setwhen a checksum calculated on the application program does not match the reference checksum If the fault was due to a temporary failure the discrete bit can be cleared by again storing the program to the CPU Ifthe fault was due to a hard RAM failure the CPU must be replaced SA0002 OV_SWP SetwhenaPLC in CONSTANT SWEEP mode detects that the previous sweep took longer than the time specified Cleared when the PLC detects that the previous sweep did not take longer than specified Also cleared during transition from STOP to RUN mode SA0003 APL_FLT
266. ount Displayed as 0 000 Repeats Sec with an implied decimal point of 3 For example a Ki entered as 1400 is displayed as 1 400 Repeats Sec and results in a Ki Error dt or 1400 20 50 1000 contribution to PID Output for an Error of 20 PV Counts and a 50ms PLC sweep time Sample Period of 0 Ki is usually the second gain set after Kp Number of CV Counts added to the PID Output before the rate and amplitude clamps It can be used to set non zero CV values if only Kp Proportional gains are used or for feed forward control of this PID loop output from another control loop Number of CV Counts that define the highest and lowest value for CV These values are required The Upper Clamp must have a more positive value than the Lower Clamp or the PID block will not work These are usually used to define limits based on physical limits for a CV output They are also used to scale the Bar Graph display for CV The block has antireset windup to modify the integrator value when a CV clamp is reached Minimum number of seconds for the CV output to move from 0 to full travel of 100 or 32000 CV Counts It is an inverse rate limit on how fast the CV output can be changed If positive CV cannot change more than 32000 CV Counts times Delta Time seconds divided by Minimum Slew Time For example if the Sample Period is 2 5 seconds and the Minimum Slew Time is 500 seconds CV cannot change more than 32000 2 5 500 or 160 CV Counts per PID solution
267. ounting Instructions 0 ccceccceeessceceeenceeeeeeeeeeeseaeeeceseneeesnneeeseeeeeeeeeeeeeeenees 4 2 Installing an Expansion Transmitter Module cccsescceeesseeeeeeeeeeeeseeeeeenees 4 4 Installing an Expansion Receiver Module essceesseeceseeesseeceseeeesseecsaeessneeeees 4 5 Installing Power Supply Modules 00 cee eeecesseeceeeeeeeeeesneecsseeeeseeeesaeecsaeessneeeees 4 9 Installing Additional Modules ecceesecceseecesneeneeceseeecsaeecseecseeessaeeeseeesaeees 4 10 Activating or Replacing the Backup Battery cccssscceesesseeeeeeeeeessneeeeeenees 4 11 Serial Port Connections a e a a a a A n a A 4 12 Ethernet Connection for CPUEOS 0 escceeseccssseeeeseecseesaeecseecseeseseeeesaeessaeers 4 18 CE Mark Installation Requirements sseseseeeseeereeereeeeeereesessreseresereseresereerresseese 4 19 CPU Configurations 5 ccicccscsesesesesesssesosesasecesesssedosedasesesesessiesesasegesssesssesss 5 1 Using Autoconfiguration or Programmer Configuration cceeseeseeeseeeeneeeees 5 2 Configuring Racks and Slots ceeseceseeceseeceeeessseeseeecsneeceseeeesaeessaeeseeeeses 5 3 Software Configuration espis cee eescecsssecesseecsneecsseeceseecesaeeesseecseeesaeecseesseeesseeeesaes 5 5 AULOCONASUTAt OMe sees oes hei sees oe e ace onde eet oda mee ees 5 11 Ethernet Configuration ssccccccccssssssssssccsssssssssssccssssssssssssssssessssees 6 1 Ethernet Co
268. ower flow unless an incorrect function number incorrect parameters or out of range references are specified Specific SVCREQ functions have additional causes for failure Parameters of the SVCREQ Function Input Output Choices Description enable flow When enable is energized the service request is performed FNC QM T G R Contains the constant or reference for the requested Al AQ constant service PARM QM T G R Contains the beginning reference for the parameter block Al AQ for the requested service ok flow none OK is energized when the function is performed without error Example of the SVCREQ Function In the example when the enabling input I0001 is ON SVCREQ function number 7 is called with the parameter block located starting at R0001 Output coil Q0001 is set ON if the operation succeeds 10001 as rl SVC_ REQ CONST _ 00007 FNC R0001 PARM GFK 1503C Chapter 11 The Service Request Function 11 3 SVCREQ 1 Change Read Constant Sweep Timer Use SVCREQ 1 to enable or disable Constant Sweep Time mode change the length of the Constant Sweep Time read whether Constant Sweep Time is currently enabled or read the Constant Sweep Time length Input Parameter Block for SCVREQ 1 For this function the parameter block has a length of two words Disable Constant Sweep Mode To disable Constant Sweep mode enter SVCREQ function 1 with this parameter block
269. p Off position move it from Run then back to Stop to affirm the change After the mode is changed to Stop No I O the PLC Run LED goes off 3 To start the update press the pushbutton on the EZ Program Store device Pushbutton The LED on the EZ Program Store device turns amber and the Port 2 LED on the PLC blinks Port 2 LED o000000 EZ Program Store LED 4 Wait for the update to complete Reading and writing large programs hardware configurations and reference tables to or from the EZ Program Store device may take 30 seconds or more to complete 15 8 VersaMax PLC User s Manual March 2001 GFK 1503C IC200ACC003 EZ Program Store Device When the device s LED turns solid green and the CPU s Run LED starts blinking the update has completed successfully EZ Program Store Device LED When the PLC is placed into Run mode by moving the Run Stop switch from Stop Off to Run On position it uses the new data immediately Error During Update If the EZ Program Store device s LED is blinking green amber and the CPU s Run LED is blinking an error was detected before the old data was erased When the PLC is placed into Run mode it continues using the old data If the device s LED is blinking green amber and the CPU s Run LED is off an error occurred during
270. ple Command Block for the Read Bytes Function eT decimal hexadecimal address Data block length address 1 address 2 Status word memory type R address 3 Status word address minus 1 R0001 address 4 Not used address 5 address 6 address 7 adress 8 address 9 0008 0008 Input data memory type R address 10 0100 0064 Input data memory address R0100 12 24 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Return Data Format for the Read Bytes Function The return data consists of the number of characters actually read the number of characters still available in the input buffer after the read is complete if any and the actual input characters Address Number of characters actually read Address 1 Address 2 first two characters first character is in the low byte Address 3 Adress n Operating Note If the input data memory type parameter is specified to be a word memory type and if an odd number of bytes are actually received then the high byte of the last word to be written with the received data is set to zero As data is received from the serial port it is placed in the internal input buffer If the buffer becomes full then any additional data received from the serial port is discarded and the Overflow Error bit in the Port Status word See Read Port Status Function is set Chapter 12 Serial I O SNP RTU Protocols 12 25 Read String Function 4403 This function
271. powerful PLC functionality They are designed to serve as the system controller for up to 64 modules with up to 2048 T O points Two serial ports provide RS 232 and RS 485 interfaces for SNP slave and RTU slave communications CPU model IC200CPUE0S provides a built in Ethernet port Basic CPU Features Programming in Ladder Diagram Sequential Function Chart and Instruction List Floating point real data functions Non volatile flash memory for program storage Battery backup for program data and time of day clock Run Stop switch Embedded RS 232 and RS 485 communications Compatible with EZ Program Store device Available VersaMax CPUs CPU with Two Serial Ports 34KB of Configurable Memory IC200CPU001 CPU with Two Serial Ports 42kB of Configurable Memory IC200CPU002 CPU with Two Serial Ports 64kB of Configurable Memory IC200CPU005 CPU with Two Serial Ports and Embedded Ethernet Interface IC200C PUE05 64kB of Configurable Memory 1 4 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Status LEDs Serial Ports 0 I l E 5 J CPUE05 CPUEOS a O Q y L o NE 8 Ci i g t J 1 3 t 88 a ee J t n 6 MA e CJ 8 rori 5 Ethernet Interface EZ Program Store CPU001 CPU002 CPU001 i CPU005 CPU005
272. privilege to the PLC when the programmer is in Online or Monitor mode Passwords are not used if the programmer is in Offline mode Passwords can restrict Changing I O and PLC configuration data Changing programs Reading PLC data Reading programs There is one password for each privilege level in the PLC Each password may be unique or the same password can be used for more than one level Passwords are one to seven ASCII characters in length By default there is no password protection Passwords are set up changed or removed using the programming software After passwords have been set up access to the PLC is restricted unless the proper password is entered Entering a correct password allows access to the requested level and to all lower levels For example the password for level 3 allows access to levels 0 1 2 and 3 If PLC communications are suspended protection automatically returns to the highest unprotected level For example If a password is set at levels 2 amp 3 but none at level 4 if the software disconnects and reconnects the access level is 4 Privilege level 1 is always available because no password can be set for this level Level Access Description 4 Write to all configuration or logic Configuration may only be written in Stop mode logic may be Least written in Stop or Run mode if run mode store is supported Protected Setor delete passwords for any level Plus all access from levels
273. program hardware configuration registers R analog inputs AJ and analog outputs AQ The amount of memory allocated to the application program and hardware configuration are automatically determined by the actual program and configuration entered from the programmer The rest of the 64K bytes can be easily configured to suit the application Application program size not configurable not configurable Registers R 256 bytes minimum Analog Inputs Al 256 bytes minimum Analog Outputs AQ 256 bytes minimum VersaMax PLC User s Manual March 2001 GFK 1503C CPU with Two Serial Ports Embedded Ethernet Interface and 64K Configurable Memory IC200CPUE05 Ethernet Interface Overview GFK 1503C CPUEOS has a built in Ethernet interface that makes it possible to communicate on a 10BaseT network Both half duplex and full duplex operation are supported Using 10 100 hubs allows CPUEOS5 to communicate on a network containing 100Mb devices SRTP Server CPUEOS5 supports up to eight simultaneous SRTP Server connections for use by other devices on the Ethernet network such as the PLC programmer CIMPLICITY HMI SRTP channels for Series 90 PLCs and Host Communications Toolkit applications No PLC programming is required for server operation Ethernet Global Data CPUEOS5 supports up to 32 simultaneous Ethernet Global Data exchanges Global Data exchanges are configured using the PLC programming software then store
274. r module is inserted after powerup Modules in the expansion rack are ignored Expansion 1 An Expansion Transmitter Module IC200ETM001 is present but not Transmitter configured mismatch 2 An Expansion Transmitter Module IC200ETM001 is configured but not present expansion bus The expansion bus speed automatically calculated by the CPU during speed change autoconfiguration has changed unsupported A module is present that is not supported by the CPU feature GFK 1503C Chapter 5 CPU Configuration 5 13 Chapter 6 GFK 1503C Ethernet Configuration This chapter describes the configuration needed for the Ethernet interface of VersaMax CPU module IC200CPUE0S Ethernet configuration overview Configuring the characteristics of the Ethernet interface Configuring Ethernet Global Data Configuring Advanced User Parameters The Ethernet interface configuration described in this chapter must be set up in addition to the basic CPU configuration described in chapter 5 6 1 sl Ethernet Configuration Overview The Ethernet configuration for CPU module IC200CPUEO0S includes Configuring the characteristics of the Ethernet interface This is part of the CPU configuration Configuring Ethernet Global Data This is reached via the rack operations configuration Optional not required for most systems Configuring advanced parameters This requires creating a separate ASCII parameter file that is
