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DL205 User Manual Volume 2 of 2

1. DirectSOFT Display Handheld Programmer Keystrokes ISG gt ssa 0 ENT STR gt X IN 0 ENT ISG SO OUT gt Your 0 ENT STR gt X IN 1 ENT XO YO JMP gt asa 1 ENT D OUT JMP gt s s6 1 0 ENT oO SG gt F s s6 1 ENT 5 S1 f X1 STR gt xmn 2 ENT Li JMP z fe JMP gt asa 1 1 ENT 30 S10 T SHFT G V gt sise 1 0 ENT 02 JMP gt SHFT C V gt sso 1 1 ENT S SG S1 str gt xan 3 ENT OUT yout 3 ENT x2 S11 STR gt X IN 4 ENT L Ll JMP SHFT G V SHFT JMP S SG 2 0 ENT SG gt S SG 2 0 ENT Gv S10 STR gt JL_xun 5 ENT JMP gt sso 0 ENT CV 11 X3 Y3 OUT a 20 CVJMP SG S20 X5 SO HA ome DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming The stage block instructions are used to activate a block of stages The Block Call Block and Block End instructions must be used together Block Call The BCALL instruction is used to activate BCALL a stage block There are several things xT A PA To see to know about the BCALL TRN 230 240 250 1 260 BCALL Uses CR Numbers The BCALL appears as an output coil but does not actually refer to a Stage numb
2. P The best tool for configuring loops in the CPU is the DirectSOFT32 programming software Release 2 1 or later DirectSOFT32 uses dialog boxes to create a forms like editor to let you individually set up the loops After completing the setup you can use DirectSOFT32 s PID Trend View to tune each loop The configuration and tuning selections you make are stored in the CPUs FLASH memory which is retentive The loop parameters also may be saved to disk for recall later DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only PID Loop Feature Specifications Number of loops DL260 selectable up to 16 DL250 1 selectable up to 4 CPU V memory needed 32 words V locations per loop selected 64 words if using ramp soak PID algorithm Position or Velocity form of the PID equation Control Output polarity Selectable direct acting or reverse acting Error term curves Selectable as linear square root of error and error squared Loop update rate time between PID calculation 0 05 to 99 99 seconds user programmable Minimum loop update rate 0 05 seconds for 1 to 4 loops DL250 1 260 0 1 seconds for 5 to 8 loops DL260 0 2 seconds for 9 to 16 loops DL260 Loop modes Automatic Manual operator control or Cascade control Ramp Soak Generator Up to 8 ramp soak
3. Startup and Real time Relays Accumulator Status Relays SPO On first scan only SP60 Acc is less than value SP1 Always ON SP61 Acc is equal to value SP2 Always OFF SP62 Acc is greater than value SP3 1 minute clock SP63 Acc result is zero SP4 1 second clock SP64 Half borrow occurred SP5 100 millisecond clock SP65 Borrow occurred SP6 50 millisecond clock SP66 Half carry occurred SP7 On alternate scans SP67 Carry occurred CPU Status Relays SP70 Result is negative sign SP11 Forced run mode DL240 only SP71 Pointer reference error SP12 Terminal run mode SP73 Overflow SP13 Test run mode SP75 Data is not in BCD DL240 only SP76 Load zero SP15 Test program mode DL240 only Communication Monitoring Relays SPIS lerminalprogram mode SP116 CPU is communicating with another SP20 STOP instruction was executed DL230 DL240 device SP22 Interrupt enabled SP116 Port 2 is communicating with another System Monitoring Relays DL250 1 DL260 device SP40 Critical error SP117 Communication error on Port 2 DL250 1 DL260 only SP41 Non critical error SP120 Module busy Slot 0 SP43 Battery low SP121 Communication error Slot 0 SP44 Program memory error SP122 Module busy Slot 1 Shae uO error SP123 Communication error Slot 1 SP46 Communications error SP124 Module busy Slot 2 Sat VO configuration error SP125 Communication error Slot 2 _ SP50 Fault instruction was executed SP126 Module busy
4. Start EpRUM CT 4 15 X1 Jog Step Preset K1 C34 Y32 C14 Y10 C4 Y5 Y13 C7 A 0 01 sec CountK 10 YD 72 c30 v20 C2 ve v42 C10 Reset Step Counts Event 1 K0001 O OO OO OO OO OO OO OO O 2 KO020 Y40 00000 00 00 010 6 0 0 6 3 K0150 X21 O 06 0686 00060 0606 4 KO048 X22 O 60 0060006666 0 06 o 5 K0180 CO GC 60 60 00600668 0 08 OO 6 K0923 C1 000060 06860680 060 0 0 ooe 7 K0120 X30 O 60 0060068 00006 6 8 K0864 X35 60000060 06006 08 00 9 K1200 X33 O OO OO 068 668 00 0 68 O0 6 10 K0400 Y17 GC 60 668 00 00668 0 0 6 11 K0000 C20 OOOO 0 CC 60 0066 12 O oO TORe Oo oa OO OO O 13 O OO OO OO OO oo oo OO 14 O OO OO OO OO OO OO OO 15 OC CO 16 Cl Cl O CL OC O T Drum Complete EG NOTE If all events are true in an event only drum a drum with O counts per step in all steps the PLC completes one step of the drum per scan thus the drum will be complete in 16 scans However as the outputs of the drum are enabled any time the CPU is in RUN Mode the drum discrete outputs will be energized as pulsed outputs for each scan DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming The handheld programmer can also enter or edit drum instructions for the EDRUM only The diagram below lis
5. Bit 15 14 13 12 11109876543210 Derivative gain limit select The derivative gain limit in location V 25 must have a value between 0 and 20 in BCD format This setting is operational only when the enable bit 1 The gain limit can be particularly useful during loop tuning Most loops can tolerate only a little derivative gain without going into wild oscillations V U Er e O je O NO e ER Q Bias Term In the widely used position form of the PID equation an important component of the control output value is the bias term shown below Its location in the loop table is in V 04 the loop controller writes a new bias term after each loop calculation Auo 09Z10 1 0SZ1a n Mn lt Ke en Ki Mei Kr en en 1 Mo i 1 Control Proportional Integral Derivative Initial Output Term Term Term Output v 04 XXXX Bias term NC 7 If we cause the error en to go to zero for two or more sample periods the proportional and derivative terms cancel The bias term is the sum of the integral term and the initial output Mo It represents the steady constant part of the control output value and is similar to the DC component of a complex signal waveform The bias term value establishes a working region for the control output When the error fluctuates around its zero point the output fluctuates around the bias value This concept is very import
6. Loop Table PV filter V 24 XXXX _ Filter constant enable disable Bit 15 14 13 12 1110 9 8 76543210 Bit 2 of PID Mode 2 Setting provides the enable disable control for the low pass PV filter O disable 1 enable The roll off frequency of the single pole low pass filter is controlled by using register V 24 in the loop parameter table the filter constant The data format of the filter constant value is BCD with an implied decimal point 00X X as follows e The filter constant has a range of 000 1 to 001 0 e A setting of 000 0 or 001 1 to 999 9 essentially disables the filter e Values close to 001 0 result in higher roll off frequencies while values closer to 000 1 result in lower roll off frequencies We highly recommend using DirectSOFT32 for the auto tuning interface The duration of each auto tuning cycle will depend on the mass of our process A slowly changing PV will result in a longer auto tune cycle time When the auto tuning is complete the proportional integral and derivative gain values are automatically updated in loop table locations V 10 V 11 and V 12 respectively The sample time in V 07 is also updated automatically You can test the validity of the values the auto tuning procedure yields by measuring the closed loop response of the PV to a step change in the output The instructions on how to so this are in the section on the manual tuning procedure DL
7. Note the stages within a block must be regular stages SG or convergence stages CV So they cannot be initial stages The numbering of stages inside stage blocks can be in any order and is completely independent from the numbering of the blocks DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming RLL PLUS D E D DL D amp ep Block Call BCALL XISSI iv 230 240 250 1 260 The purpose of the Block Call instruction is to activate a stage block At powerup or upon Program to Run mode transitions all stage blocks and the stages within them are inactive Shown in the figure below the Block Call instruction is a type of output coil When the XO contact is closed the BCALL will cause the stage block referenced in the instruction CO to become active When the BCALL is turned off the corresponding stage block and the stages within it become inactive We must avoid confusing block call operation with how a subroutine call works After a BCALL coil executes program execution continues with the next program rung Whenever program execution arrives at the ladder location of the stage block named in the BCALL then logic within the block executes because the block is now active Similarly do not classify the BCALL as type of state transition is not a JMP Block CO X0 Co C BC ALL I ee Activate S next rung ES
8. DL205 User Manual 3rd Ed Rev A 08 03 9 17 Maintenance and Troubleshooting Noise Troubleshooting Electrical Noise Noise is one of the most difficult problems to diagnose Electrical noise can enter a Problems system in many different ways and falls into one of two categories conducted or radiated It may be difficult to determine how the noise is entering the system but the corrective actions for either of the types of noise problems are similar e Conducted noise is when the electrical interference is introduced into the system by way of an attached wire panel connection etc It may enter through an I O module a power supply connection the communication ground connection or the chassis ground connection e Radiated noise is when the electrical interference is introduced into the system without a direct electrical connection much in the same manner as radio waves Reducing While electrical noise cannot be eliminated it can be reduced to a level that will not Electrical Noise affect the system e Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct noise problems If a ground is not available install a ground rod as close to the system as possible Insure all ground wires are single point grounds and are not daisy chained from one device to another Ground metal enclosures around the system A loose wire is no more tha
9. For most applications the freeze bias PID Mode 1 Setting V 00 feature will work with the loop as described above You may enable the Hair rer ee Cer feature using the DirectSOFT32 PID View K setup dialog or set bit 10 of PID Mode 1 Bias freeze Setting word as shown to the right select NOTE The bias freeze feature stops the bias term from changing when the control output reaches the end of the data range If you have set limits on the control output other than the range i e O 4095 for a unipolar 12bit loop the bias term still uses the end of range for the stopping point and bias freeze will not work In the feedforward method discussed later in this chapter ladder logic writes directly to the bias term value However there is no conflict with the freeze bias feature because bias term writes due to feedforward are relatively infrequent when in use DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only EE Loop Tuning Procedure This is perhaps the most important step in closed loop process control The goal of a loop tuning procedure is to adjust the loop gains so the loop has optimal performance in dynamic conditions The quality of a loop s performance may generally be judged by how well the PV follows the SP after a SP step change Auto Tuning versus Manual Tuning you may change the PID gain values directly manual tuning or you can have the PID processing engine