275. rameter Block Format for SVCREQ 11 The output parameter block has a length of four words It returns eight ASCII characters the last is a null character 00h If the PLC ID has fewer than seven characters null characters are added to the end Low Byte High Byte Example of SVCREQ 11 In this example when enabling input 10302 goes OFF register location R0099 is loaded with the value 11 which is the function code for the Read PLC ID function The program block READ_ID is then called to retrieve the ID The parameter block is located at address RO100 10303 MOVE UINT CONST IN QJ R0099 0011 READ_ID Program Block READ_ID SVC_ REQ R0099 FNC R0100 PARM 11 18 VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 13 Shut Down Stop PLC GFK 1503C Use SVCREQ 13 to stop the PLC at the end of the next sweep All outputs go to their designated default states at the start of the next PLC sweep An informational Shut Down PLC fault is placed in the PLC Fault Table The I O scan continues as configured Parameter Block for SVCREQ 13 This function has no parameter block Example of SVCREQ 13 In the example when a Loss of I O Module fault occurs SVCREQ 13 executes The PARM input is not used This example uses a JUMP to the end of the program to force a shutdown if the Shutdown PLC function executes successfully This JUMP a
276. rds ccsscccsseecesseesseecseecsseesseecsseeeesaeeeseeesaeers 7 10 Elements of an Application Program sscccssssssccssssssscsscssesssssssees 8 1 Structure of an Application Program escseseccsseecsseeeseecsceceeessseeeseeseseeeesaes 8 2 SUDLOULINES Siero tates tees E EA E ties eos epee Seva erste ton RA etn en EAA 8 3 Program Lan Qua ges ricci cis scbi seeks cots Sus cobdgevkccebs E EE O EE E AEE EE ER EEEREN 8 5 The Instruction Sets 2 5 9 2 sepo en E os ea dobsta te sas Benn Pee Ee vs naan an Poets 8 7 PrOSTA Data siicisercccsscecsvasssensvesescesecesssesssueesesecuvusesssuecseiecsvusesssueeseseesteees 9 1 Data Memory References da an enous TEA ne nda ae 9 2 Retentiveness Of Data Tasir e a set cecckstenbuts a e aeea Eee eeh EAEE OnE 9 4 System Status References n oriee sorier erto neairt enean ineei oien en p snai Te desea eop EEA ai 9 5 How Program Functions Handle Numerical Data eeeeeseeesseeeneeeeneeeeneeeee 9 9 Tame Tick Contacts m eoe a o aE eae EEE EEA E sna i begdetusbaetbeacesbans 9 11 Instruction Set Reference seseeseeseesosereeeseesorsoeeeeeseeecesorseeeseesorsoreoeecee 10 1 The Service Request Function sooosssooosssoesessoosessoosssosssssoessssoesesssoe 11 1 SVCREQ Function Numbers cccesecceceesseeeeeeeeceeseeceecseneeeceseaeeeeeenaeeeeseanees 11 2 Format of the SVCREQ Function ccecccceesssceeeesceeeeeeeeeeseeeeeeeneeeeeseeeeenenees 11 3 SVCREQ 1 Change Read C
277. reated as a Loss of Programmer Communications The programmer may send a new protocol via configuration or a Serial Port Setup COMMREQ COMMREQs not supported by SNP Slave protocol are rejected If a new protocol is received it will not take effect until the programmer is disconnected After the programmer is removed there is a slight delay equal to the configured SNP T3 timeout before the CPU recognizes its absence During this time no messages are processed on the port The CPU detects removal of the programmer as an SNP Slave protocol timeout Therefore it is important to be careful when disabling timeouts used by the SNP Slave protocol When the CPU recognizes the disconnect it reinstalls RTU Slave protocol unless a new protocol has been received In that case the CPU installs the new protocol instead Example 1 Port 1 is running RTU Slave protocol at 9600 baud 2 A programmer is attached to port 1 The programmer is using 9600 baud 3 The CPU installs SNP Slave on port 1 and the programmer communicates normally 4 The programmer stores a new configuration to port 1 The new configuration sets the port for SNP Slave at 4800 baud it will not take effect until the port loses communications with the programmer 5 When the CPU loses communications with the programmer the new configuration takes effect 12 6 VersaMax PLC User s Manual March 2001 GFK 1503C Example COMMREQ Command Block for Configuring SNP Protoco
278. remains ON When the current value equals or exceeds the Preset Value PV the function begins passing power flow to the right The timer continues accumulating time until the maximum value is reached When the enabling parameter transitions from ON to OFF the timer stops accumulating time and the Current Value is reset to zero Parameters for the On Delay Timer Function Input Choices Description Output address R The function uses three consecutive words registers of R memory to store the following e Current value CV word 1 Preset value PV word 2 e Control word word 3 Do not use this address with other instructions Careful Overlapping references cause erratic operation of the timer enable flow When enable receives power flow the timer s current value is incremented When the TMR is not enabled the current value is reset to zero and Q is turned off PV 1Q M T G R Al AQ PV is the value to copy into the timer s preset value when the timer is constant none enabled or reset Q flow none Output Q is energized when TMR is enabled and the current value is greater than or equal to the preset value time tenths 0 1 hundredths Time increment for the low bit of the PV preset and CV current value 0 01 or thousandths 0 001 of seconds GFK 1503C Chapter 10 Instruction Set Reference 10 77 10 78 Timer and Counter Functions On Delay Timer Operation of the
279. rements beginning at the retained value When reset R receives power flow the current value is set back to zero and output Q is deenergized unless PV equals zero Example In the example a retentive ondelay timer is used to create a signal QOO11 that turns on 8 0 seconds after Q0010 turns on and turns off when QO010 turns off Q0010 Q0011 ONDTR Q0010 R CONST ooos0 PY R0004 VersaMax PLC User s Manual March 2001 GFK 1503C Timer and Counter Functions On Delay Timer The On Delay Timer TMR increments while it receives power flow and resets to zero when power flow stops Time may be counted in tenths of a second the default selection hundredths of a second or thousandths of a second The range is 0 to 32 767 time units The state of this timer is retentive on power failure no automatic initialization occurs at powerup Enable TMR Q TENTHS Preset Value 7 py Current Value Address 3 words When the On Delay Timer function receives power flow the timer starts accumulating time Current Value The Current Value is updated when it is encountered in the logic to reflect the total elapsed time the timer has been enabled since it was last reset If multiple occurrences of the same timer with the same reference address are enabled during a CPU sweep the Current Values of the timers will be the same This update occurs as long as the enabling logic
280. riers and Interposing Terminals Barrier S tyle Auxiliary I O Terminal Strip C200TBM001 Box Style Auxiliary I O Terminal Strip C200TBM002 Spring Style Auxiliary I O Terminal Strip C200TBM005 Other Carriers Communications Carrier C200CHS 006 Power Supply Booster Carrier C200PWBO001 Chapter I Introduction 1 11 Expansion Modules There are two basic types of VersaMax I O expansion systems Multi Rack and Single ended Multi Rack A VersaMax PLC or NIU I O Station with an Expansion Transmitter Module IC200ETMO001 and one to seven expansion racks each with an Expansion Receiver Module IC200ERMO001 or IC200ERMO002 If all the Expansion Receivers are the Isolated type IC200ERMO001 the maximum overall cable length is 750 meters If the expansion bus includes any non isolated Expansion Receivers IC200ERMO002 the maximum overall cable length is 15 meters VersaMax PLC or I O Station Main Rack 0 l ETM PS g D CPU NIU VersaMax ExpansionRack 1 15M with re with any IC200ERM002 ERMs bc 750M with all IC200ERM001 ERMs ERM IC200CBL601 VersaMax ExpansionRack 7 602 615 PS Aull TE Sy a Terminator Plug
281. rithm Selection PIDISA or PIDIND and Gains The PID block can be programmed selecting either the Independent PID_IND term or standard ISA PID_ISA versions of the PID algorithm The only difference in the algorithms is how the Integral and Derivative gains are defined Both PID types calculate the Error term as SP PV which can be changed to Reverse Acting mode PV SP by setting the Error Term low bit 0 in the Config Word Ref 12 to 1 Reverse Acting mode may be used if you want the CV output to move in the opposite direction from PV input changes CV down for PV up rather than the normal CV up for PV up Error SP PV or PV SP if low bit of Config Word set to 1 The Derivative is normally based on the change of the Error term since the last PID solution which may cause a large change in the output if the SP value is changed If this is not desired the third bit of the Config Word can be set to 1 to calculate the Derivative based on the change of the PV The dt or Delta Time is determined by subtracting the last PID solution clock time for this block from the current PLC elapsed time clock dt Current PLC Elapsed Time clock PLC Elapsed Time Clock at Last PID solution Derivative Error previous Error dt or PV previous PV dt if 3rd bit of Config Word set to 1 The Independent term PID PID_IND algorithm calculates the output as PID Output Kp Error Ki Error dt Kd Derivative CV Bias The standard ISA PI
282. rnet interface along with Ethernet network s high capacity allow CPUE05 to communicate with several other devices at the same time Indirectly attach to other Local Area Networks and or wide area networks via third party IP routers CPUEOS can communicate with remote PLCs and other nodes via an IP Router Communicate with remote computers via Serial Line Protocol SLIP using modems and or serial lines Using third party SLIP devices a remote host computer can be attached to a TCP IP network Once attached the serial communications can be routed over the Ethernet interface to the CPUEOS Maintain compatibility with other devices CPUEOS is compatible with the GE Fanuc Series 90 30 Ethernet Interface Series 90 30 CPU364 Embedded Ethernet Interface and Series 90 70 Ethernet Interface Type 2 It is also compatible with GE Fanuc programming packages supporting TCP IP Ethernet communications 13 2 VersaMax PLC User s Manual March 2001 GFK 1503C Ethernet Global Data CPUEOS also supports up to 32 simultaneous Ethernet Global Data exchanges Ethernet Global Data exchanges are configured using the PLC programming software then stored to the PLC Both Produced and Consumed exchanges may be configured CPUEOS5 supports up to 1200 data ranges across all Ethernet Global Data exchanges and can be configured for selective consumption of Ethernet Global Data exchanges SRTP Server CPUEOS supports up to eight simultaneous SRTP Se
283. rom OFF to ON the Current Value increments by 1 The current value can be incremented past the Preset Value PV The output is ON whenever the Current Value is greater than or equal to the Preset Value The state of the CTU is retentive on power failure no automatic initialization occurs at powerup Enable cru Q Reset R uie e Address Parameters of the Up Counter Function Input Choices Description Output address R The function uses three consecutive words registers of R memory to Store the following e Current value CV word 1 Preset value PV word 2 e Control word word 3 Do not use this address with another up counter down counter or any other instruction or improper operation will result Careful Overlapping references cause erratic operation of the counter enable flow On a positive transition of enable the current count is incremented by one R flow When R receives power flow it resets the current value back to zero PV l Q M T G R PV is the value to copy into the counter s preset value when the counter is Al AQ enabled or reset constant none Q flow none Output Q is energized when the Current Value is greater than or equal to the Preset Value GFK 1503C Example of the Up Counter Function In the example every time input I0012 transitions from OFF to ON up counter PRT_CNT counts up by 1 internal coil MO0001 is en