10. Converge Stage The Converge Stage instruction is used to CV and Converge group certain stages together by defining Jump CVJMP them as Converge Stages R AT VE When all of the Converge Stages within a Sam 230 240 2601 26 group become active the CVJMP instruction and any additional logic in the final CV stage will be executed All preceding CV stages must be active before the final CV stage logic can be executed All Converge Stages are deactivated one scan after the CVJMP instruction is executed Additional logic instructions are only San allowed following the last Converge Stage cvumP instruction and before the CVJMP instruction Multiple CVJUMP instructions are allowed CV Converge Stages must be programmed in the main body of the application program This means they cannot be programmed in Subroutines or Interrupt Routines Stage S 0 777 0 1777 0 1777 DL205 User Manual 3rd Ed 06 02 7 26 RLLPLUS Stage Programming In the following example when Converge Stages S10 and S11 are both active the CVJMP instruction will be executed when X4 is on The CVJMP will deactivate S10 and S11 and activate S20 Then if X5 is on the program execution will jump back to the initial stage SO
11. 20 6 us 1 1 us LDIF 1st X 2nd K Constant E lt 26 6uS 1 4 us 0 9us x N STRI X 27 us 9 8 us 29 us 10 7us 193us 193us 19 3 us 19 3 us STRNI X 26 us 8 6 us 29 us 10 7 us 194us 194us 194us 19 4 us ORI X 27 us 9 8 us 29 us 8 4 us 19 1us 18 7 us 19 1us 18 7 us ORNI X 26 us 8 6 us 29 us 8 4 us 192us 189us 192us 18 9 us ANDI X 25 us 8 0 us 27 us 8 4 us 18 7 us 18 7us 18 7 us 18 7 us ANDNI X 24 us 6 8 us 28 us 8 4 us 188us 188us 18 8us 18 8 us OROUTI Y 45 us 45 us 39 us 40 us 27 5us 27 5us 27 5us 27 5 us OUTI Y 45 us 45 us 39 us 40 us 25 5us 25 5us 25 5us 25 5 us OUTIF 1st Y 2nd K Constant nn Lt C Si en 66 lus 1 4 us 0 9us x N SETI 1ist Y 25 5us 6 8us 390us 84us 23 1us O 9us 23 1us 0 9 us 2nd Y N pt 5 5us 2 6 8us 44us 25 84us 22 8us 0 9 us 22 8us 0 9 us 0 xN xN 1 4xN 1 4xN RSTI ist Y 25 5 us 6 8 us 37 us 8 4 us 23 2 us 0 9 us 23 2 us 0 9 us 2nd Y N pt 5us 20 6 8 us 45us 22 8 4us 22 8us 0 9 us 22 8us 0 9 us 5 xN xN 1 4xN 1 4xN C 15 9 xipueddy 5 a G m x lt QO CC O S 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 16 Instruction Execution Times Timer Counter Shift Register Instructions Timer Counter Shift Register DL230 DL240 DL250 1 DL260 Instructions Instruc Legal Data Types Ex
12. 8 25 PLC Modes Effect on Loop Modes 8 25 LOOD MOS OV acc vic id 8 25 Bumpless Transfers seg 5 A A ae MEN Ream ene ea SRE eet 8 26 PID Loop Data Configuration 5s 64s A ee ee Gee ete ek oe 8 27 IV Table of Contents Loop Parameter Data Formats nanara eanan 8 27 Choosing Unipolar or Bipolar Format 8 27 Handling Data Offsets irske a Ra R OE aaa 8 28 Setpoint SP LOCO ti A id e CL 8 28 Remote Setpoint SP Location ss dus e ee Pr ated 8 29 Process Variable PV Configuration 8 29 Control Output Configuration s seas es seee ar eeaeee 8 30 Error Term COnNQUIaION ia A T ue vA eae A aw ies 8 31 PID Alg rithMS a A a A foe AI RER en 8 32 POSHION AIGOIMNM criterios ea AR sa 8 32 V locity Alors tee d nt rate nn ee Nul tates 8 33 Direct Acting and Reverse Acting Loops 8 34 P D Loop Terms M ET A I SS 8 35 Using a Subset of PID Control tata A sail 8 36 Derivative Gain LIMINO tias to o Gee ae A eee Bhat E E ey 8 37 Blas Tern pts rts 75 5 9 a ad ias weeds Pale T ORE tk ca ae poh ia a riadas heals 8 37 Blas Freeze Le Dr E ain S sade is hake A Rate ae aan W s bees las ee tam E a GAR 8 38 Loop TUnIRd POCO dure incas or ai AS a ai 8 39 Open Loop Testa mb it A re NE bs 8 39 Manual Tuning Proc dur ts soa dese e id oe tee tis e
13. 299us 299us 299us 29 9 us K Constant 274us 274us 274us 27 4us gt P Indir Data 51 0us 510us 51 0us 51 0us 2 P Indir Bit 51 0us 510us 51 0us 51 0us m gt P Indir Bit V Data Reg 29 9 us 29 9us 29 9us 29 9 us oo V Bit Reg 299us 29 9us 299us 29 9 us 22 K Constant 274us 274us 274us 27 4 us Se P Indir Data 51 0us 510us 51 0us 51 0 us 5 P Indir Bit 51 0us 51 0us 51 0us 51 0 us 3 D n DL205 User Manual 3rd Ed Rev A 08 03 C 10 Ls E H Oc x D 5 ED Si XI A U Instruction Execution Times Comparative Boolean cont DL230 DL240 DL250 1 DL260 In Legal Data Types Execute Not Execute Not Execute Not Execute Not struc Execute Execute Execute Execute tion OR 1st 2nd T CT V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 12 0us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 140us 110 0us 30 2 us 30 2us 30 2us 30 2 us P Indir Bit 234 us 114 0 us 30 2 us 30 2 us 30 2 us 30 2 us ist 2nd V Data Reg V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 12 0us 134 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us
14. 8 14 Loop Sample Rates cion dont weg diese a mA Be Re RER ed eres hes 8 14 Choosing the Best Sample Hate 0 ccc eee teens 8 14 Programming the Sample Hate nnna neee 8 15 PID Loop Effect on CPU Scan Time 8 16 Ten Steps to Successful Process Control 8 18 Step Know ihe Recipe ES LA Ra Me lea tis ba ae ted Ghee SEER et ANS NT ee wee ee 8 18 Step 2 Plan Loop Control Strategy ro 8 18 Step 3 Size and Scale Loop Components 8 18 Slop 4 Select PO MOdUIBS Saran canter als 8 18 Step 5 Wiring and Installation ted oneal ides Bebta ew eke Gade tes d 8 19 plep 6 Loop Paramelers ss HRSA due Sete id a a AA A a Ae NO ek 8 19 Step 7 Check Open Loop Performance 8 19 DISD Loop TUNING iei eae a A se Piet Rakha delete 8 19 Step 9 Run Process Cycle bi a e os A ad la ad 8 19 Step 10 Save Loop Parameters ane de nn Mon a 8 19 Basic Loop Operation 2000 A A A 8 20 Data Locations reoi il A nes dae AAA wee loan AAA A 8 20 Data SOU ts BUA earth ds la tes Hate 8 20 Auto Transterto Analog WO son A io 8 21 Loop Modes EX rss ae a RRR RR eE 8 22 CPU Modes and Loop Modes 2000 A a dd 8 23 How to Change Loop Modes a Pate rente s te des sa oe tees atid ee Dot als 8 24 Operator Panel Control of PID Modes
15. Set Reset Latch X0 X1 Co a 1 OUT Latch Output Co YO ouT SG So OFF State Transition XO S1 CAMP gt ON State Output SP1 Always on YO OUT Transition X1 SO MP When the Off pushbutton X1 is pressed a transition back to the Off State occurs The JMP SO instruction executes which simply turns off the Stage bit S1 and turns on Stage bit SO On the next PLC scan the CPU will not execute Stage S1 so the motor output YO will turn off The Off state Stage 0 will be ready for the next cycle DL205 User Manual 3rd Ed 06 02 7 5 RLLPLUS Stage Programming Let s Compare Right now you may be thinking I don t see the big advantage to Stage Programming in fact the stage program is longer than the plain RLL program Well now is the time to exercise a bit of faith As control problems grow in complexity stage programming quickly out performs RLL in simplicity program size etc For example consider the diagram below Notice how easy it is to correlate the OFF 56 and ON states of the state transition SO OFF State diagram below to the stage program at the right Now we challenge anyone to easily X0 S1 identify the same states in the RLL l JMP program on the previous page ON State S 82 SP1 YO DC PA Cun EE _ x1 So VC r 30 T lt gt
16. STR X IN 3 ENT OUT Y OUT 6 ENT SHFT E N D ENT SG S SG 1 5 ENT STR X IN 7 ENT d I AISI NY ee LU L L RST S SG 1 ENT Stage View in The Stage View option in DirectSOFT32 will let you view the ladder program as a DirectSOFT32 flow chart The figure below shows the symbol convention used in the diagrams You may find the stage view useful as a tool to verify that your stage program has faithfully reproduced the logic of the state transition diagram you intend to realize SG Sta Transition ge Reference to a a Stage Logic gt Jump lt gt Set Stage O Output P gt Reset Stage The following diagram is a typical stage view of a ladder program containing stages Note the left to right direction of the flow chart He L 0 gt E gt DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming Questions and Answers about Stage Programming We include the following commonly asked questions about Stage Programming as an aid to new students All question topics are covered in more detail in this chapter Q What does stage programming do that cannot do with regular RLL programs A Stages allow you to identify all the states of your process before you begin programming This approach is more organized because you divide up a ladder program into section
17. DL205 User Manual 3rd Ed Rev A 08 03 8 40 PID Loop Operation DL250 1 DL260 only PID Loop Operation gt GO o N a m _ T O Ye A S Manual Tuning Procedure The discussion below covers the manual tuning procedure If you want to perform only auto tuning please skip this next section and proceed directly to the section on auto tuning Now comes the exciting moment when we actually close the loop go to Auto Mode for the first time Use the following checklist before switching to Auto mode e Monitor the loop parameters with a loop trending instrument We recommend using the PID view feature of DirectSOFT32 NOTE We recommend using the PID trend view setup menu to select the vertical scale feature to manual for both SP PV area and Bias Control Output areas The auto scaling feature will otherwise change the vertical scale on the process parameters and add confusion to the loop tuning process e Adjust the gains so the Proportional Gain 10 Integrator Gain 9999 and Derivative Gain 0000 This disables the integrator and derivative terms and provides a little proportional gain e Check the bias term value in the loop parameter table V 04 If it is not zero then write it to zero using DirectSOFT32 or HPP etc Now we can transition the loop to Auto Mode Check the mode monitoring bits to verify its true mode If the loop will not stay in Auto Mod
18. c2 SUBR V1400 from the real number in the oS V1400 accumulator and stores the result in the ZO accumulator V1400 is the designated ae workspace in this example an Multipl h b h ultiplies the real number in the On or accumulator by 0 2 the filter factor ss and stores the result in the accumulator This is the filtered value tO a ite Adds the real number stored in ADDR location V1400 to the real number an Q V1400 filtered value in the accumulator and A stores the result in the accumulator Copies the value in the accumulator SA to location V1400 Converts the real number in the __ RTOB accumulator to a binary value and stores the result in the accumulator Converts the binary value in the accumulator BCD to a BCD number Note the BCD instruction is not needed for PID loop PV loop PV is a binary number OUT Loads the BCD number filtered value from the accumulator into location V1402 to use V1402 h Su in your application or PID loop DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only 8 49 Feedforward Control Feedforward control is an enhancement to standard closed loop control It is most useful for diminishing the effects of a quantifiable and predictable loop disturbance or sudden change in setpoint Use of this feature is an option available to you on the DL250 1 and DL260 However it s best to im