284. rror code 2 02H is returned in the COMMREQ status word This will occur for any unsupported baud rate Chapter 12 Serial I O SNP RTU Protocols 12 9 Calling Serial YO COMMREQs from the PLC Sweep Implementing a serial protocol using Serial I O COMMREQs may be restricted by the PLC sweep time For example if the protocol requires that a reply to a certain message from the remote device be initiated within 5mS of receiving the message this method may not be successful if the PLC sweep time is 5mS or longer since timely response is not guaranteed Since the Serial I O is completely driven by the application program in STOP mode a port configured as Serial I O automatically reverts to SNP slave to facilitate programmer communication Therefore while in Stop mode Serial I O protocol is not active it is only active when the PLC is in Run mode When the port reverts back to SNP Slave the same serial communications parameters baud rate parity stop bits as the currently active Serial I O protocol are used Therefore the programmer must use the same parameters for it to be recognized If any of the parameter values associated with the Serial I O protocol are not supported by the SNP Slave protocol the programmer will not be able to communicate with the PLC via that port Compatibility The COMMREQ function blocks supported by Serial I O are not supported by other currently existing protocols such as SNP slave SNP master an
285. rs 15 Pin Female Connector PIN BIN BIN PIN Connector E a B S RBG Elen E 2a RTS 7 4 5 cts C m 10 heOI mdi spay H q CTS 8 Li 20 DTR L JRDB 11 13 SDB H E fea BRECA eno E Jee n Re E GND 5 4 7 GND T q7 i Ay BD C ii oT say 15 6 RTS A H ci LL CTS B 8 14 RTS B ii RATSIA 6 15 CTS A isdi RTS B 14 8 CTS B Ln 1 suo ay 2 ay SHLD 1 z 1 SHLD i 15 PIN FEMALE FEMALE MALE i RS 232 RS 485 i PORT PORT Gsv i i Power Source for Converter i Must be wired no less than 3 o meters 10 feet from the converter TO OTHER PLC s GFK 1503C Termination resistance for the Receive Data RD signal must be connected only on units at the ends of lines This termination is made at the CPU by connecting a jumper between pin 9 and pin 10 inside the D shell connector Ground Potential Multiple units not connected to the same power source must have common ground potential or ground isolation for proper operation of the system Chapter 4 Installation 4 17 Ethernet Connection for CPUEO5S The Ethernet port on PLC module IC200CPUE0S connects directly to a 10BaseT twisted pair network without an external transceiver Connect the port to an external 10BaseT hub or switch or a hub or repeater with auto sense of 10 100 using a twisted pair cable Cables are readily available from commercial distributors GE Fanuc recommends purchasing rather than making cables Your 10BaseT tw
286. rsaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C RTU and Serial IO Delays 29 66 The receive to transmit turnaround and RTS drop delay parameters can be configured to customize communications timing for radio modems receive to transmit delay The minimum length of time between the CPU receiving the last character of an incoming message and the CPU asserting RTS Asserting RTS is followed by the transmission of the response message This delay is configured as a minimum time because the actual delay is dependent upon the CPU sweep time turnaround delay The length of time between the CPU asserting RTS and the CPU beginning to transmit a message RTS drop delay The length of time between the CPU transmitting the last character of a response message and the CPU dropping RTS The RTS drop delay can vary by 1 ms RTS CPU Nip A CTS Master i Tx CPU transmit TD is the Receive to Transmit delay TD is the Turnaround Delay TD3 is the RTS Drop Delay Configuration Required to use Winloader The Winloader utility which can be used for firmware updates requires SNP configuration If Port 1 is configured for another mode or forced to Local Station Manager operation Winloader will not be able to do a firmware update on port 1 Note for RTU Communications When using RTU communications it may be necessary to increase the RTU timeout confi
287. rsaMax PLC User s Manual March 2001 GFK 1503C Routers Routers connect individual physical networks into a system of networks When a node on one network needs to communicate with a node on another network a Router transfers the data between the two networks Example Networks Connected by a Router The following figure shows Network 1 and Network 2 connected by Router R A 172 16 0 2 Network 1 172 16 0 1 R Router c 172 17 0 1 172 17 0 2 172 17 0 3 Network 2 Host B can communicate with host C directly because they are on the same network Their IP addresses have the same netid However to send data to host A which is on another network it has a different netid host B must send it via the router The router has two IP addresses 172 16 0 1 and 172 17 0 1 The first is used by hosts on Network 1 and the second is used by hosts on Network 2 In this example the router s IP address on Network 2 is 172 17 0 1 This address would be configured in host B as its default gateway address GFK 1503C Chapter 13 Ethernet Communications 13 5 Ethernet Global Data Ethernet Global Data is data that is automatically sent from one Ethernet device to one or more others Once Ethernet Global Data has been configured the data is sent automatically during system operation No program interaction is necessary to produce or consume the global data The device that send
288. rt numbers below are provided for reference only Any part that meets the same specification can be used Cable Low Capacitance Computer cable overall braid over foil shield Belden 8105 5 Twisted pairs t Shield Drain Wire t 30 Volt 80 C 176 F 24 AWG tinned copper 7x32 stranding Velocity of Propagation 78 Nominal Impedance 100Q t 15 Pin Male Vendor Plug Pin Connector ITT Cannon DAA15PK87F0 030 2487 017 AMP 205206 1 66506 9 Solder ITT Cannon ZDA15P AMP 747908 2 Connector Kit ITT Cannon DA121073 50 15 pin size backshell kit Shell Metal Plated Plastic Plastic with Nickel over Copper t Cable Grounding Clamp included 40 cable exit design to maintain low profile installation Plus ITT Cannon 250 8501 009 Extended Jackscrew Threaded with metric M3x0 5 for secure attachment t Order Qty 2 for each cable shell ordered Critical Information any other part selected should meet or exceed this criteria GFK 1503C Chapter 4 Installation 4 15 4 16 RS485 Point to Point Connection with Handshaking In pointtopoint configuration two devices are connected to the same communication line For RS485 the maximum cable length is 1200 meters 4000 feet Modems can be used for longer distances Computer Shielded Twisted Pairs PLC BIN NCR SSNS eo tpt PIN RD A rd 12 SD A RD B i a 131SD B SD A iq lt lt ry 10 RD A SD B a 11 RD B I I1 ee CTS A a
289. rup diagnostics Slow blinking indicates the CPU is configuring I O modules Simultaneous blinking of this LED and the green Run LED indicates that the CPU is in boot mode and is waiting for a firmware update through port 1 Green when the CPU is in Run mode Amber when the CPU is in Stop lO Scan mode If this LED is OFF butOK is ON the CPU is in Stop No IO Scan mode If this LED is flashing green and the Fault LED is ON the module switch was moved from Stop to Run mode while a fatal fault existed Toggling the switch will continue to Run mode ON ifthe CPU is in Stop Faulted mode because a fatal fault has occurred To turn off the Fault LED clear both the I O Fault Table and the PLC Fault Table If this LED is blinking and the OK LED is OFF a fatal fault was detected during PLC powerup diagnostics Contact PLC Field Service ON if an override is active ona bit reference Blinking indicates activity on that port Chapter 2 CPU Module Datasheets CPU001 CPU002 CPU005 2 7 CPU with 34kB Configurable Memory IC200CPU001 CPU with 42kB Configurable Memory IC200CPU002 CPU with 64kB Configurable Memory IC200CPU005 Configurable Memory CPU0Q001 and CPU002 release 2 0 or later and CPU005 have configurable user memory The configurable memory is the amount of memory required for the application program hardware configuration registers R analog inputs AT and analog outputs AQ The amount of memory allocated to the appl
290. rver connections for use by other devices on the Ethernet network such as the PLC programmer CIMPLICITY HMI SRTP channels for Series 90 PLCs and Host Communications Toolkit applications No PLC programming is required for server operation SRTP Channels SRTP Channels can be used by a Series 90 30 or Series 90 70 PLC to communicate with CPUEO0S The CPUE05 cannot initiate SRTP channels Attachment to the Ethernet LAN The Ethernet port uses a twisted pair cable of up to 100 meters in length between each node and a hub or repeater Typical hubs or repeaters support 4 to 12 nodes connected in a star wiring topology The Station Manager Software CPUEOS provides built in Station Manager support It accommodates on line diagnostic and supervisory access through either the Station Manager port or via Ethernet Station Manager services include e An interactive set of commands for interrogating and controlling the station e Unrestricted access to observe internal statistics an exception log and configuration parameters e Password security for commands that change station parameters or operation e Access to the Station Manager requires a user provided computer terminal or terminal emulator GFK 1503C Chapter 13 Ethernet Communications 13 3 13 4 IP Addressing The CPUEOS5 must have a unique IP address that identifies it on the Ethernet network The IP Address is assigned using the configuration software as described in chapt
291. ry location as the input parameter IN The entire shifted string is written on each scan that power is received Output B2 is the last bit shifted out For example if four bits were shifted B2 would be the fourth bit shifted out 10 8 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Bit Operation Functions Shift Bits Right Shift Bits Left Parameters of the Shift Right Left Functions Input Choices Description Output enable flow When the function is enabled the shift is performed IN Q M T S G R Al IN contains the first word to be shifted AQ N 1 Q M T G R Al AQ N contains the number of places bits that the array is to constant be shifted Bl flow B1 contains the bit value to be shifted into the array B2 flow none B2 contains the bit value of the last bit shifted out of the array Q Q M T SA SB SC Output Q contains the first word of the shifted array G R Al AQ Example In the example whenever input I0001 is set the output bit string contained in the memory location represented by the nickname WORD is made a copy of of the bits in location WORD1 The output string is leftshifted by 8 bits as specified by the input LENGTH The resulting open bits at the beginning of the output string are set to the value of I0002 10001 Iof SHIFTL WORD WORD1 IN B2 OUTBIT LENGTH JL worpe 10002 t B1 Chapter 10 Instruction Set Referen
292. s 2 Status word memory type R address 3 Status word address minus 1 R0001 address 4 address 5 address 6 Operating Notes Note COMMREQs that are cancelled due to this command executing do not have their respective COMMREQ status words updated Caution If this COMMREQ is sent when a Write Bytes 4401 COMMREQ is transmitting a string from a serial port transmission is halted The position within the string where the transmission is halted is indeterminate In addition the final character received by the device the CPU is sending to is also indeterminate VersaMax PLC User s Manual March 2001 GFK 1503C Set Up Input Buffer Function 4301 GFK 1503C This function can be used to change the size of the internal memory buffer where input data will be placed as it is received By default the buffer is set to a maximum of 2K bytes As data is received from the serial port it is placed in the input buffer If the buffer becomes full any additional data received from the serial port is discarded and the Overflow Error bit in the Port Status word See Read Port Status Function is set Retrieving Data from the Buffer Data can be retrieved from the buffer using the Read String or Read Bytes function It is not directly accessible from the application program If data is not retrieved from the buffer in a timely fashion some characters may be lost Example Command Block for the Set Up Input Buffer Function VALUE VALU
293. s 4 Idle Timeout Value address 5 Maximum Communication Time address 6to Data Block address 133 Example In the example when enabling input M0020 is ON a Command Block starting at ROO016 is sent to communications task 1 in the device located at rack 1 slot 2 of the PLC If an error occurs processing the COMMREQ Q0100 is set M0020 COMM REQ Q0100 R0016 IN FT CONST _ oto2 SYSID CONST Task 00001 10 40 VersaMax PLC User s Manual March 2001 GFK 1503C Data Type Conversion Functions The Data Type Conversion functions are used to change a data item from one number type to another Many programming instructions such as math functions must be used with data of one type Convert data to BDC 4 Convert data to signed integer Convert data to double precision integer Convert data to Real Convert data to Word Round a Real number toward zero TRUN GFK 1503C Chapter 10 Instruction Set Reference 10 4 Data Type Conversion Functions Convert Signed Integer Data to BCD 4 The Convert to BCD 4 function outputs the four digit BCD equivalent of signed integer data The original data is not changed by this function Data can be converted to BCD format to drive BCD encoded LED displays or presets to external devices such as high speed counters When the function receives power flow it performs the conversion making the
294. s a constant or reference for the first value to be For INT data only I compared IN1 must be a valid number Constants must be integers Q M T G for double precision signed integer operations 1 is on the left side of the relational equation as in IN1 lt IN2 IN2 R Al AQ constant 2 contains a constant or reference for the second value to be For INT data only I compared IN2 must be a valid number Constants must be integers Q M T G for double precision signed integer operations 2 is on the right side of the relational equation as in IN1 lt IN2 Q flow none Output Q is energized when IN1 and IN2 match the specified relation Example In the example two double precision signed integers are tested for equality When the relay I0001 passes power flow to the LE Less or Equal function the value presently in the reference nicknamed PWR_MDE is compared to the value presently in the reference BIN_FUL If the value in PWR_MDE is less than or equal to the value in BIN_FUL coil QO002 is turned on ae LE INT PWR_MDE N1 Q BIN_FUL N2 ar Chapter 10 Instruction Set Reference 10 59 Relational Functions Range The Range function determines if a value is within the range of two numbers Data Types for the Range Function The Range function operates on these types of data INT Signed integer default DINT Double precision signed integer WORD Word data type When the Rang
295. s found or until the end of the array is reached If an array element is found the Found Indication FD is set ON and the Output Index output NX is set to the relative position of this element within the array If no array element is found before the end of the array is reached the Found Indication FD is set OFF and the Output Index output NX is set to zero Valid values for input NX are 0 to length 1 NX should be set to zero to begin searching at the first element This value increments by one at the time of execution Therefore the values of output NX are to length If the value of input NX is outofrange lt 0 or gt length its value defaults to zero Parameters of the Search Functions Input Choices Description Output enable flow When the function is enabled the search is performed AR Forall R Al AQ Contains the starting address of the array For INT BYTE WORD I Q M T G For BYTE WORD S Input NX 1 Q M T G R Al AQ constant Contains the zero based index into the array at which to begin the search IN For all R Al AQ constant IN contains the object of the search For INT BYTE WORD I Q M T G For BYTE WORD S Output 1 Q M T G R Al AQ Holds the one based position within the array of the NX search target FD flow none FD indicates that an array element has been found and the function was successful length 1 to 32 767 bytes or words The number of elements s
296. s the Ethernet Global Data is called the producer Each device that receives Ethernet Global Data is called a consumer Each unique Ethernet Global Data message is called an exchange PLC1 Producer PLC2 Consumer Ethernet Network Ethernet Global Data provides simple regular communication of data between devices It should not be used for event notification if possible loss of data would be significant VersaMax CPU IC200CPUE0S can be configured for up to 32 produced Ethernet Global Data exchanges total of Produced and Consumed s Each Ethernet Global Data exchange must be configured individually for each PLC and consists of one or more data ranges See chapter 6 for configuration information The Frequency of Sending Receiving an Exchange During configuration the repetition period of each Ethernet Global Data exchange is set up for the producer The range is 10 milliseconds to 1 hour which is selectable in increments of 10 mS It is not necessary to produce and consume data faster than the application requires This reduces the load on the network and on the devices providing capacity for other transfers The Consumer Update Timeout Period As part of the configuration for each consumed exchange a timeout period can be set up for the exchange The CPU reports an error if the first or subsequent packet of data has not arrived within the specified time The range is 0 for no timeout detection or 10 to 3 600 000 millisecon
297. ser s Manual March 2001 GFK 1503C SVCREQ 7 Read or Change the Time of Day Clock Use SVCREQ 7 to read or change the time of day clock in the PLC The data can be either BCD or ASCII Either 2 digit year or 4 digit year format is available The function is successful unless some number other than 0 read or 1 change is entered for the requested operation or an invalid data format is specified or data is provided in an unexpected format Parameter Block Format for SVCREQ 7 For the date time functions the length of the parameter block depends on the data format The data block is either BCD or ASCII BCD format requires 6 words packed ASCII requires 12 words 13 words for 4 digit year For both data types m Hours are stored in 24 hour format m Day of the week is a numeric value from Sunday to 7 Saturday 2 Digit Year Format 4 Digit Year Format address 0 read time and date 0 read time and date 1 set time and date 1 set time and date address 1 1 BCD format 81h BCD format 3 packed ASCII format 83h packed ASCII format address 2 data data to end Words 3 to the end of the parameter block contain output data returned by a read function or new data being supplied by a change function In both cases format of these data words is the same When reading the date and time words address 2 to the end of the parameter block are ignored on input GFK 1503C Chapter 11 The Service Request Function 11 11
298. ss 9 0008 0008 Input data memory type R address 10 0100 0064 Input data memory address R 0100 12 26 VersaMax PLC User s Manual March 2001 GFK 1503C GFK 1503C Return Data Format for the Read String Function The return data consists of the number of characters actually read the number of characters still available in the input buffer after the read is complete if any and the actual input characters Address Number of characters actually read Address 1 Number of characters still available in the input buffer if any Address 2 first two characters first character is in the low byte Address 3 third and fourth characters third character is in the low byte Address n subsequent characters Operating Note If the input data memory type parameter is specified to be a word memory type and if an odd number of bytes are actually received then the high byte of the last word to be written with the received data is set to zero As data is received from the serial port it is placed in the internal input buffer If the buffer becomes full then any additional data received from the serial port is discarded and the Overflow Error bit in the Port Status word See Read Port Status Function is set Chapter 12 Serial I O SNP RTU Protocols 12 27 Chapter 13 GFK 1503C Ethernet Communications This chapter describes the Ethernet communications features of VersaMax CPU model IC200CPUE0S O
299. stall the CPU Connect the modules and press them together until the connectors are mated After completing any additional system installation steps apply power and observe the module LEDs On indicates presence of 5VDC power Off indicates no 5VDC power PWR O EXP TX O Blinking or On indicates active communications on expansion bus Off indicates no communications Removing an Expansion Transmitter Module 1 2 3 4 4 Make sure rack power is off Slide module on DIN rail away from the CPU in the main rack Using a small screwdriver pull down on the tab on the bottom of the module and lift the module off the DIN rail VersaMax PLC User s Manual March 2001 GFK 1503C Installing an Expansion Receiver Module GFK 1503C An Expansion Receiver Module IC200ERMO001 or 002 must be installed in the leftmost slot of each VersaMax expansion rack 1 Insert the label inside the small access door at the upper left corner of the module 2 Attach the module to the DIN rail at the left end of the expansion rack 3 Select the expansion rack ID 1 to 7 using the rotary switch under the access door at upper left corner of the module Each rack must be set to a different rack ID With a single ended cable one expansion rack only set the Rack ID to 1 165 4 Install a VersaMax Power Supply module on top of the Expansion Receiver See Installing a Power Supply in
300. status of I O overrides memory into location R1003 The equality function checks R1003 to see if it is equal to the constant 1 If it is the equality function turns on output T0001 aia KEA SVC_ EQ_ eee REQ PNE INT T0001 00018 7 FNC 00001 11 Q R1003 PARM R1003 7 12 11 24 VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 23 Read Master Checksum GFK 1503C Use SVCREQ 23 to read the master checksums of the application program and the configuration The SVCREQ output is always ON if the function is enabled Output Parameter Block for SVCREQ 23 For this function the output parameter block has a length of 12 words with this format The first two items in the output parameter block indicate when the program and configuration checksums are valid Program checksums may not be valid during a Run Mode Store address Master Program Checksum Valid 0 not valid 1 valid address 1 Master Configuration Checksum Valid 0 not valid 1 valid address 2 Number of Program Blocks including _ MAIN address 3 Size of User Program in Bytes DWORD data type address 5 Program Additive Checksum address 6 Program CRC Checksum DWORD data type address 8 Size of Configuration Data in Bytes address 9 Configuration Additive Checksum address 10 Configuration CRC Checksum DWORD data type Example of SVCREQ 23 In the example when inp
301. stored to the PLC with the hardware configuration Optional not required for most systems Setting up Port 1 for Local Station Manager operation This is part of the basic CPU configuration as described in chapter 5 Note that Local Station Manager parameters are configured independently of the Port 1 parameters After the configuration is completed and stored to the PLC it is maintained in memory by the PLC CPU The configuration may be saved into and retrieved from Flash memory which provides nearly permanent backup of the configuration data across loss of power and battery backup Every time CPUE0S is powered up or has its configuration changed or cleared it delivers the Ethernet configuration data back to the Ethernet interface The Ethernet interface portion of CPUEOS saves its configuration data in battery backed memory If the CPU battery backup is lost and the configuration has not been saved to Flash the Ethernet interface loses its backup configuration data If that happens after powerup the Ethernet interface operates with its factory default settings until it is reconfigured This default operation includes reverting to an IP address of 0 0 0 0 Because the backup Ethernet configuration data is actually stored by the Ethernet interface portion of CPUE0S it is not affected by a PLC Clear Configuration operation When the PLC Configuration is cleared the CPU operates in Autoconfiguration mode as described below Autoconfigur