19. 30 3 us 30 3 us 30 3 us 30 3 us K Constant 274us 27 4us 27 4us 27 4 us P Indir Data 50 4 us 50 4 us 50 4 us 50 4 us P Indir Bit 50 4us 50 4us 50 4us 50 4us P Indir Bit V Data Reg 30 3 us 30 3 us 30 3 us 30 3 us V Bit Reg 30 3 us 30 3 us 30 3 us 30 3 us K Constant 27 4us 27 4us 27 4us 27 4 us vn P Indir Data 50 4 us 50 4us 50 4 us 50 4 us P Indir Bit 50 4us 50 4us 50 4us 50 4 us 5 le ORNE list 2nd x S V Data Reg V DataReg 75us 12 0us 44us 13 9us 7 6us 7 6us 7 6us 7 6us D 5 V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us gt 3 K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us y x P Indir Data s 141 us 110 0 us 30 2us 30 2 us 30 2 us 30 2 us lt x E P Indir Bit 234us 114 0 us 30 2us 30 2us 30 2us 30 2 us 2 V Bit Reg V Data Reg 158 us 12 0 us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us gt V Bit Reg 239 us 12 0us 223us 139us 7 6us 7 6 us 7 6 us 7 6 us K Constant 137 us 120us 1383 us 13 9us 48us 4 8 us 4 8 us 4 8 us P Indir Data i 230 us 110 0 us 30 2us 30 2 us 30 2 us 30 2 us P Indir Bit 323 us 114 0 us 30 2us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9 us 29 9us 29 9us 29 9 us V Bit Reg
20. 51 0us 51 0us 51 0us 51 0 us P Indir Bit V Data Reg 29 9 us 29 9 us 29 9us 29 9 us V Bit Reg 29 9 us 29 9 us 29 9 us 29 9 us K Constant 27 4us 27 4us 27 4 us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0us 9 xipueddy 5 a oes m x lt QO CC Q 5 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 12 Instruction Execution Times x 9 D G GL lt Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute AND ist 2nd T CT V Data Reg 76 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158 us 12 0 us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 139 us 109 0 us 30 2 us 30 2 us 30 2 us 30 2 us P Indir Bit 233us 113 0 us 30 2 us 30 2us 30 2us 30 2 us 1st 2nd V Data Reg V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 140us 109 0 us 30 2us 30 2us
21. When a stage block becomes active the first stage in the block automatically becomes active on the same scan The first stage in a block is the one located immediately under the block BLK instruction in the ladder program So that stage plays a similar role to the initial type stage we discussed earlier The Block Call instruction may be used in several contexts Obviously the first execution of a BCALL must occur outside a stage block since stage blocks are initially inactive Still the BCALL may occur on an ordinary ladder rung or it may occur within an active stage as shown below Note that either turning off the BCALL or turning off the stage containing the BCALL will deactivate the corresponding stage block You may also control a stage block with a BCALL in another stage block SG Stage Block SO BLK Co X0 Co BCALL SG All other rungs in stage S10 All rungs in stage SG S11 SG S11 All other rungs in stage NOTE Stage Block may come before or after the location of the BCALL instruction BEND in the program The BCALL may be used in many ways or contexts so it can be difficult to find the best usage Remember the purpose of stage blocks is to help you organize the application problem by grouping related stages together Remember that initial stages must exist outside stage blocks DL205 User Manual 3rd Ed 06 02 7 23 RLLP
22. 299us 29 9us 299us 29 9 us V Bit Reg 29 9 us 29 9 us 29 9 us 29 9 us K Constant 27 4us 27 4us 27 4 us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit l 51 0us 51 0us 51 0us 51 0us 9 xipueddy 5 a oes m x lt QO CC Q 5 l 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 14 Instruction Execution Times Bit of Word Boolean Instructions Bit of Word Boolean DL230 DL240 DL250 1 DL260 Instructions Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute STRB V Data Reg 3 1 us 3 1 us 3 1 us 3 1 us V Bit Reg Eu 3 1 us 3 1 us 3 1 us 3 1 us P Indir Data 30 0 us 30 0 us 30 0 us 30 0 us P Indir Bit 30 0 us 30 0 us 30 0 us 30 0 us STRNB V Data Reg 3 0 us 3 0 us 3 0 us 3 0 us V Bit Reg un 3 0 us 3 0 us 3 0 us 3 0 us P Indir Data 29 8 us 29 8 us 29 8 us 29 8 us P Indir Bit 29 8 us 29 8 us 29 8 us 29 8 us ORB V Data Reg 2 9 us 2 9 us 2 9 us 2 9 us V Bit Reg 2 9 us 2 9 us 2 9 us 2 9 us P Indir Data 29 9 us 29 9 us 29 9 us 29 9 us P Indir Bit 29 9us 29 9us 29 9us 29 9 us ORNB V Data Reg 2 8 us 2 8 us 2 8 us 2 8 us V Bit Reg 2 8 us 2 8 us 2 8 us 2 8 us P Indir Data 29 6 u
23. Ranges application requires additional retentive ranges or no retentive ranges at all The default settings are DL230 DL240 DL250 1 DL260 e Default Range Avail Range Default Range Avail Range Default Range Avail Range Default Range Avail Range Control Relays C300 C377 CO C377 C300 C377 CO C377 C1000 C1777 CO C1777 C1000 C1777 CO C3777 V Memory V2000 V7777 VO V7777 V2000 V7777 VO V7777 V1400 V3777 VO V17777 V1400 V3777 VO V37777 Timers None by default TO T77 None by default TO T177 None by default TO T377 None by default TO T377 Counters CTO CT77 CTO CT77 CTO CT177 CTO CT177 CTO CT177 CTO CT177 CTO CT177 CTO CT377 Stages None by default S0 S377 None by default S0 S777 None by default S0 S1777 None by default S0 S1777 Use AUX 57 to change the retentive ranges You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu WARNING The DL205 CPUs do not come with a battery The super capacitor will Y y retain the values in the event of a power loss but only up to 1 week The retention A en time may be less in some conditions If the retentive ranges are important for your application make sure you obtain the optional battery AUX 58 Test Operations In normal Run Mode the outputs are turned off when you return to Program Mode In TEST RUN mode you can set each individual output to either turn off
24. _ os 13 7 us 1 0 us OUTX V Data Reg 17 2 us 1 0 us V Bit Reg E e un gt 17 2 us 1 0 us P Indir Data 43 4 us 1 0 us P Indir Bit 43 4us 1 0us POP None 55 us 7 2 US 50 us 8 4 us 8 4 us 1 0us 8 4 us 1 0us DL205 User Manual 3rd Ed Rev A 08 03 eE Instruction Execution Times Logical Instructions Logical Accumulator DL230 DL240 DL250 1 DL260 Instructions Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute AND V Data Reg 58 us 10 4 us 54 us 8 4 us 7 9 us 1 0 us 7 9 us 1 0 us V Bit Reg 261us 104us 145 us 8 4 us 7 9 us 1 0 us 7 9 us 1 0 us P Indir Data 162 us 8 4 us 33 4 us 0 9 us 33 4 us 0 9 us P Indir Bit 241 us 8 4us 334us 09us 334us 0 9us ANDD V Data Reg LL 8 9 us 1 0 us 8 9 us 1 0 us V Bit Reg 8 9 us 1 0 us 8 9 us 1 0 us K Constant 53 us 8 4 us 60 us 8 4 us 5 7 us 1 0 us 5 7 us 1 0 us P Indir Data E 344us 09us 344us 0 9us P Indir Bit a NN 34 4us O9us 344us 0 9 us ANDF 1st 2nd X Y C S K Constant 21 6us 1 0us 21 6us 1 0 us T CT SP 0 9us x 0 9us x GX GY N d ANDS None 10 0us 1 0us a Ub OR V Data Reg 59 us 10 4 us 54 us 8 4 us 8 1 us 1 0 us 8 1 us 1 0 us DS V Bit Reg 257us 10 4us 144us 8 4 us 8 1 us 1 0 us 8 1 us 1 0 us Q D P In
25. oO DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting Some Quick Steps When troubleshooting the DL series I O modules there are a few facts you should be aware of These facts may assist you in quickly correcting an I O problem e The output modules cannot detect shorted or open output points If you suspect one or more points on a output module to be faulty you should measure the voltage drop from the common to the suspect point Remember when using a Digital Volt Meter leakage current from an output device such as a triac or a transistor must be considered A point which is off may appear to be on if no load is connected to the the point e The I O point status indicators on the modules are logic side indicators This means the LED which indicates the on or off status reflects the status of the point in respect to the CPU On an output module the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input module if the indicator LED is on the input circuitry should be operating properly To verify proper functionality check to see that the LED goes off when the input signal is removed e Leakage current can be a problem when connecting field devices to I O modules False input signals can be generated when the leakage current of an output device is great enough to turn on the connected input device To corr
26. 2 AUX 58 Test Operations ss cocoa a aeeia Sie ees al abe eee A AUX SO Bit eU Ta re sata Pen ot ee Mon et TT eee eee eee AUX 5B Counter Interface Configuration AUX 5C Display Error HIStory issues ras ore eed Abe Saha a a es AUX 6 Handheld Programmer Configuration ALCOR OP AMG OS sates x seed tearm een enr den et wae De ee AUX 61 Show Revision Numbers ses semer dete nr tement TA eee Eee AUX 62 Beeper ON Off pee AMEL nd Ent een e aR dd R Nr AUX 65 Run Self DiagNOS CS sans sordas alee fem sheets t nee a date die AUX 7 EEPROM Operations oooococccncccn AUX TTA 76 pa wage Senso tbe eee pa is Sewanee eee uns Transt rrable Memory Areas exo sit Codie e K K K tate ado ths ue slide cea AUX FT CPU to HPP EEPROM nordeste ee nent Cubs etes ear ees AUX 72 HPP EEPROM to CPU 22scsovaravevariieniacbearei nement enter tele AUX 73 Compare HPP EEPROM to CPU exit di ea eee ee le ae AUX 74 HPP EEPROM Blank Check waa uma odes AUX 75 Erase HPP EEPROM lt cna Lean wc eked tl a mes AUX 76 Show EEPROM TYPE road tices Gn ee Sn Sart os AUX 8 Password Operations 0 e e x x x K eee eee eee eee eee eee eens AUX Ol 60 0 Oe of o de oe eMedia H E a e O ed e did ott AUX 81 Modify Password unitat sente avd md a dh tte Br AUX 82 Iae CPU ida anida bai Saray AUX 83 Eeee Aiia esse a MA nd ee Appendix B DL205 Error Codes Appendix C Ins
27. MSB LSB 15 0 x Vv y KL Y xr X xr Base Base Not Channel Number Slot Used Number Number CPU Base Number Base Channel Number Slot Number DL250 1 Local CPU base 0 0 7 1 8 Local expansion base 1 2 DL260 Local base 0 Local expansion base 1 4 DL205 User Manual 3rd Ed Rev A 08 03 AE doo Aid g C D O1 L g C o O G PID Loop Operation DL250 1 DL260 only Loop Sample Rate and Scheduling Loop Sample Rates The main tasks of the CPU fall into L categories as shown to the right The list y represents the tasks done when the CPU Read is in Run Mode on each PLC scan Note L Inputs that PID loop calculations occur after the ladder logic task From the user Servico point of view loops can be running when Peripherals the ladder is not nn The sample rate of a control loop is simply fp the frequency of the PID calculation Each al calculation generates a new control output PLC a value With the DL250 1 and DL260 Scan CPUs you can set the sample rate of a Calculate loop from 50 mS to 99 99 seconds So for most loops the PID calculation will not occur on every PLC scan In fact some loops may need calculating only once in Internal 1000 scans Diagnostics You select the desired sample rate for each loop and the CPU automatically Write schedules and executes PID calculations Outputs on the appropriate scans tt Choosing the