302. style I O Carriers Modules mount perpendicular to the DIN rail These carriers are normally used with Interposing I O Terminals as illustrated below See the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 for information about VersaMax I O Carriers Terminal style I O carriers have 36 individual terminals for direct connection of field wiring Auxiliary I O Terminal Strips are available for applications requiring additional wiring terminals Terminal style I O Carrier Compact Terminal style Connector style I O 1 0 Carrier Carrier and Interposing Terminals S FS eerie i yh SS yh E i i l oS o llo fo oO Ao K a EAn L 4 1989900080000000800 l _ pseeveesce0e0008 08 OOO aonn Auxiliary I O Terminal Strip Creer erica o AANA lo
303. t resets the Current Value to zero PV Q M T G R Al AQ The Preset Value which is used when the timer is enabled or constant none reset Q flow none Output Q is energized when the current value of the timer is greater than or equal to the Preset Value time tenths hundredths or Time increment for the low bit of the PV preset and CV current thousandths of seconds value GFK 1503C Chapter 10 Instruction Set Reference 10 75 10 76 Timer and Counter Functions On Delay Stopwatch Timer Operation of the On Delay Timer Function a42931 ENABLE _ Lo L RESET i ee a T l l l l lIl A B c D E FG H A ENABLE goes high timer starts accumulating B Current value reaches preset value PV Q goes high RESET goes high Q goes low accumulated time is reset CV 0 D RESET goes low timer then starts accumulating again E ENABLE goes low timer stops accumulating Accumulated time stays the same F ENABLE goes high again timer continues accumulating time G Current value becomes equal to preset value PV Q goes high Timer continues to accumulate time until ENABLE goes low RESET goes high or current value becomes equal to the maximum time H ENABLE goes low timer stops accumulating time When power flow to the timer stops the current value stops incrementing and is retained Output Q if energized will remain energized When the function receives power flow again the current value again inc
304. t the high end MSB LSB Bim 1 1 0 1 1 1 1 1 1 1 0 0 1 0 0 0 gt B2 A string length of 1 to 256 words can be selected for either function Enable SHIFTL WORD Word to be shifted in IN B2 Last bit shifted out Number of bits IN Q Output Bit shifted in B1 If the number of bits to be shifted N is greater than the number of bits in the array 16 the array Q is filled with copies of the input bit B1 and the input bit is copied to the output power flow B2 If the number of bits to be shifted is zero then no shifting is performed the input array is copied into the output array and input bit B1 is copied into the power flow The bits being shifted into the beginning of the string are specified via input parameter B1 Ifa length greater than 1 has been specified as the number of bits to be shifted each of the bits is filled with the same value 0 or 1 This can be The boolean output of another program function All 1s To do this use the special reference nickname ALW_ON as a permissive to input B1 All Os To do this use the special reference nickname ALW_OFF as a permissive to input B1 The function passes power flow to the right unless the number of bits specified to be shifted is zero Output Q is the shifted copy of the input string If you want the input string to be shifted the output parameter Q must use the same memo
305. ta IS retentive Q and M references that have not been declared to be retentive Q and M references that are used with non retentive coils coils negated coils S SET coils R RESET coils VersaMax PLC User s Manual March 2001 GFK 1503C Le System Status References The PLC stores system status data in predefined references in S SA SB and SC memory Each system status reference has a descriptive name For example time tick references are named T_10MS T_100MS T_SEC and T_MIN Examples of convenience references include FST_SCN ALW_ON and ALW_OFF Using the System Status References System status references can be used as needed in application programs For example the following function block uses the FST_SCN first scan status reference to control power flow to a Block Clear function In this example at powerup 32 words of Q memory 512 points beginning at QO001 are filled with zeros FST_SCN ig BLK_ CLR WORD Q0001 IN LEN 00032 GFK 1503C Chapter 9 Program Data 9 5 Ll S References References in S memory are read only Reeves Name omon removed and when the PLC fault table is cleared 50010 1O_FULL Set when the I O fault table fills up Cleared when an entry is removed from the 1 0 fault table and when the 1 0 fault table is cleared 50011 OVR_PRE Setwhen an override exists in 1 Q M or G memory 0013 PRG CHK Setwhen backgr
306. tarting at AR that make up the array to be searched Chapter 10 Instruction Set Reference 10 71 Table Functions Search for Array Values Example 1 The array AR is defined as memory addresses ROOO1 R0005 When EN is ON the portion of the array between RO0004 and R0005 is searched for an element whose value is equal to IN If R0001 7 RO002 9 RO003 6 RO004 7 ROOOS 7 and RO100 7 then the search will begin at R0004 and conclude at RO004 when FD is set ON and a 4 is written to R0101 10001 SRCH_ EQ INT Q0001 R0001 AR FD CONST NX NX o 00003 R0101 R01007 IN Example 2 Array AR is defined as memory addresses AI001 AIO16 The values of the array elements are 100 20 0 5 90 200 0 79 102 80 24 34 987 8 0 and 500 Initially AQ001 is 5 When EN is ON each sweep will search the array looking for a match to the IN value of 0 The first sweep will start searching at AI006 and find a match at AI007 so FD is ON and AQO001 is 7 The second sweep will start searching at AI008 and find a match at AIO15 so FD remains ON and AQOOI is 15 The next sweep will start at AI016 Since the end of the array is reached without a match FD is set OFF and AQO01 is set to zero The next sweep will start searching at the beginning of the array 10001 SRCH_ EQ I INT M001 Al001 7 AR FD Ce AQ001 NX NX o 00005 AQ001
307. ten to could contain overrides due to additional overhead The times shown in the following table represent the time to transfer one data byte Consumed Exchange Produced Exchange Byte Transfer Time 1 3 6 Times are in microseconds Represents transfer time if memory type supports overrides Appendix A Performance Data A 13 Support for Large Ethernet Global Data Configurations The VersaMax CPUEO0S Ethernet Global Data EGD feature supports a configuration of up to 32 exchanges at periods as short as 10 ms with data sizes as large as 1400 bytes However the CPUEOS cannot support a configuration in which every aspect of EGD is maximized The chart below indicates the maximum number of EGD exchanges that the CPUEOS can realistically support of a certain size and data refresh period under Best Case conditions These numbers will scale downwards based on the size of the user program the presence of other Ethernet traffic etc The term Best Case indicates the following setup parameters apply No user logic is present so the logic sweep time is nearly 0 There are no modules present in the system No other Ethernet traffic present on the network Assumed data refresh timeout is 2x refresh period 10ms CPUE05 System Best Case EGD Capacity Number of 16 Exchanges 200 Supported 400 Period of Exchange ms 40 a Size per Exchange bytes VersaMax PLC User s Manual March 2001 GFK 1
308. term When itis set to the derivative action is applied to PV All remaining bits ould be zero it 3 Deadband action When the Deadband action bit is 0 then no deadband action is chosen If the error is within the deadband limits then the erroris to be zero Otherwise the error is not affected by the deadband limits Ifthe Deadband action bit is 1 then deadband action is chosen If the error is within the deadband limits then the error is forced to be zero If however the error is outside the deadband limits then the error is reduced by the deadband limit error error deadband limit Bit 4 Antireset windup action When this bit is 0 the antireset windup action uses a reset back calculation When he output is clamped this replaces the accumulated Y remainder value with whatever value is necessary to produce the clamped output exactly When the bit is 1 this replaces accumulated Y erm with the value of the Y term at the start of the calculation In this way the preclamp Y value is held as long as the output is clamped Remember that the bits are set in powers of 2 For example o set Config Word to 0 for default PID configuration you would add 1 to change the Error Term from SP PV to PV SP oradd 2 to change the Output Polarity from CV PID Output to CV PID Output or add 4 to change Derivative Action from Error rate of change to PV rate of change etc Set to the current CV output while the PID block is in Automatic mode
309. tes has timed out been canceled or finished ite Success Se Previously invoked Write Bytes has successfully completed New Write Bytes invoked 10 WT Write Time out Se Transmit timeout occurred during Write Bytes Cleared New Write Bytes invoked Se Unread characters are in the buffer eared No unread characters in the buffer Overflow error occurred on the serial port or internal buffer atus invoked 5 CT CTS is active Se CTS line on the serial port is active or the serial port does not have a CTS line CTS line on the serial port is not active notused shouldbeo J o ooo VersaMax PLC User s Manual March 2001 GFK 1503C Write Port Control Function 4304 GFK 1503C This function forces RTS for the specified port Example Command Block for the Write Port Control Function te ete Fe decimal hexadecimal address Data block length address 1 address 2 Status word memory type R address 3 Status word address minus 1 R0001 address address 5 0000 0000 Not used address 6 304 address 7 00 Port Control Word a5 ae ete ir vo oe e sri eS ae a ieee 0 The Port Control Word can be 15 RTS Commanded state of the RTS output 1 Activates RTS 0 Deactivates RTS 0 144 U Unused should be zero Operating Note For CPU port 2 RS 485 the RTS signal is also controlled by the transmit driver Therefore control of RTS is dependent on the current state of the trans
310. the consumed exchange will be placed See chapter 13 for details of the status value Note that the Status Word address must be unique itis not automatically assigned the next highest address example Offset Reference Low Point High Point Description Status R Status Where the PLC will place the status data 6 6 VersaMax PLC User s Manual March 2001 GFK 1503C a Defining a Global Data Exchange for a Consumer continued Time Stamp A data range that identifies the memory location where the timestamp of the last data packet will be placed The timestamp is not an actual date itis an 8 byte value representing the time elapsed since midnight J anuary 1 1970 The first four bytes contain a signed integer representing seconds and the next four bytes contain a signed integer representing nanoseconds This value represents the time in the producer when the data sample originated It can be examined to determine if a new packet received from the network has a new data sample or if itis the same data received previously The timestamp information produced by the PLC currently has a resolution of 100 microseconds if no network synchronization is used If NTP is used to perform network time synchronization the timestamp information has a resolution of 1 millisecond and has 10 millisecond accuracy between PLCs on the same LAN NTP may be enabled in the configuration of the CPUE05 Once NTP time synchronization is configured
311. thernet LEDs section earlier in this chapter for descriptions of runtime diagnostic fatal error codes All Ethernet Global Data EGD exchanges default to status code 18 0012H during a loss or reset of the Ethernet interface EGD operation will resume after the restart is complete These restart and runtime errors occur when the CPUE0S5 cannot process the attempted volume of EGD and or SRTP requests As these errors have been observed only when the CPUE0S is connected to a repeater type network hub the primary remedy is to replace the repeater type hub with a switching type network hub A secondary remedy is to reduce the number size or frequency of the EGD exchanges and or transfers over SRTP connections GFK 1503C Chapter 13 Ethernet Communications 13 23 EGD Configuration Mismatch Errors When using Ethernet Global Data the produced exchange defined at the producer must agree with the consumed exchange defined at the consumer The consumer generates an error when the size of an exchange received from the network differs from the configured size for that consumed exchange This error is indicated in the PLC Fault Table as LAN system software fault resuming with exception Event 28 Entry 2 1d As this error is generated each time the mismatched exchange is received the Ethernet exception log can quickly fill up with mismatch error events Cause Corrective Action Producer and Consumer Review the conflicting ex
312. this chapter for details 5 Attach the cables If the system includes an Expansion Transmitter Module attach the terminator plug to the EXP2 port on the last Expansion Receiver Module 6 After completing any additional system installation steps apply power and observe the module LEDs On indicates presence of 5VDC power PWR Green indicates CPU NIU is scanning SCAN I O in expansion racks EXP RX Amber indicates not scanning Blinking or On indicates module is communicating on expansion bus Off indicates module not communicating Removing an Expansion Receiver Module 1 Make sure rack power is off 2 Uninstall the Power Supply module from the Expansion Receiver Module 3 Slide the Expansion Receiver Module on DIN rail away from the other modules 4 Using a small screwdriver pull down on the tab on the bottom of the module and lift the module off the DIN rail Chapter 4 Installation 4 5 4 6 Expansion Rack Power Sources Power for module operation comes from the Power Supply installed on the Expansion Receiver Module If the expansion rack includes any Power Supply Booster Carrier and additional rack Power Supply it must be tied to the same source as the Power Supply on the Expansion Receiver Module Connecting the Expansion Cable RS 485 Differential For a multiple rack expansion system connect the cable from the expansion port on the Expansion Transmitter to the Expansion Receivers as shown
313. tion CPU Operation Configuration Configuration Off has no effect has no effect All modes are allowed On has no effect Run On All modes are allowed On has no effect Stop Off CPU not allowed to go to Run mode Off has no effect Toggle Switch from CPU goes to Run mode if no fatal faults are Stop to Run present otherwise the Run LED blinks for 5 seconds On No Toggle switch from PLC goes to STOP NO I0 Run to Stop On Yes Toggle switch from PLC goes to STOP 10 Run to Stop VersaMax PLC User s Manual March 2001 GFK 1503C Flash Memory GFK 1503C A VersaMax PLC stores the current configuration and application in non volatile battery backed RAM The programmer software can be used to store a copy of the current configuration application program and reference tables excluding overrides to Flash memory The programmer can also be used to read a previously stored configuration application program or reference tables from Flash into RAM or to verify that Flash and RAM contain identical data By default the PLC reads the configuration program logic and reference tables from RAM at powerup However it can be configured to read them from Flash This is recommended because data in Flash is non volatile even in the case of a battery failure Chapter 7 CPU Operation 7 9 Privilege Levels and Passwords Passwords are an optional configurable feature of the VersaMax PLC Passwords provide different levels of access
314. tions SNP RTU Serial I O or local Station Manager use While Port 1 is configured as a local Station Manager it cannot be used for CPU serial communications or firmware loading However if the port is configured as a CPU port instead the default setting it can temporarily be forced to local Station Manager operation using the Restart pushbutton or using the chport1 Station Manager command The CPUEOS5 also supports remote Station Manager operation over the Ethernet network via UDP protocol With UDP protocol the remote station is addressed via an IP address Unlike some Series 90 Ethernet products CPUEOS5 cannot send or receive remote Station Manager messages that have been sent to a specified MAC address For a detailed description of Station Manager functions please refer to GFK 1876 the VersaMax PLC Ethernet Station Manager User s Manual Chapter 13 Ethernet Communications 13 21 Troubleshooting Common Ethernet Difficulties Some common Ethernet errors are described below Ethernet errors are generally indicated in the PLC Fault Table and the Ethernet exception log As previously explained in Using the PLC Fault Table PLC Faults generated by the Ethernet interface contain Ethernet exception events within the extra fault data See the VersaMax Station Manager Manual GFK 1876 for detailed descriptions of Ethernet exception events PLC Timeout Errors When the SRTP traffic to the CPUEOS5 exceeds the PLC s ability
315. tions 13 7 13 8 Timestamping of Ethernet Global Data Exchanges The PLC CPU adds a timestamp to each Ethernet Global Data Message it produces The timestamp indicates when the data was transferred from the producing PLC s CPU to its Ethernet interface for transmission over the network The PLC CPU obtains the timestamp data from the time clock in the Ethernet interface The CPU only uses this timestamp for Ethernet Global Data exchanges The timestamp from the Ethernet interface does not affect the time of the CPU s internal time clock CPUE05 CPU time clock EGD with imestamp Ethernet interface j Synchronizing the Timestamp The timestamp clock in the Ethernet interface is synchronized to either the clock in the CPU or an external Network Time Protocol NTP server The CPU Time Clock If no NTP servers are configured the Ethernet interface s built in time clock is synchronized once at power up or restart to the clock in the CPU Because the clocks in the other devices on the network are not synchronized with the CPUEOS their timestamps cannot be compared accurately CPUE05 K timestamp Ethernet interface VersaMax PLC User s Manual March 2001 GFK 1503C NTP Server s Time Clock If time servers are configured and present on the network see chapter 6 for configuration details the Ethernet int
316. tive Negated ON Sets reference OFF non retentive OFF Sets reference ON non retentive Retentive M ON Sets reference ON retentive OFF Sets reference OFF retentive Negated Retentive M ON Sets reference OFF retentive OFF Sets reference ON retentive Positive Transition P OFF ON __ If power flow into the coil was OFF the previous sweep and is ON this sweep sets the coil ON Negative Transition N ON OFF _ If power flow into the coil was ON the previous sweep and is OFF this sweep sets the coil ON SET S 0 Sets reference ON until resetOFF by R non retentive OFF Does not change the coil state non retentive RESET R 0 Sets reference OFF until setON by S non retentive OFF Does not change the coil state non retentive Retentive SET SM 0 Sets reference ON until reset OFF by RM retentive OFF Does not change the coil state Retentive RM 0 Sets reference OFF until set ON by SM retentive OFF Does not change the coil state Continuation Coil lt gt 0 Sets next continuation contact ON OFF Sets next continuation contact OFF VersaMax PLC User s Manual March 2001 GFK 1503C Relay Functions Coils GFK 1503C A coil sets a discrete reference ON while it receives power flow It is nonretentive therefore it cannot be used with system status references SA SB SC or G Example In the example coil E3 is ON when reference E1 is ON and reference E2 is OF
317. to process the requests PLC Timeout errors may occur PLC Timeout errors will take down an SRTP Server connection in this case the remote SRTP client must reestablish a new SRTP connection to the CPUEOS This error is indicated in the PLC Fault Table as Backplane communication with PLC fault lost request with exception Event 8 Entry 2 8 Backplane communication with PLC fault lost request no exception Event These errors may also be accompanied by either of the following Backplane communication with PLC fault lost request with exception Event 8 Entry 2 6 LAN system software fault resuming with exception Event 8 Entry 2 16 The PLC Timeout condition occurs when the CPUE0S5 cannot process requests within a specified timeout period The remedy is to reduce the requests or increase the processing capacity in the PLC Cause Corrective Action Heavy SRTP traffic Reduce the size number or frequency of SRTP requests at the remote SRTP client Long PLC sweep time Modify the PLC application to reduce the PLC sweep time PLC Communication Window set Change to RUN TO COMPLETION mode to LIMITED mode If none of the above corrective actions is feasible the timeout interval may be lengthened The timeout interval is specified by the crsp_tmot Advanced User Parameter The default timeout value is 15 seconds See Configuring Advanced User Parameters in chapter 6 to change Advan
318. twork The default is the same as the IP address of the CPUEO5 The default can be changed Exchange ID A number that identifies that specific data exchange It must match the Exchange ID Specified in the produced exchange in the sending device Adapter Name Always 0 0 for CPUE05 Producer ID The Local Producer ID of the device sending the exchange Used only if the same data is consumed by more than one consuming device Enter the same Group ID that has been configured as the Consumer Address in the producer device Consumer Not used Default is 200mS Period Update Timeout The maximum time the Ethernet interface allows between seeing samples on the network without reporting a refresh error status This error status means a first or subsequent packet of data has not arrived within the specified time The range is 0 or 10 3 600 000 milliseconds The value should be at least double the producer s producer period value The default is 0 which disables timeout detection The update timeout period should be greater than the exchange production period A value at least twice the production period is recommended Round this value to the nearest 10 milliseconds before you enter it The update timeout has a resolution of 10 milliseconds If you enter a value such as 22 milliseconds the actual update timeout will be rounded up to 30 milliseconds Status Word A data range that identifies the memory location where the status value for
319. twork and or network operation may be disrupted Itis especially important that each node on the network is assigned a unique IP address These values should be assigned by the person in charge of your network the network administrator TCP IP network administrators are familiar with these parameters If you have no network administrator and are using a simple isolated network with no gateways you can use the following values as local IP addresses 10 0 0 2 First PLC 10 0 0 3 Second PLC 10 0 0 4 Third PLC 10 0 0 254 PLC Programmer or host Also in this case set the subnet mask and Gateway IP address to 0 0 0 0 See chapter 13 for more detailed information about IP Addressing and gateways Note If this simple isolated network is ever connected to another network the IP addresses 10 0 0 2 through 10 0 0 254 must not be used and the subnet mask and Gateway IP address must be assigned by the network administrator The IP addresses must be assigned so that they are compatible with the connected network Status Address The beginning reference for 10 bytes of Ethernet status data The content of this data is described in chapter 13 Checking the Status of the Ethernet Interface The Status address can be assigned to 1 Q R Al or AQ memory The default value is the next available 1 address Note Do not use the 10 bytes assigned to the Status bits for other purposes or your data will be overwritten Status Length This value is
320. ty Not Equal Test two numbers for nonequality Greater Than Test whether one number is greater than another Greater Than or Equal Test whether one number is greater than or equal to another Less Than Test whether one number is less than another Less Than or Equal Test whether one number is less than or equal to another Range Tests whether one number lies between two other numbers When the function receives power flow it compares input IN1 to input IN2 These parameters must be the same data type Enable 7 EQ_ INT Input 1 1 Q Output Input 2 7 12 If inputs IN1 and IN2 match the specified relational condition output Q receives power flow and is set ON 1 otherwise it is set OFF 0 Data Types for Relational Functions Relational functions operate on these types of data INT Signed integer DINT Double precision signed integer REAL Floating Point The S0020 bit is set ON when a relational function using Real data executes successfully Itis cleared when either input is NaN Not a Number 10 58 VersaMax PLC User s Manual March 2001 GFK 1503C Relational Functions Equal Not Equal Less Than Less Equal Greater Than Greater Equal Parameters for the Relational Functions GFK 1503C Input Choices Description Output enable flow When the function is enabled the operation is performed IN1 R Al AQ constant 1 contain