28. e Counter The counter number specifies the first of four consecutive counters which the drum uses for step control You can monitor these to determine the drum s progress through its control cycle e Events Either an X Y C S C CT or SP type discrete point serves as step transition inputs Each step has its own event However programming the event is optional on Timer Event drums WARNING The outputs of a drum are enabled any time the CPU is in Run Mode The Start Input does not have to be on and the Reset input does not disable the outputs Upon entering Run Mode drum outputs automatically turn on or off according to the pattern of the preset step This includes any effect of the output mask when applicable The choice of the starting step on powerup and program to run mode transitions are important to consider for your application Please refer to the following chart If the counter memory is configured as non retentive the drum is initialized the same way on every powerup or program to run mode transition However if the counter memory is configured to be retentive the drum will stay in its previous state Counter Function Initialization on Powerup Number Non Retentive Case Retentive Case CTA n Current Step Initialize O Use Previous no Count change CTA n 1 Counter Timer Initialize O Use Previous no Value change CTA n 2 Preset Step Initialize Preset Step Use Pre
29. 2 KO020 Y40 00000 00 00 010 68 0 0 o 3 K0150 X21 O 06 086 0006006606 4 k0048 X22 O 0 OO 60 00666 0 06 08 5 K0180 CO GC 60 60 00600668 0 08 OO 6 K0923 C1 000060 0 686060 080 0 0 ooe 7 k0120 X30 O O0 OO 60 0068 Oo 0066 8 K0864 X35 OO 60 06 0060668 00 9 K0120 X33 O OO OO 068 668 00 0 68 O0 6 10 K4000 Y17 GC 60 668 00 00668 0 0 6 11 c20 OO 0060 00 60 00 6 12 Cl OC O 13 O OO OO OO OO OO OO 00 0 14 O OO OO OO 000000000 15 Cl O O O 16 Cl Cl Cl HOMO O qT Drum Complete Le SPo Set Mask Registers LD K ffff NOTE The ladder program must load constants in V2000 through V2012 to cover all mask registers for the eleven steps used in this drum R g Ue fo 82 o 32 3c 52 WO O 5 DL205 User Manual 3rd Ed Rev A 08 03 HLL PLUS Stage Programming In This Chapter Introduction to Stage Programming Learning to Draw State Transition Diagrams Using the Stage Jump Instruction for State Transitions Stage Program Example Toggle On Off Lamp Controller Four Steps to Writing a Stage Program Stage Program Example Garage Door Opener Stage Program Design Considerations Parallel Processing Concepts Managing Large Programs RLLPEUS Instructions Questions and Answers About Stage Programming 7 2 RLL PLUS
30. 29 9 us 29 9 us 29 9 us 29 9 us K Constant 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0 us P Indir Bit V Data Reg l BE 29 9 us 29 9 us 29 9 us 29 9 us V Bit Reg 299us 29 9us 29 9us 29 9 us K Constant 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit Si 51 0 us 51 0us 51 0 us 51 0 us DL205 User Manual 3rd Ed Rev A 08 03 Instruction Execution Times C 7 Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ANDE ist 2nd V Data Reg V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 139 us 109 0 us 30 2 us 30 2 us 30 2us 30 2 us P Indir Bit 233us 113 0 us 30 2us 30 2us 30 2 us 30 2 us V Bit Reg V Data Reg 158us 120us 134us 13 9us 7 6us 7 6 us 7 6 us 7 6 us V Bit Reg 239 us 120us 223us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 137us 12 0us 133us 13 9us 4 8us 4 8 us 4 8 us 4 8 us P Indi
31. D E D DL D Ky ep RLLPLUS Stage Programming Introduction to Stage Programming SILIL Y 230 240 250 1 260 Overcoming Stage Fright Stage Programming available in all DL205 CPUs provides a way to organize and program complex applications with relative ease when compared to purely relay ladder logic RLL solutions Stage programming does not replace or negate the use of traditional boolean ladder programming This is why Stage Programming is also called RLLPLUS You will not have to discard any training or experience you already have Stage programming simply allows you to divide and organize a RLL program into groups of ladder instructions called stages This allows quicker and more intuitive ladder program development than traditional RLL alone provides Many PLC programmers in the industry have become comfortable using RLL for xo Co every PLC program they write but often RST remain skeptical or even fearful of learning new techniques such as stage X4 C1 YO programming While RLL is great at SET solving boolean logic relationships it has VA J gt disadvantages as well STAGE e Large programs can become almost unmanageable because of a lack of N structure ya Y2 e In RLL latches must be tediously T created from self latching relays Coun e When a process gets stuck it is difficult to find the rung where the error occurred s P
32. OUT image register update by CPU XO override enabled XO at input module XO in image register YO in image register The following diagram shows how the bit override works for an output point Notice the bit override maintains the output in the current state If the output is on when the bit override is enabled then the output stays on If it is off then the output stays off Program Rung Override holds XU YU previous state and disables A A 1 OUT image register update by CPU YO override enabled XO at input mdoule YO in image register YO at output module je The following diagram shows how you can use a programming device in combination with the bit override to 2 change the status of the point Remember bit override only disables CPU changes You can still use a ES f E E c p ano programming device to force the status of the point Plus since bit override maintains the current status this S 5 enables true forcing The example shown is for an output point but you can also use the other bit data types zo nD JJ Program Rung The force operation from the 88 XU YU programming device can still Gun change the point status a l YO override enabled XO at input mdoule YO force fr
33. RLLPLUS Stage Programming RLL PLUS D E D DL D amp ep Add Emergency Stop Feature Exclusive Transitions Some garage door openers today will detect an object under the door This halts further lowering of the door Usually implemented with a photocell electric eye a door in the process of being lowered will halt and begin raising We will define our safety feature to work in this way adding the input from the photocell to the block diagram as shown to the right X3 will be on if an object is in the path of the door Next we make a simple addition to the state transition diagram shown in shaded areas in the figure below Note the new transition path at the top of the LOWER state If we are lowering the door and detect an obstruction X3 we then jump to the Push UP State We do this instead of jumping directly to the RAISE state to give the Lower output Y2 one scan to turn off before the Raise output Y1 energizes X2 and X3 Inputs Toggle E y AU Up limit Ladder 0 o Program Down limit gt X2 Obstruction ops Outputs m Raise eae Lower YS Light XO It is theoretically possible the down limit X2 and the obstruction input X3 could energize at the same moment In that case we would jump to the Push UP and DOWN states simultaneously which does not make sense Instead we give priority to the obstr
34. The end user of the products must comply with any Directives that may cover maintenance disposal etc of equipment or various components Although we strive to provide the best assistance available it is impossible for us to test all possible configurations of our products with respect to any specific Directive Because of this it is ultimately your responsibility to ensure that your machinery as a whole complies with these Directives and to keep up with applicable Directives and or practices that are required for compliance CE conformity will be impaired if the recommended installation guidlines are not met D a x lt ba ip Currently the DLO5 DLO6 DL205 DL305 and DL405 PLC systems manufactured by Koyo Electronics Industries FACTS Engineering or Host Engineering when properly installed and used conform to the Electromagnetic Compatibility EMC and Low Voltage Directive requirements of the following standards s EMC Directive Standards Revelant to PLCs EN50081 1 Generic immunity standard for residential commercial ad light industry DLO5 only at this time EN50081 2 Generic emission standard for industrial environment EN50082 1 Generic immunity standard for residential commercial and light industry EN50082 2 Generic immunity standard for industrial environment s Low Voltage Directive Standards Applicable to PLCs EN61010 1 Safety requirements for electrical equipment for Measurement control and labor
35. 30 2us 30 2 us P Indir Bit 233us 113 0 us 30 2 us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 158us 12 0us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 240 us 120us 223us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 137 us 120us 1383 us 13 9us 4 8us 4 8 us 4 8 us 4 8 us P Indir Data 229 us 109 0 us 30 2 us 30 2 us 30 2 us 30 2 us P Indir Bit 323 us 113 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9 us 29 9 us 29 9 us 29 9 us E V Bit Reg 29 9 us 29 9 us 29 9 us 29 9 us B K Constant 27 4us 27 4us 27 4us 27 4 us E P Indir Data NN 51 0us 51 0us 51 0us 51 0 us H P Indir Bit Wa 51 0us 51 0us 51 0us 51 0 us 5 P Indir Bit V Data Reg 29 9us 29 9 us 29 9us 29 9 us 5 V Bit Reg 299us 29 9us 299us 29 9 us 8 K Constant 27 4us 27 4us 27 4us 27 4 us L P Indir Data 51 0us 51 0us 51 0us 51 0 us E P Indir Bit 51 0us 51 0us 51 0us 51 0us on al DL205 User Manual 3rd Ed Rev A 08 03 Instruction Execution Times eE Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ANDN 1st 2nd T CT V Data Reg
36. CTn Drum Complete CTA n 1 2 175 2 375 Timer value CT n 1 not used CTA n 2 3 176 3 376 Preset Step CT n 2 not used CTA n 3 4 177 4 377 Current Step CT n 1 not used The following ladder program shows the MDRMD instruction in a typical ladder program as shown by DirectSOFT32 Steps 1 through 11 are used and all sixteen output points are used The output mask word is at V2000 The final drum outputs are shown above the mask word as a word at V2001 The data bits in V2000 are logically ANDed with the output pattern of the current step in the drum generating the contents of V2001 If you want all drum outputs to be off after powerup write zeros to V2000 on the first scan Ladder logic may update the output mask at any time to enable or disable the drum outputs The preset step is step 1 The timebase runs at K50 x 0 01 0 5 seconds per count Therefore the duration of step 1 is 5 x 0 5 2 5 seconds Note that step 1 is time based only event is left blank In the last rung the Drum Complete bit CT14 turns on output YO upon completion of the last step step 10 A drum reset also resets CT14 DirectSOFT32 Display XO Stat MDRMW CT 14 A vao LA Jog Step Preset K1 x2 0 01 sec Count K 50 15 V2000 0 Reset Step Counts Event 1 KO005 O O6 0066 0 68 00 0 68 OO
37. In DirectSOFT32 s trend view you can program the gains values and units in real time while the loop is running This is typically done only during the loop tuning process Proportional Gain This is the most basic gain of the three Values range from 0000 to 9999 but they are used internally as xx xx An entry of 0000 effectively removes the proportional term from the PID equation This accommodates applications which need integral only loops Integral Gain Values range from 0001 to 9998 but they are used internally as xx xx An entry of 0000 or 9999 causes the integral gain to be effectively removing the integrator term from the PID equation This accommodates applications which need proportional only loops The units of integral gain may be either seconds or minutes as shown above Derivative Gain Values range from 0001 to 9999 but they are used internally as xx xx An entry of 0000 allows removal of the derivative term from the PID equation a common practice This accommodates applications which need proportional and or integral only loops The derivative term has an optional gain limiting feature discussed in the next section NOTE It is very important to know how to increase and decrease the gains The proportional and derivative gains are as one might expect smaller numbers produce less gains and larger numbers produce more gain However the integral term has a reciprocal gain 1
38. Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ADD V Data Reg 1988 us 10 6us 291 us 84us 784us 09us 78 4us 0 9us V Bit Reg 397us 10 6us 363 us 84us 784us 09us 78 4us 0 9us P Indir Data 441 us 84us 101 2us O9us 101 2us 0 9us P Indir Bit 520 us 84us 101 2us O9us 101 2us 0 9 us ADDD V Data Reg 198 us 8 4 us 291 us 84us 83 8us O9us 83 3us 0 9us V Bit Reg 397 us 8 4 us 512 us 8 4 us 83 3 us 0 9 us 83 3 us 0 9 us K Constant 188 us 8 4 us 298 us 8 4 us 67 7 us 0 9 us 67 7 us 0 9 us P Indir Data 442 us 84us 1012us 09us 101 2us 0 9 us P Indir Bit 608 us 84us 101 2us O9us 101 2us 0 9 us SUB V Data Reg 200 us 10 6us 287 us 8 4 us 77 4 us 0 9 us 77 4 us 0 9 us V Bit Reg 397us 10 6us 360 us 84us 774us 09us 77 4us 0 9us P Indir Data 434 us 8 4 us 95 1 us 0 9 us 95 1 us 0 9 us P Indir Bit 513 us 84us 95 1us O9us 95 1us 0 9us SUBD V Data Reg 198 us 8 4 us 288 us 8 4us 82 5us 0 9us 82 5us 0 9us V Bit Reg 392 us 8 4 us 504 us 84us 82 5us 0 9us 82 5us 0 9us K Constant 190 us 8 4 us 294 us 8 4 us 66 0 us 0 9 us 66 0 us 0 9 us 5 P Indir Data 434 us 84us 99 7us 09us 99 7us 0 9 us CA P Indir Bit 600 us 8 4us 99 7us 09us 99 7us 0 9 us m gt xO OO MUL V Data Reg 497 us 10 6us 311 us 84us 266 1us 0 9us 266 1
39. Kpc 4M x Xo Tpc To M amplitude of output PID tuning PI tuning P 0 45 Kpc P 0 30 Kpc 0 60 Tpc 1 00 Tpc D 0 10 Tpc D 0 Sample Rate 0 014 Tpc Sample Rate 0 03 Tpc Auto tuning error if the auto tune error bit bit 13 of Loop Mode and Alarm status word V 06 is on please verify the PV and SP values are within 5 of full scale difference as required by the auto tune function The bit will also turn on if the open loop method is in use and the output goes to the limits of the range Tuning In tuning cascaded loops we will need to de couple the cascade relationship and Cascaded Loops _ tune the loops individually using one of the loop tuning procedures previously covered 1 If you are not using auto tuning then find the loop sample rate for the minor loop using the method discussed earlier in this chapter Then set the sample rate of the major loop slower than the minor loop by a factor of 10 Use this as a starting point EE doo did g C D O1 L g C o O G gt 2 Tune the minor loop first Leave the major loop in Manual Mode and you will need to generate SP changes for the minor loop manually as described in the loop tuning procedure 3 Verify the minor loop gives a critically damped response to a 10 SP change while in Auto Mode Then we are finished tuning the minor loop 4 ln this step you will need to get the minor loop in Cascade Mode and then the
40. Run Process Cycle running an actual process cycle Now we must do the programming to generate the desired SP in real time In this step you may run a small test batch of product through the machine while the SP changes according to the recipe ET WARNING Be sure the Emergency Stop and power down provision is readily gt accessible in case the process goes out of control Damage to equipment and or serious injury to personnel can result from loss of control of some processes Step 10 When the loop tests and tuning sessions are complete be sure to save all loop setup Save Loop parameters to disk Loop parameters represent a lot of work in loop tuning and are Parameters well worth saving DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation GO ro N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Data Locations Data Sources Setpoint V 02 Basic Loop Operation Each PID loop is completely dependent on the instructions and data values in its respective loop table The following diagram shows the loop table locations corresponding to the main three loop I O variables SP PV and Control Output The example loop table below begins at V2000 an arbitrary location to be chosen by the user The SP PV and Control Output are located at the addresses shown Setpoint V 02 5 Error Loop Control Output V 05 _ Term Calculation Process Vari
41. SP47 1 0 Configuration Error oO o Q GQ CC cS E252 95 Program Control Information 3 NEW I O CFG SH xe lt oO DL205 User Manual 3rd Ed Rev A 08 03 Error Message Tables xl viv Y 230 240 250 1 260 9 7 Maintenance and Troubleshooting The DL240 CPU will automatically log any system error codes and any custom messages you have created in your application program with the FAULT instructions The CPU logs the error code the date and the time the error occurred There are two separate tables that store this information e Error Code Table the system logs up to 32 errors in the table When an error occurs the errors already in the table are pushed down and the most recent error is loaded into the top position If the table is full when an error occurs the oldest error is pushed erased from the table e Message Table the system logs up to 16 messages in this table When a message is triggered the messages already stored in the table are pushed down and the most recent message is loaded into the top position If the table is full when an error occurs the oldest message is pushed erased from the table The following diagram shows an example of an error table for messages Date Time Message 1993 05 26 08 41 51 11 Conveyor 2 stopped 1993 04 30 17 01 11 56 Conveyor 1 stopped 1993 04 30 17 01 11 12 Limit
42. SP555 Current target value on when the counter current value equals the value in V3662 SP556 Current target value on when the counter current value equals the value in V3664 SP557 Current target value on when the counter current value equals the value in V3666 SP560 Current target value on when the counter current value equals the value in V3670 SP561 Current target value on when the counter current value equals the value in V3672 SP562 Current target value on when the counter current value equals the value in V3674 SP563 Current target value on when the counter current value equals the value in V3676 SP564 Current target value on when the counter current value equals the value in V3700 SP565 Current target value on when the counter current value equals the value in V3702 SP566 Current target value on when the counter current value equals the value in V3704 SP567 Current target value on when the counter current value equals the value in V3706 DL205 User Manual 3rd Ed Rev q xipueddy 0 D O L D D D lt n A 08 03 fp oz ESO DT C a 28 to 09 Special Relays Equal Relays for Multi step Presets with Up Down Counter 2 for use with a Counter Interface Module SP570 Current target value on when the counter current value equals the
43. The step changes in the bias are the result of our two feed forward writes to the bias term We can see the PV variations are greatly reduced The same technique may be applied for changes in setpoint DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only 8 51 The PID loop controller in the DL250 1 and DL260 CPUs generate a smooth control output signal across a numerical range The control output value is suitable to drive an analog output module which connects to the process In the process control field this is called continuous control because the output is on at some level continuously While continuous control can be smooth and robust the cost of the loop components such as actuators heater amplifiers can be expensive A simpler form of control is called time proportioning control This method uses actuators which are either on or off no in between Loop components for on off based control systems are lower cost than their continuous control counterparts In this section we will show you how to convert the control output of a loop to time proportioning control for the applications that need it Lets take a moment to review how alternately turning a load on and off can control a process The diagram below shows a hot air balloon following a path across some mountains The desired path is the setpoint The balloon pilot turns the burner on and off alternately which is his control output The la
44. 1 DL260 only 8 23 CPU Modes and One very powerful aspect of the loop controller on the DL250 1 and DL260 CPUs is Loop Modes it s ability to run PID calculations while the CPU is in Program Mode It is usually true that a CPU in Program Mode has halted all operations However the CPU in Program Mode may or may not be running PID calculations depending on your configuration settings Having the ability to run loops independently of the ladder logic makes it feasible to make a ladder logic change while the process is still running This is especially beneficial for large mass continuous processes that are difficult or costly to interrupt Of course loops that run independent of the ladder scan must have the ability to directly access the analog module channels for the PV and control output values The loop controller does have this capability which is covered in the section on direct access of analog I O located prior to this section in this chapter The relationship between CPU modes and loop modes is depicted in the figure below The vertical dashed line shows the optional relationship between the mode changes Bit 15 of PID Mode 1 setting word V 00 determines the selection If set to zero so the loop follows the CPU mode then placing the CPU in Program Mode will force all loops into Manual Mode Similarly placing the CPU in Run mode will allow each loop to return to the mode it was in previously which includes Manual Automatic an
45. 27 X2 Ladder Program balers Raise BERI Lower LYS Light We can think of the Light state as a parallel process to the raise and lower state The paths to the Light state are not a transition Stage JMP but a State Set command In the logic of the Light stage we will place a three minute timer When it expires timer bit TO turns on and resets the Light stage The path out of the Light stage goes nowhere indicating the Light stage becomes inactive and the light goes out DL205 User Manual 3rd Ed 06 02 Output equations Y1 RAISE Y2 LOWER Y3 LIGHT Using a Timer Inside a Stage The finished modified program is shown to the right The shaded areas indicate the program additions In the Push UP stage S1 we add the Set Stage Bit S6 instruction When contact XO opens we transition from S1 and go to two new active states S2 and S6 In the Push DOWN state S4 we make the same additions So any time someone presses the door control pushbutton the light turns on Most new stage programmers would be concerned about where to place the Light Stage in the ladder and how to number it The good news is that it doesn t matter e Choose an unused Stage number and use it for the new stage and as the reference from other stages e Placement in the program is not critical so we place it at the end You might think that each stage has to be directly under the stage that transitions to it While