321. ual to the length input Dwell Time R Al AQ This optional input array of words has one element for each element in the Pattern none array Each value in the array represents the dwell time for the corresponding step of the Drum Sequencer in 0 1 second units When the dwell time expires for a given step the Dwell Timeout bit is set If a Dwell Time is specified the drum cannot sequence into its next step until the Dwell Time has expired Fault R Al AQ This optional input array of words has one element for each element in the Pattern Timeout none array Each value in the array represents the fault timeout for the corresponding step of the Drum Sequencer in 0 1 second units When the fault timeout has expired the Fault Timeout bit is set Control R The beginning reference address of the function s parameter block The length of Block the Control Block is 5 words A more complete description of what is contained within this block is listed below Length CONST Value between 1 and 128 that specifies the number of steps ok flow none OK is energized if Enable is On and no error condition is detected If Enable is Off this output will always be Off OUT Q M T G A word of memory containing the element of the Pattern Array that corresponds to R Al AQ the current Active Step Drum Coil Q M T G This optional bit reference is set whenever the function block is enabled and Active none Step is not equal to Preset Step Dwell Q
322. ug Pin Connector Crimp ITT Cannon DEAQPK87F0 030 2487 017 AMP 205204 1 66506 9 Solder ITT Cannon ZDE9P AMP 747904 2 Connector Kit ITT Cannon DE121073 54 9 pin size backshell kit Shell Metal P lated Plastic Plastic with Nickel over Copper t Cable Grounding Clamp included 40 cable exit design to maintain low profile installation Plus ITT Cannon 250 8501 010 Extended J ackscrew Threaded with 4 40 for secure attachment to CPU001 port t Order Qty 2 for each cable shell ordered f Critical Information any other part selected should meet or exceed this criteria Use of this kit maintains the 70mm installed depth 4 14 VersaMax PLC User s Manual March 2001 GFK 1503C Port 2 RS 485 Pin Assignments for Port 2 Port 2 is an RS 485 port with a 15 pin female D sub connector This can be attached directly to an RS 485 to RS 232 adapter 1 shp f Cable Shield Drain wire connection CEAT es P5V 5 1VDC to power external devices 100mA max Request to Send A output ono 0v GNDrreferencesina SSCS Clear to Send B input a el Resistor Termination 120 ohm for RDA 10 RDA Receive Data A input 11 Receive Data B input 12 Transmit Data A output 13 Transmit Data B output 14 Request to Send B output 15 Clear to Send A input Shell SHLD Cable Shield wire connection 100 Continuous shielding cable shield connection Connector and Cable Specifications for Port 2 Vendor Pa
323. umber occupies registers ROO05 and R0006 then RO0005 is the least significant register and RO0006 is the most significant register The range of numbers that can be stored in this format is from 1 401298E 45 to 3 402823E 38 and the number zero Errors in Real Numbers and Operations Overflow occurs when a number greater than 3 402823E 38 or less than 3 402823E 38 is generated by a REAL function The ok output of the function is set OFF and the result is set to positive infinity for a number greater than 3 402823E 38 or negative infinity for a number less than 3 402823E 38 You can determine where this occurs by testing the sense of the ok output POS_INF 7F800000h IEEE positive infinity representation in hex NEG_INF FF800000h IEEE negative infinity representation in hex If the infinities produced by overflow are used as operands to other REAL functions they may cause an undefined result This result is referred to as NaN Not a Number For example the result of adding positive infinity to negative infinity is undefined When the ADD_REAL function is invoked with positive infinity and negative infinity as its operands it produces NaN for its result VersaMax PLC User s Manual March 2001 GFK 1503C TimeTick Contacts GFK 1503C There are four timetick contacts They can be used to provide regular pulses of power flow to other program functions The four time tick contacts have time durations of 0 01 seco
324. unding are located in the VersaMax Modules Power Supplies and Carriers Manual GFK 1504 4 1 4 2 Mounting Instructions All VersaMax modules and carriers in the same PLC rack must be installed on a single section of 7 5mm X 35mm DIN rail Imm thick Steel DIN rail is recommended The DIN rail must be electrically grounded to provide EMC protection The rail must have a conductive unpainted corrosion resistant finish DIN rails compliant with DIN EN50022 are preferred For vibration resistance the DIN rail should be installed on a panel using screws spaced approximately 15 24cm 6 inches apart The base snaps easily onto the DIN rail No tools are required for mounting or grounding to the rail ALLA Removing the CPU from the DIN Rail Turn off power to the power supply 2 If the CPU is attached to the panel with a screw remove the power supply module Remove the panel mount screw 3 Slide the CPU along the DIN rail away from the other modules until the connector disengages 4 With a small flathead screwdriver pull down on the DIN rail latch tab s on the bottom of the module and lift the module off the DIN rail VersaMax PLC User s Manual March 2001 GFK 1503C Panel Mounting For maximum resistance to mechanical vibration and shock the equipment must also be installed on a panel Using the module as a template mark the location of the module s panel mount hole on the panel Dr
325. ups of 8 16 Point Module C200MDL640 nput 5 12VDC TTL Positive Negative Logic 16 Point Module C200MDL643 nput 5 12VDC TTL Positive Negative Logic Grouped 32 Point Module C200MDL644 nput 24VDC Positive Negative Logic 4 Groups of 8 32 Point Module C200MDL650 Discrete Output Modules Output 120VAC 0 5A per Point Isolated 8 Point Module C200MDL329 Output 120VAC 0 5A per Point Isolated 16 P oint Module C200MDL330 Output 120VAC 2 0A per Point Isolated 8 Point Module C200MDL331 Output 24VDC Positive Logic 2 0A per Point 1 Group of 8 w ESCP 8 Point Module C200MDL730 Output 12 24VDC Positive Logic 0 5A per Point 1 Group of 16 16 Point Module C200MDL740 Output 24VDC Positive Logic 0 5A per Point 1 Group of 16 w ESCP 16 Point Module C200MDL741 Output 24VDC Positive Logic 0 5A per Point 2 Groups of 16 w ESCP 32 Point Module IC200MDL742 Output 5 12 24VDC Negative Logic 0 5A per Point 1 Group of 16 16 Point Module C200MDL743 Output 5 12 24VDC Negative Logic 0 5A per Point 2 Groups of 16 32 Point Module C200MDL744 Output 12 24VDC Positive Logic 0 5A per Point 2 Groups of 16 32 Point Module C200MDL750 Output Relay 2 0A per Point Isolated Form A 8 Point Module C200MDL930 Output Relay 2 0A per Point Isolated Form A 16 Point Module C200MDL940 VersaMax PLC User s Manual March 2001 GFK 1503C Discr
326. ustrial environments that utilize antistatic materials such as concrete or wood flooring If the equipment is used in an environment that contains static material such as carpets personnel should discharge themselves by touching a safely grounded surface before accessing the equipment m If the AC mains are used to provide power for I O these lines should be suppressed prior to distribution to the I O so that immunity levels for the I O are not exceeded Suppression for the AC I O power can be made using linerated MOVs that are connected linetoline as well as linetoground A good highfrequency ground connection must be made to the linetoground MOVs m AC or DC power sources less than 50V are assumed to be derived locally from the AC mains The length of the wires between these power sources and the PLC should be less than a maximum of approximately 10 meters m Installation must be indoors with primary facility surge protection on the incoming AC power lines m In the presence of noise serial communications could be interrupted Chapter 4 Installation 4 19 Chapter 5 GFK 1503C CPU Configuration This chapter describes the process by which a VersaMax CPU and the modules it serves are configured Configuration determines certain characteristics of module operation and also establishes the program references that will used by each module in the system Autoconfiguration or programmer configuration Configuring racks and
327. ut 10251 is ON the master checksum information is placed into the parameter block at R0050 and the output coil QO001 is turned on l0251 Q0001 l SVC_ REQ aos FNC R0050 PARM Chapter 11 The Service Request Function 11 25 SVCREQ 26 30 Interrogate I O Use SVCREQs 26 and 30 to check whether the installed modules match the software configuration If not these SVCREQs place appropriate addition loss and mismatch faults in the PLC and or I O fault tables SVCREQs 26 and 30 both perform the same function The more configuration faults there are the longer it takes these SVCREQs longer to execute These SVCREQs have no parameter block They always output power flow Example of SVCREQ 26 In the example when input 10251 is ON the SVCREQ checks the installed modules and compares them to the software configuration Output QO001 is turned on after the SVCREQ is complete l0251 Q0001 SVC_ REQ CONST 00026 FNC R0050 7 PARM 11 26 VersaMax PLC User s Manual March 2001 GFK 1503C SVCREQ 29 Read Elapsed Power Down Time GFK 1503C Use SVCREQ 29 to read the amount of time elapsed between the last power down and the most recent powerup If the watchdog timer expired before power down the PLC is not able to calculate the power down elapsed time so the time is set to 0 The SVCREQ output is always ON Output Parameter Block for SVCREQ 29 This functi
328. utput Parameters of the Logical Invert Function Input Choices Description Output enable flow When the function is enabled the operation is performed I1 1 Q M T S G R Al Constant or reference for the word to be negated AQ constant ok flow none The OK output is energized whenever enable is energized Q l Q M T SA SB SC Output Q contains the result of the operation notS G R Al AQ Example In the example whenever input I0001 is set the bit string represented by the nickname TAC is set to the inverse of bit string CAT AS NOT WORD CAT 1 QF TAC GFK 1503C Chapter 10 Instruction Set Reference 10 7 Bit Operation Functions Shift Bits Right Shift Bits Left The Shift Left function shifts all the bits in a word or group of words to the left by a specified number of places When the shift occurs the specified number of bits is shifted out of the output string to the left As bits are shifted out of the high end of the string the same number of bits is shifted in at the low end MSB LSB B2 1 1 0 1 1 1 1 1 1 1 0 0 1 0 o o est The Shift Right function is used to shift all the bits in a word or group of words a specified number of places to the right When the shift occurs the specified number of bits is shifted out of the output string to the right As bits are shifted out of the low end of the string the same number of bits is shifted in a
329. value equivalent of the input data The original data is not changed by this function When the function receives power flow it performs the conversion making the result available via output Q The function passes power flow when power is received unless the specified conversion would result in a value that is out of range Note that loss of precision can occur when converting from Double Precision Integer to Real data because since the number of significant bits is reduced to 24 Enable INT_ OK TO REAL Value to be converted IN Q Output Parameters of the Convert to Real Function Input Choices Description Output enable flow When the function is enabled the conversion is performed IN R Al AQ constant IN contains a reference for the integer value to be converted to For INT only Q M T G Real ok flow none OK is energized when the function is performed without error Q R Al AQ The Real form of the original value in IN Example In the example the integer value of input IN is 678 The result value placed in T0016 is 678 000 10002 te INT TO REAL T00017 IN Q R0016 GFK 1503C Chapter 10 Instruction Set Reference 10 45 Data Type Conversion Functions Convert Real Data to Word Data The Convert to Word function outputs the Word equivalent of Real data The original data is not changed by this function When the function receives power f