46. 5 Kdddd O OO OFO OO OO OO OO OO O Counts per Step 6 Kdddd O OO OFO OO OO OO OO OO O 7 Kdddd O1 CO O O Q 8 Kdddd ON O ON ECHO ROMO QO Output Pattern 9 Kdddd Q OO OO OO OO OO OO OO O O Off On 10 Kdddd O OO 0 O OO QO OO OO OO O 11 Kdddd OC CO O Ol Ome HOMO 12 Kdddd ON C1 O CO CC QO 13 Kdddd O OO OO OO OO OO OO OO O 14 Kdddd O OO OO OO OO OO OO OO O 15 Kdddd CHO CO O HOMO OC QO 16 Kdddd OO CO O CO CO O All of the DL250 1 and DL260 drum instructions may be programmed by using DirectSOFT32 The EDRUM is the only drum instruction that can be programmed with a handheld programmer firmware version v1 8 or later This section covers editting using DirectSOFT32 for all of the drum instructions plus the handheld mnemonics for the EDRUM instruction The Timed Drum with Discrete Outputs is the most basic of the DL250 1 and DL260 drum instructions It operates according to the principles covered on the previous pages Below is the instruction in chart form as displayed by DirectSOFT32 Counter Number ep Pree Discrete Output Assignment Tmebase SEN DRUM CT aaa 15 Fit The Timed Drum features 16 steps and 16 outputs Step transitions occur only on a timed basis specified in count
47. Anal oop nalog V memor Auto Transfer Filter PV Calculation module from V memory Address 3 Analog pointer method or program logic used to get value into V memory DL205 User Manual 3rd Ed Rev A 08 03 8 48 PID Loop Operation DL250 1 DL260 only Creating an Analog You can build a similar algorithm in ladder logic Analog inputs can be filtered Filter in Ladder effectively using either method The following programming example describes the Logic ladder logic you will need Be sure to change the example memory locations to those that fit your application Filtering can induce a small error in your output because of rounding Because of the potential rounding error you should not use zero or full scale as alarm points Additionally the smaller the filter constant the greater the smoothing effect but the slower the response time Be sure a slower response is acceptable in controlling your process SP1 LD Loads the analog signal which is a BCD value V2000 and has been loaded from V memory location V2000 into the accumulator Contact SP1 is always on Converts the BCD value in the accumulator __ BIN to binary This instruction is not needed if the analog value is originally brought in as a binary number BTOR Converts the binary value in the accumulator to a real number Subtracts the real number stored in location
48. CO TL Drum Complete E DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Event Drum with Discrete Outputs EDRUM XxX X Y 230 240 250 1 260 Start EDRUM og 0 g Step Preset K bb Ffff EF Ff ER En Pfff E Emm fae Na sec Count K cccc a AE 1 CEY e N fi RE a CEARA Reset Step Counts Event Eeeee O OLO OO OO OO OO OO OO O Eeeee O O O OO OO OO OO OO OO O ESS Om CO CO ONO LOMO Et OO Cl CNE Step Number ER O El ECHO El CIO OMS Eeeee O OLO OO OO OO OO OO OO O Counts per Step Eeeee O O O OO OO OO OO OO OO O ESS HOMO Cl 6 0 CO Cl O CI EG Es OC GO Cl Event per step 9 Kdddd Eeeee O OO O0 OC O OC O OO OO oo 10 Kdddd Eeeee O OOO OO O OO OC O 00 OC CO O Output Pattern 11 Kdddd Eeeee O OIO OO OJO OJO OJO O O O O O O Off On 12 Kdddd Eeeee CO OF O 00 00 OO OLO O 13 Kdddd Eeeee O OOO OO O OO OO 00 OC CO O 14 Kdddd Eeeee O OOO OO O OO O OC CO OC OC O 15 Kdddd Eeeee O OO OO OO OO CO OC 000 CO OC O 16 Kdddd Eeeee O OO OO OC O Of O 000 O CO OO O Drum Instruction Programming The Event Drum with Discrete Outputs has all the features of the Timed Drum plus event based step transitions It operates according to the general principles of drum operation covered in the beginning
49. DL250 1 DL260 only CPU on 1 Electrical noise interference 2 CPU defective BATT on 1 CPU battery low 2 CPU battery missing or disconnected N ea T Status Indicators Yir O pwR Ga E run y nun A sarral E cpu 1250 48 Bu DL260 en DLO E ceuta ports Mode Switch ga on Port 2 _ Ea CR ls Pen Bale Slot di 7 Status Indicators AE eee PRE O R BAT CPU DL230 CPU 0 0000 O 0 0000 00000 0 0 00 0 N 0 0 0 00 O 00000 O D amp o Q 00 cc On 52 Faj ES 52 gt Le Kd Mode Switch DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting ES PWR Indicator There are four general reasons for the CPU power status LED PWR to be OFF 1 Power to the base is incorrect or is not applied 2 Base power supply is faulty 3 Other component s have the power supply shut down 4 Power budget for the base has been exceeded Incorrect Base If the voltage to the power supply is not correct the CPU and or base may not Power operate properly or may not operate at all Use the following guidelines to correct the problem E T WARNING To minimize the risk of electrical shock always disconnec
50. DL260 only Loop Table Word Definitions The parameters associated with each loop are listed in the following table The address offset is in octal to help you locate specific parameters in a loop table For example if a table begins at V2000 then the location of the reset integral term is Addr 11 or V2011 Do not use the word to calculate addresses Word Address Offset Description Format Read on the fly 1 Addr 0 PID Loop Mode Setting 1 bits Yes 2 Addr 1 PID Loop Mode Setting 2 bits Yes 3 Addr 2 Setpoint Value SP word binary Yes 4 Addr 3 Process Variable PV word binary Yes 5 Addr 4 Bias Integrator Value word binary Yes 6 Addr 5 Control Output Value word binary Yes 7 Addr 6 Loop Mode and Alarm Status bits 8 Addr 7 Sample Rate Setting word BCD Yes 9 Addr 10 Gain Proportional Setting word BCD Yes 10 Addr 11 Reset Integral Time Setting word BCD Yes 11 Addr 12 Rate Derivative Time Setting word BCD Yes s5 12 Addr 13 PV Value Low low Alarm word binary No BS 13 Addr 14 PV Value Low Alarm word binary No EN 14 Addr 15 PV Value High Alarm word binary No ae 15 Addr 16 PV Value High high Alarm word binary No Sg 16 Addr 17 PV Value deviation alarm YELLOW word binary No RS 17 Addr 20 PV Value deviation alarm RED word binary No S 18 Addr 21 PV Value rat
51. If you need to use a drum and stages be sure to place the drum instruction in an ISG stage that is always active 3rd Ed 06 02 7 17 RLLPLUS Stage Programming Using a Stage as a You may recall the light bulb on off Supervisory controller example from earlier in this N Process chapter For the purpose of illustration Toggle o Ladder vo suppose we want to monitor the 9 Program productivity of the lamp process by counting the number of on off cycles which occurs This application will require the addition of a simple counter but the key decision is in where to put the counter Powerup ai OFF State 5 sweet Supervisor Process xo S1 D D MP UE a Su E y Push On State 3 5 XO s2 gt Q 1 Camp as ON State SP1 YO New stage programming students will OUT typically try to place the counter inside one the the stages of the process they are trying to XO S3 monitor The problem with this approach is JMP that the stage is active only part of the time In order for the counter to count the count input se Push Off State must transition from off to on at least one scan after its stage activates Ensuring this X0 So requires extra logic that can be tricky L IMP In this case we only need to add another supervisory stage as shown above to watch ISG Supervisor State the
52. Instruction Execution Times Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute STRN 1st 2nd T CT V Data Reg 78 us 13 8 us 46 us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 13 8us 136us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 57 us 13 8 us 46 us 16 2 us 48us 4 8 us 4 8 us 4 8 us P Indir Data 141us 111 0 us 302us 30 2us 30 2us 30 2 us P Indir Bit 235us 115 0 us 30 2 us 30 2us 30 2us 30 2 us ist 2nd V Data Reg V Data Reg 78 us 13 8 us 46 us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 159us 13 8us 135us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 57 us 13 8 us 46 us 16 2 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 141us 111 0 us 302us 30 2us 30 2us 30 2 us P Indir Bit 235us 115 0us 30 2 us 302us 30 2us 30 2 us V Bit Reg V Data Reg 159us 138us 136us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 241 us 13 8us 225us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 139us 138us 135us 16 2us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 231 us 111 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Bit 324us 115 0 us 30 2us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 299us 299us 29 9 us V Bit Reg
53. It is OFF when the CPU DL250 1 260 is in any other mode SP15 Test program on when the CPU is in the TERM position and the CPU is in the TEST mode PROGRAM MODE SP16 Terminal on when the CPU switch is in the TERM position and the CPU is in program mode the PROGRAM MODE SP17 Forced stop on anytime the CPU keyswitch is in the STOP position mode relay DL250 1 260 SP20 Forced on when the STOP instruction is executed stop mode SP21 Break Relay 2 on when the BREAK instructions is executed It is OFF when the CPU DL250 1 260 mode is changed to RUN only SP22 Interrupt enabled on when interrupts have been enabled using the ENI instruction SP25 CPU battery dis on when the CPU battery is disabled by special V memory abled relay DL250 1 260 DL205 User Manual 3rd Ed Rev A 08 03 Special Relays System Monitoring SP40 Critical error on when a critical error such as I O communication loss has Relays occurred SP41 Warning on when a non critical error such as a low battery has occurred SP43 Battery low dead on when the CPU battery voltage is low or dead Note The CPU must have a battery installed SP44 Program on when a memory error such as a memory parity error has memory error occurred SP45 I O error on when an I O error occurs For example an I O module is withdrawn from the base or an I O bus error is detected SP46 Communications on when
54. Mn Kc en Ki Set Kr en en 1 Mo J K a Control Proportional Integral Derivative Initial Output Term Term Term Output No Bias Y Term The initial output is the output value assumed from Manual mode control when the loop transitioned to Auto Mode The sum of the initial output and the integral term is the bias term which holds the position of the output Accordingly the Velocity Algorithm discussed next does not have a bias component Jg le D O1 L g le o O G gt AE doo Aid Velocity Algorithm The Velocity Algorithm form of the PID equation can be obtained by transforming Position Algorithm formula with subtraction of the equation of n 1 th degree from the equation of nth degree The velocity algorithm variables and related variables are Ts Sample rate Kc Proportional gain Ki Kc Ts Ti coefficient of integral term Kr Kc Td Ts coefficient of derivative term Ti Reset time integral time Td Rate time derivative time SPn Set Point for sampling time n SP value PVn Process variable for sampling time n PV en SPn PVn Error term for sampling time n Mn Control Output for sampling time n The resulting equations for the Velocity Algorithm form of the PID equation are AMn Mhn Mn 1 AMn Kc en en 1 Ki en Kr en 2 en 1 en 2 DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation G