330. vative term is used Once initial gains are determined convert them to integers Calculate the Process gain K as a change in input PV Counts divided by the output step change in CV Counts and not in process PV or CV engineering units Specify all times in seconds Once Kp Ki and Kd are determined Kp and Kd can be multiplied by 100 and entered as integer while Ki can be multiplied by 1000 and entered into the User Parameter RefArray VersaMax PLC User s Manual March 2001 GFK 1503C Sample PID Call GFK 1503C The following PID example has a sample period of 100Ms a Kp gain of 4 00 and a Ki gain of 1 500 The set point is stored in R0001 the control variable output in AQ0002 and the process variable is returned in AI0003 CV Upper and CV Lower Clamps must be set in this case to 20000 and 4000 and an optional small Dead Band of 5 and 5 has been included The 40 word RefArray starts in R0100 Normally User Parameters are set in the RefArray but M0006 can be set to reinitialize the 14 words starting at RO102 Ref 2 from constants stored in logic a useful technique M0006 wey BLK BLKMV BLKMV F CLR INT INT CONST IN1 QF R00102 CONST IN1QP R001 7 WORD 00010 00102 320000 7AOO108 ject came CONST IN2 CONST J IN2 00035 00005 00400 CONST IN3 CONST IN3 00005 00000 CONST 7 IN4 CONST 7 IN4 00400 00000 CONST 7 INS CONST 7 INS 00000 00000 CONST
331. ver if possible STAT No exception detected FORTS Amter PORT 1 Forced to Station Manager use Software Load No action necessary the Ethemet WD soy blink green Loading new firmware via CPU serial port interface restarts automatically after STAT all LEDS blink in loading is complete PORT 9 unison VersaMax PLC User s Manual March 2001 GFK 1503C Using the PLC Fault Table Most error conditions involving the Ethernet interface generate faults in the PLC Fault table The table on the next page lists Ethernet interface faults and corrective actions To display fault text for the Ethernet interface access the PLC Fault Table from the programmer For the Ethernet interface the leftmost 14 digits of extra fault data show the corresponding log Events 2 digits and Entries 2 3 4 5 and 6 in that order 4 digits each and other optional data The following example reports an Event 8 Entry 2 9 Entry 3 4 Entry 4 22H Entry 5 1 Entry 6 c74H and SCode 80050028H 0800090004002200010c7480050028000000000000000000 SCode Entry 6 Entry 5 Entry 4 Entry 3 Entry 2 Event This information can be used to refer directly to detailed fault descriptions included in the Log event table under the LOG command in the VersaMax PLC Station Manager Manual Please note some internal system errors display error messages as ASCII text in the fault extra data GFK 1503C Chapter 13 Ethernet Communications 13 17
332. verview of the Ethernet interface IP Addressing Routers Ethernet Global Data Checking the status of an Ethernet Global Data exchange Diagnostic Tools Troubleshooting Common Ethernet Difficulties 13 1 Overview of the Ethernet Interface VersaMax CPU model IC200CPUE0S has a built in Ethernet interface that makes it possible to communicate on a 10BaseT network in either half duplex or full duplex mode Using 10 100 hubs allows CPUE0S5 to communicate on a network containing 100Mb devices Host Computer or Control Device Running a Host Communications Toolkit Application Series 90 70 PLC with Programmer Software O Ethemet Interface runninng on a PC VersaMax PLC with VersaMax PLC with Series 90 30 PLC with CPUE05 CPUE05 ll C EP eles amp ey Ethemet Cable ll Use the Ethernet interface to Send and receive Ethernet Global Data Ethernet Global Data can be used for highly efficient periodic data transfer on the LAN Access data from CPUE05 using a Host computer Computer applications can access data from CPUE0S through its SRTP server capability Communicate simultaneously to multiple devices The multiplexing capabilities of Ethe
333. viously configured modules are not removed from the configuration during autoconfiguration unless no modules are present in the system For example if modules are configured in slots 1 2 and 3 then power is removed and the module in slot 1 is removed when power is reapplied the modules in slots 2 and 3 are autoconfigured normally The original module in slot is not removed from the configuration The CPU generates a loss of module diagnostic for slot 1 Different Module Present During Autoconfiguration If a slot was previously configured for one module type but has a different module installed during autoconfiguration the CPU generates a configuration mismatch diagnostic The slot remains configured for the original module type Unconfigured Module Installed After Autoconfiguration If a module that was not previously configured is installed after powerup the CPU generates an extra module diagnostic and the module is not added to the configuration Previously configured Module Installed After Autoconfiguration If a module that was previously configured but missing at powerup is installed after powerup the CPU generates an addition of module diagnostic and the module is added back into the TO scan All Modules Removed After Autoconfiguration If all modules are absent at powerup the CPU clears the configuration This allows modules to be inserted and added to the configuration at the next powerup VersaMax PLC User s Manual M
334. weep Time mode becomes the default sweep mode The Constant Sweep Timer During operation in Constant Sweep Time mode the CPU s Constant Sweep Timer controls the length of the sweep The timer length can be 5 to 500 milliseconds The time should be at least 10 milliseconds longer than the CPU s sweep time when it is in Standard Sweep mode to prevent extraneous oversweep faults If the Constant Sweep Timer expires before the sweep completes the CPU still completes the entire sweep including the windows However it automatically provides noticewhen a too long sweep has occurred On the next sweep after the oversweep the CPU places an oversweep alarm in the PLC fault table Then at the beginning of the following sweep the CPU sets the OV_SWP fault contact SA0002 The CPU automatically resets the OV_SWP contact when the sweep time no longer exceeds the Constant Sweep Timer The CPU also resets the OV_SWP contact if it is not in Constant Sweep Time mode As with other fault contacts the application program can monitor this contact to keep informed about the occurrence of oversweep conditions Enabling Disabling Constant Sweep Time Reading or Setting the Length of the Timer SVCREQ can be included in the application program to enable or disable Constant Sweep Time mode change the length of the Constant Sweep Time read whether Constant Sweep Time is currently enabled or read the Constant Sweep Time length Chapter 7 CPU Operat
335. x A Performance Data A 7 I O Module Scan Times The tables that follow show typical scan times for modules in a VersaMax PLC Each module was configured with its default settings and user power was applied when applicable Four tables are included Modules Located in Main Rack Modules Located in Local Single Rack Modules Located in Multiple Remote Rack Modules Located in Isolated Rack Reference to Discrete Module Types in the Scan Time Tables In the scan time tables discrete modules are grouped by type Module Type Module Catalog Number IC200 Discrete Input Type 1 DL140 DL141 DL143 DL144 DL631 DL635 DL640 DL643 DD842 DD843 DD844 DD845 DD846 DD847 DD848 DD849 DD850 DL930 Discrete Input Type 2 DL240 DL241 DL243 DL244 DL632 DL636 DL644 DL650 DD840 Discrete Output Type 1 DL329 DL331 DL740 DL741 DL743 DD842 DD843 DD844 DD845 DD846 DD847 DD848 DD849 DD850 Discrete Output Type 2 DL330 DL742 D744 DL750 DL840 DL940 Discrete Output w ESCP MDL730 Per Point Fault R eporting For additional information on VersaMax I O Modules please refer to VersaMax Modules Power Supplies and Carrier User s Manual GFK 1504 A 8 VersaMax PLC User s Manual March 2001 GFK 1503C Modules Located in Main PLC Rack CPU005 CPUE05 CPU001 CPU002 Main Rack 1 1 3 1 3 5 2 3 3 Module Type Discrete Input Type 1 lt eo
336. y this function When the function receives power flow it performs the conversion making the result available via output Q The function always passes power flow when power is received unless the real value is out of range Enable Value to be converted REAL TO DINT IN Q OK Output Note that loss of precision can occur when converting from Real type data to Double Precision Integer because Real data has 24 significant bits Parameters of the Convert to Double Precision Signed Integer Function Input Choices Description Output enable flow When the function is enabled the conversion is performed IN 1 Q M T G R Al AQ Constant or reference for the value to be converted constant ok flow none OK is energized whenever enable is energized unless the real value is out of range Q R Al AQ Reference that contains the double precision signed integer form of the original value Example In the example whenever input I0002 is set the integer value at input location 10017 is converted to a double precision signed integer and the result is placed in location RO001 The output Q1001 is set whenever the function executes successfully l0002 Q1001 INT TO DINT 10017 IN Q F R0001 VersaMax PLC User s Manual March 2001 GFK 1503C Data Type Conversion Functions Convert to Real Data The Convert to Real function outputs the real
337. ycling PLC power and when the configuration matches the hardware Chapter 9 Program Data 9 7 9 8 Reference Name Definition SB0001 9 reserved SB0010 BAD_RAM Set when the CPU detects corrupted RAM memory at powerup Cleared when RAM memory is valid at powerup SB0011 BAD PWD Set when a password access violation occurs Cleared when the PLC fault table is cleared SB0012 reserved SB0013 SFT_CPU Set when the CPU detects an unrecoverable error in the software Cleared by clearing the PLC fault table SB0014 STOR_ER Set when an error occurs during a programmer store operation Cleared when a store operation is completed successfully SC0001 8 reserved SC0009 ANY_FLT Set when any fault occurs Cleared when both fault tables have no entries SC0010 SY_FLT Set when any fault occurs that causes an entry to be placed in the PLC fault table Cleared when the PLC fault table has no entries SC0011 IO_FLT Set when any fault occurs that causes an entry to be placed in the 1 0 fault table Cleared when the I O fault table has no entries SC0012 SY_PRES Set as long as there is at least one entry in the PLC fault table Cleared when the PLC fault table has no entries SC0013 IO_PRES Setas long as there is at least one entry in the I O fault table Cleared when the 1 0 fault table has no entries SC0014 HRD_FLT Set when a hardware fault occurs Cleared when both fault tables have n
338. ytes OoOagaqgq oo Oo 00 Read Bytes O Read String Details of RTU and SNP protocol are described in the Serial Communications User s Manual GFK 0582 GFK 1503C 12 1 Format of the Communication Request Function Serial I O is implemented through the use of Communication Request COMMREQ functions The operations of the protocol such as transmitting a character through the serial port or waiting for an input character are implemented through the COMMREQ function block In CPUEOS5 Serial I O is not available for Port 1 when that port is configured or forced for Station Manager operation The COMMREQ requires that all its command data be placed in the correct order in a command block in the CPU memory before it is executed The COMMREQ should then be executed by a contact of a oneshot coil to prevent sending the data multiple times A series of Block Move BLKMV commands should be used to move the words to create a command block in the Register tables The COMMREQ function has three inputs and one output When the function receives power flow a command block of data is sent to the specified module Enable COMM REQ First word of command block IN FT Location sysID Task identifier TASK Parameters of the COMMREQ Function Input Choices Description Output enable flow When the function is energized the communications request is performed IN R Al AQ IN contains the first word of the command b

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