55. P Indir Data 193 us 159 us 81 2us 30 2us 81 2us 30 2 us P Indir Bit 366 us 331us 81 2us 30 2us 81 2us 30 2 us CNT 1st 2nd CT V Data Reg 68 us 61 us 59 us 38 us 25 8 us 7 3 us 25 8 us 7 3 us V Bit Reg 148 us 141 us 157 us 133 us 25 8us 7 3us 25 8us 7 3us K Constant 56 us 45 us 59 us 45 us 222us 46us 22 2us 46us P Indir Data 176 us 152us 53 5us 30 2us 53 5us 30 2 us P Indir Bit 270us 245us 53 5us 30 2us 53 5us 30 2 us SGCNT 1st 2nd CT V Data Reg 57 us 64 us 58 us 38 us 27 3 us 7 3 us 27 3 us 7 3 us V Bit Reg 140 us 148 us 155 us 133 us 27 3us 7 3us 27 3us 7 3 us K Constant 46 us 53 us 67 us 45 us 23 5 us 4 6 us 23 5 us 4 6 us P Indir Data 175 us 152us 549us 30 2us 549us 30 2 us P Indir Bit 268us 245us 54 9us 30 2us 54 9us 30 2 us UDC 1st 2nd CT V Data Reg 103 us 74 us 80 0 us 56 us 39 8 us 7 3 us 39 8 us 7 3 us V Bit Reg 310 us 281 us 261 us 224us 39 8 us 7 3 US 39 8 us 7 3 US K Constant 102 us 70 us 97 us 60 us 35 4 us 4 6 us 35 4 us 4 6 us P Indir Data 202 us 165 us 67 8us 30 2us 67 8us 30 2 us P Indir Bit 374us 336us 67 8us 30 2us 67 8us 30 2 us SR C N points to shift 30us 17 2 us 25us 19 7 us 17 8us 98us 17 8us 9 8us 4 6usxN 4usxN 0 9usxN 0 9usxN DL205 User Manual 3rd Ed Rev A 08 03 C 17 Instructi
56. Sd With ag E Normal Output Limits aa L 4 a Setpoint Loop noe Control Output 2 Calculation fore N Inverted Output Process Variable A Loop Table PID Mode 1 Setting V 00 V 30 XXXX Control Output Lower Limit Bit 15 1413 12 1110 9 8 7 6 5 i 3210 V 31 XXXX Control Output Upper Limit Normal Inverted Output Select The other available selection is the normal inverted output selection called forward reverse in DirectSOFT32 Use bit 4 of the PID Mode 1 Setting V 00 word to configure the output Independently of unipolar or bipolar format a normal output goes upward on positive errors and downward on negative errors where Error SP PV The inverted output reverses the direction of the output change The normal inverted output selection is used to configure direct acting reverse acting loops This selection is ultimately determined by the direction of the response of the process variable to a change in the control output in a particular direction Refer to the PID Algorithms section for more on direct acting and reverse acting loops DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Error Term The Error term is internal to the CPUs PID loop controller and is generated again in Configuration each PID calculation Although its data is not directly accessible you can eas
57. TTT with the Block instruction It marks the end of a block of stages There is no 230 240 28001 200 operand with this instruction Only one BEND Block End is allowed per Block Call DL205 User Manual 3rd Ed 06 02 7 28 RLLPLUS Stage Programming In this example the Block Call is executed DirectSOFT Display when stage 1 is active and X6 is on The 56 Block Call then automatically activates st stage S10 which immediately follows the Y5 E Xo Block instruction aur This allows the stages between S10 and co the Block End instruction to operate as Ie BCALL programmed If the BCALL instruction is turned off or if the stage containing the BLK BCALL instruction is turned off then all Co stages between the BLK and BEND instructions are automatically turned off SG S10 If you examine S15 you will notice that Y6 X7 could reset Stage S1 which would OUT disable the BCALL thus resetting all stages within the block BEND RLL PLUS Handheld Programmer Keystrokes SG S SG 1 ENT S15 D E D DL D amp ep SG STR gt X IN 2 ENT S1 OUT Y OUT 5 ENT RST STR X IN 6 ENT C A L C gt ccn 0 ENT is K gt cer SG 1 0 ENT SHFT SHFT o m Z 3 SG
58. a E x1 a Initial Stages At powerup and Program to Run Mode Powerup in OFF State transitions the PLC always begins with all ISG normal stages SG off So the stage SO Initial Stage programs shown so far have actually had no way to get started because rungs are XO S1 not scanned unless their stage is active JMP Assume that we want to always begin in the Off state motor off which is how the sG RLL program works The Initial Stage S1 ISG is defined to be active at powerup In SP1 YO the modified program to the right we have OUT changed stage SO to the ISG type This ensures the PLC will scan contact XO after x1 E powerup because Stage SO is active UMP After powerup an Initial Stage ISG works like any other stage We can change both programs so the Powerup in ON State motor is ON at powerup In the RLL below we must add a first scan relay SPO SS latching CO on In the stage example to the right we simply make Stage S1 an initial XU S1 stage ISG instead of SO IMP Powerup in ON State Xo x1 Co 88 Initial Stage a OUT 4 D SP1 YO L ou OUT x1 S0 SPO r First Scan JMP DL205 User Manual 3rd Ed 06 02 7 6 RLLPLUS Stage Programming We can mark our desired powerup state Powerup as shown to the right which helps us XO remember to use the appropriate Initial Stages when creating a stage program It C CON X1 is permissible to have as many initial stages as the pr
59. as shown to the right The other ramp soak controls in V 33 shown in the table above will not operate unless this bit 1 during the entire ramp soak process The four main controls for the ramp soak generator are in bits O to 3 of the ramp soak settings word in the loop parameter table DirectSOFT32 controls these bits directly from the ramp soak settings dialog However you must use ladder logic to control these bits during program execution We recommend using the bit of word instructions PID Mode 1 Setting V 00 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 210 Ramp Soak Generator Enable Ramp Soak Settings V 33 Bit 15 14 13 12 11 10 9 8 7 6 5 43 210 Jog Hold Start Resume NI Ladder logic must set a control bit to a 1 to command the corresponding function When the loop controller reads the ramp soak value it automatically turns off the bit for you Therefore a reset of the bit is not required when the CPU is in Run Mode Start R S Generator The example program rung to the right shows how an external switch XO can turn on and the PD contact uses the leading edge to set the proper control bit to start the ramp soak profile This uses the Set Bit of word instruction DL205 User Manual 3rd Ed Rev A 08 03 B2033 0 SET PID Loop Operation DL250 1 DL260 only 8 63 The normal state
60. gt 14 7 Ramp End SP Value 34 15 Ramp End SP Value 15 7 Ramp Slope 35 15 Ramp Slope 16 8 Soak Duration 36 16 Soak Duration 17 8 Soak PV Deviation 37 16 Soak PV Deviation Ramp Soak Table The individual bit definitions of the Ramp Soak Table programming error flags Programming Error Addr 35 word is listed in the following table Further details are given in the PID Flags Loop Mode section and in the PV Alarm section later in this chapter Addr 35 Bit R S Error Flag Bit Description Read Bit 0 Bit 1 Write 0 Starting Addr out of lower V memory range read Error 1 Starting Addr out of upper V memory range read Error 2 3 Reserved for Future Use 4 Starting Addr in System Parameter read Error V memory Range 5 15 Reserved for Future Use DL205 User Manual 3rd Ed Rev A 08 03 PV Auto Transfer PID Loop Operation DL250 1 DL260 only 8 13 The nibble definitions for PV Auto Transfer word Addr 36 are listed in the table Addr 36 from below for the Transfer from Base Slot option When this option is used for any 1 0 Module channel on an analog input module the ladder logic pointer method cannot be Base Slot Channel used for this module Refer to the DL205 Analog I O Modules D2 ANLG M for Option pointer method information MSB LSB 152 0 Bi
61. m o From a clear display use the following keystrokes to force Y10 ON Solid fill indicates point is on Y B A SHFT ON amy ms L 0 INS BIT FORCE Y10 From a clear display use the following keystrokes to force Y10 OFF No fill indicates point is off Y B A SHFT OFF SET MLS 1 0 DEL BIT FORCE Y10 DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 9 29 Bit Override From a clear display use the following keystrokes to Forcing turn on the override bit for Y10 OS o xTITITI Solid fill indicates point is on X B A ON 230 240 250 1 260 ser gt l o SFT ON qi TORCE SET Y 10 Small box indicates override bit is on Note at this point you can use the PREV and NEXT keys to move to adjacent memory locations and use the SHFT ON keys to set the override bit on From a clear display use the following keystrokes to turn off the override bit for Y10 Solid fill indicates point is on est Ps fe J LST Lins BIT FORCE RST Y 10 Small box is not present when override bit is off Like the example above you can use the PREV and NEXT keys to move to adjacent memory locations and use the SHFT OFF keys to set the override bit off Bit Override Override bit indicators are also shown on the h
62. on bits O 1 and 2 of the Loop Mode and Alarm Status word location V 06 in the loop table The parallel request monitoring functions are shown in the figure below The figure also shows the mode dependent two possible SP sources and the two possible Control Output sources PID Loop Operation GO Q N a m _ T O Ye A S Manual l tf O t Control Output c d Nput rom Y perator from another loop ascace Control Output K Setpoint y Error Term Loop Calculation Normal Source o _ Auto Cascade Auto Manual Process Variable Mode Select me PID Mode Ne Control PID Mode 1 Setting V 00 Loop Mode and Alarm Status V 06 Bit 15 14 13 12 11 10 9 8 76543 210 Bit 15 14 13 12 11 10 9 8 76543210 Mode Request Mode Monitoring E Cascade Manual Cascade Manual Automatic Automatic DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only 8 25 Operator Panel Since the modes Manual Auto and Cascade are the most fundamental and Control of important PID loop controls you may want to hard wire mode control switches to PID Modes an operator s panel Most applications will need only Manual and Auto selections Cascade is used in a few advanced applications Remember that mode controls are really mode
63. or hold its last output state on the transition to TEST PGM mode The ability to hold the output states is especially useful since It allows you to maintain key system I O points for examination See Chapter 9 for a description of the Test Modes You can use AUX 58 to configure each individual output You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu gt amp S DO O lt 8 da D gt X 2 gt Le ao DL205 User Manual 3rd Ed Rev A 08 03 ES Auxiliary Functions U ZS 2 xe iP 2S E G x AUX 59 Bit Override AUX 5B Counter Interface Configuration Bit override can be enabled on a point by point basis by using AUX 59 from the Handheld Programmer or by a menu option from within DirectSOFT32 Bit override basically disables any changes to the discrete point by the CPU For example if you enable bit override for X1 and X1 is off at the time then the CPU will not change the state of X1 This means that even if X1 comes on the CPU will not acknowledge the change So if you used X1 in the program it would always be evaluated as off in this case Of course if X1 was on when the bit override was enabled then X1 would always be evaluated as on NOTE DirectNet protocol does not support single bit write operations There is an advantage available when you use the bit override feature The regular forcing is not disa
64. s SP The minor loop s normal SP location V 02 remains unchanged Now we use the loop parameter arrangement above and draw its equivalent loop schematic shown below Major loop Minor Cascaded loop Cascade Leon Control Output V 05 _ Control Sal Remote an Setpoint y Loop Output SP Local SP Calculation O EE V 02 Auto Manual Process Variable Remember that a major loop goes to Manual Mode automatically if its minor loop is taken out of Cascade Mode DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Process Alarms The performance of a process control loop may be generally measured by how closely the process variable matches the setpoint Most process control loops in industry operate continuously and will eventually lose control of the PV due to an error condition Process alarms are vital in early discovery of a loop error condition and can alert plant personnel to manually control a loop or take other measures until the error condition has been repaired The DL250 1 and DL260 CPUs have a sophisticated set of alarm features for each loop e PV Absolute Value Alarms monitors the PV with respect to two lower limit values and two upper limit values It generates alarms whenever the PV goes outside these programmed limits e PV Deviation Alarm monitors the PV value as compared to the SP It alarms when the difference between the
65. then the values in bits 0 1 and 9 define only the input range and data format and bits 11 12 and 13 are read and define the output range and data format Note 3 If bit 10 has a value of 1 and bit 13 has a value of 0 then bits 11 and 12 are read and define the output range and data format If bit 10 and bit 13 each have a value of 1 then bits 11 and 12 are not read and bit 13 defines the data format the output range is automatically unipolar DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Mode Alarm The individual bit definitions of the Mode Alarm monitoring word Addr 06 are listed Monitoring Word in the following table More details are in the PID Mode section and Alarms section Addr 06 Bit Mode Alarm Bit Description Read Write Bit 0 Bit 1 0 Manual Mode indication read Manual 1 Automatic Mode indication read Auto 2 Cascade Mode indication read Cascade 3 PV Input LOW LOW alarm read Off On 4 PV Input LOW alarm read Off On 5 PV Input HIGH alarm read Off On 6 PV Input HIGH HIGH alarm read Off On 7 PV Input YELLOW Deviation alarm read Off On 8 PV Input RED Deviation alarm read Off On 9 PV Input Rate of Change alarm read Off On 10 Alarm Value Programming error read Error 11 Loop Calculation Overflow Underflow read Error 12 Loop in Auto Tune indication read O
66. 00 00 to 99 99 uses implied decimal point s Soak Duration specifies the time for the soak segment in minutes ranging from 000 1 to 999 9 minutes in BCD implied decimal point s Soak PV Deviation optional specifies an allowable PV deviation above and below the SP value during the soak period A PV deviation alarm status bit is generated by the ramp soak generator Ramp End oy Ces SP Value Soak PV Ramp Soak Table deviation V 00 XXXX Ramp End SP Value Slope ER AAA V 01 XXXX Ramp Slope 5 SP n V 02 XXXX Soak Duration Ro L V 03 XXXX Soak PV Deviation a segment becomes active T 9 yo The ramp segment becomes active when the previous soak segment ends If the 59 ramp is the first segment it becomes active when the ramp soak generator is oe started and automatically assumes the present SP as the starting SP OF Offset Step Description Offset Step Description lt gt 00 1 Ramp End SP Value 20 9 Ramp End SP Value 01 1 Ramp Slope 21 9 Ramp Slope 02 2 Soak Duration 22 10 Soak Duration 03 2 Soak PV Deviation 23 10 Soak PV Deviation 04 3 Ramp End SP Value 24 11 Ramp End SP Value 05 3 Ramp Slope 25 11 Ramp Slope 06 4 Soak Duration 26 12 Soak Duration 07 4 Soak PV Deviation 27 12 Soak PV Deviation 10 5 Ramp End SP Value 30 13 Ramp End SP Value 11 5 Ramp Slope 31 13 Ramp Slope 12 6 Soak Du
67. 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 140us 110 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Bit 234 us 114 0 us 30 2 us 30 2 us 30 2 us 30 2 us V Bit Reg V Data Reg 158 us 120us 134us 139us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 240us 120us 223us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 137us 120us 133 us 139us 48us 4 8 us 4 8 us 4 8 us P Indir Data 230 us 110 0 us 30 2 us 30 2 us 30 2 us 30 2 us P Indir Bit 323 us 114 0 us 30 2us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 29 9us 29 9us 29 9 us V Bit Reg 299us 29 9us 29 9us 29 9 us K Constant 27 4us 27 4us 27 4us 27 4us P Indir Data NN TE 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0 us P Indir Bit V Data Reg 29 9 us 29 9 us 29 9 us 29 9 us V Bit Reg TI 29 9 us 29 9 us 29 9 us 29 9 us K Constant 27 4us 27 4us 27 4 us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0us P Indir Bit 51 0us 51 0us 51 0us 51 0us DL205 User Manual 3rd Ed Rev A 08 03 Instruction Execution Times C 11 Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute
68. 2 us 30 2 us 302us 30 2 us P Indir Bit 323 us 113 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 299us 299us 29 9 us V Bit Reg 299us 299us 299us 29 9 us K Constant 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 510us 510us 510us 51 0 us P Indir Bit V Data Reg S 29 9us 299us 299us 29 9 us V Bit Reg 29 9 us 29 9us 299us 29 9 us K Constant 274us 274us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0us P Indir Bit i 510us 510us 510us 51 0 us 9 xipueddy 5 a G m x lt le CC O 5 I 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 8 Instruction Execution Times Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute STR 1st 2nd T CT V Data Reg 78 us 13 8 us 46 us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 13 8us 135us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 57 us 13 8 us 46 us 162us 48us 4 8 us 4 8 us 4 8 us P Indir Data 141us 111 0 us 30 2us 30 2us 30 2us 30 2 us P Indir Bit E 235us 115 0 us 30 2 us 30 2us 30 2us 30 2
69. 62 us 7 2 us 98 us 84us 33 9us 0 9us 33 9us 0 9 us DECO None 34 us 7 2 us 28 us 8 4 us 5 7 us 1 0 us 5 7 us 1 0 us 9 xipueddy 5 a GRS m x lt QO O 5 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 26 Ls Er Oc x 345 ED B XI U Instruction Execution Times Number Conversion Instructions Number Conversion DL230 DL240 DL250 1 DL260 Instructions Accumulator Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute BIN None 359 us 7 2 us 267 us 84us 100 2us 0 9us 100 2us 0 9 us BCD None 403 us 7 2 us 383 us 84us 95 2us 09us 95 2us 0 9us INV None 27 us 5 0us 120us 8 4 us 2 5 us 1 0 us 2 5 us 1 0 us BCDCPL None 296 us 7 2 us 69 us 84us 75 6us 1 0us 75 6us 1 0 us ATH V 25 4us 1 0us HTA V 254us 1 0us GRAY None 227 us 90us 110 8us 1 0us 1108us 1 0 us SFLDGT None 258 us 90us 23 1us 1 0us 23 1us 1 0us BTOR None 186us 1 0us 18 6us 1 0us RTOB None 8 6 us 1 0 us 8 6 us 1 0 us RADR None e LL 51 4 us 1 0 us DEGR None 81 5us 1 0us DL205 User Manual 3rd Ed Rev A 08 03 C 27 Instruction Execution Times Tab
70. 7 3us 7 3us 7 3us 7 3us ORPD X Y C S T CT 6 8 us 5 2us 68us 5 2us ORND X Y C S T CT 7 1 us 4 9 us 7 1 us 4 9 us ANDPD x Y C S T CT 68us 52us 68us 5 2us ANDND x Y C S T CT 7 1us 49us 7 1us 49us DL205 User Manual 3rd Ed Rev A 08 03 Bit Instructions C 25 Instruction Execution Times Bit Instructions Accumulator DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute SUM None E a 6 7 us 1 0 us SHFR V Data Reg N bits 44us 14 10 4 us 35us 6 8 4us 12 lus O 9us 12 1us 0 9 us V Bit Reg N bits 6xN 8 4 us xN 84us 0 1xN 0 1xN K Constant N bits 243us 1 84us 110us 6 8 4 us 46xN xN 8 4us 8 4us 34us 14 35us 6 0 1xN 0 1xN 6xN xN SHFL V Data Reg N bits 44us 14 10 4 us 33us 6 8 4us 12 lus O 9us 12 1us 0 9 us V Bit Reg N bits 6xN 8 4 us xN 84us 0 1xN 0 1xN K Constant N bits 243us 1 84us 107us 6 8 4 us 46xN xN 8 4us 8 4us 34us 14 33us 6 0 1xN 0 1xN 6xN xN ROTR V Data Reg N bits 16 4 us 1 0 us V Bit Reg N bits es cd me 16 4 us 1 0 us K Constant N bits 12 9 us 1 0 us ROTL V Data Reg N bits 16 4 us 1 0 us V Bit Reg N bits a es es 16 4 us 1 0 us K Constant N bits 12 7 us 1 0 us ENCO None
71. 7 us 1 0 us P Indir Data 76 3 us 10us 76 3 us 1 0 us P Indir Bit 76 3us 1 0us 76 3us 1 0 us DL205 User Manual 3rd Ed Rev A 08 03 C 23 Instruction Execution Times Math Instructions cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute MULR V Data Reg 54 2 us 1 0 us 54 2 us 1 0 us V Bit Reg 54 2 us 1 0 us 54 2 us 1 0 us K Constant NN 42 7 us 10us 42 7 us 1 0 us P Indir Data E 80 4 us 1 0 us 80 4 us 1 0 us P Indir Bit 80 4 us 1 0us 80 4 us 1 0 us DIVR V Data Reg 50 1 us 1 0 us 50 1 us 1 0 us V Bit Reg 50 1 us 1 0 us 50 1 us 1 0 us K Constant 58 7 us 1 0 us 58 7 us 1 0 us P Indir Data 76 3 us 1 0 us 76 3 us 1 0 us P Indir Bit 76 3 us 1 0us 76 3 us 1 0 us ADDF 1st 2nd X Y C S K Constant 109 3us 1 0 us T CT SP 0 9us x GX GY N SUBF 1st 2nd X Y C S K Constant 107 3us 1 0 us T CT SP 0 9us x N G GX GY MULF ist 2nd DLE X Y C S K Constant 3525us 1 0 us Sg TCT SP 0 8us x SA GX GY N S DIVF list 2nd X Y C S K Constant 477 3us 1 0 us p T CT SP 0 8us x GX GY N ADDS None 99 5 us 1 0
72. 76 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 139us 48us 4 8 us 4 8 us 4 8 us P Indir Data 139 us 110 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Bit 233us 1140us 30 2us 30 2us 30 2us 30 2 us ist 2nd V Data Reg V Data Reg 76 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 139 us 109 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Bit 233us 113 0 us 30 2us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 158us 120us 134us 13 9us 7 6us 7 6 us 7 6 us 7 6 us V Bit Reg 240us 120us 223us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 137us 12 0us 133us 139us 48us 4 8 us 4 8 us 4 8 us P Indir Data 229 us 109 0 us 30 2 us 30 2us 30 2 us 30 2 us P Indir Bit 322 us 113 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 29 9us 29 9us 29 9 us V Bit Reg 299us 29 9us 299us 29 9 us K Constant ur E NN 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0 us P Indir Bit V Data Reg
73. 7843xN 8 4us N of words 520us 181xN 565us 344 x N LDLBL K 58us 8 4us 56 us 8 4us 6 4us 1 3 us 6 4us 1 3us DL205 User Manual 3rd Ed Rev A 08 03 C 29 Instruction Execution Times CPU Control Instructions CPU Control DL230 DL240 DL250 1 DL260 Instructions Instruc Legal Data Execute Not Execute Not Execute Not Execute Not tion Types Execute Execute Execute Execute NOP None O us O us O us O us 0 5 us 0 5 us 0 5 us 0 5 us END None 27 us 27 us 16 us 16 us 12 8 us O us 12 8 us O us STOP None 16 us 5 us 15 us 7 4 us Ous 0 9 us Ous 0 9 us RSTWT None 19 us 8 4 us 4 7 us 0 9 us 4 7 us 0 9 us Program Control Instructions Program Control Instruc DL230 DL240 DL250 1 DL260 2 tions S m gt Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not as tion Execute Execute Execute Execute 2 a GOTO K 14us 84us 51us 48us 5 1us 4Bus og 0 LBL K 0 6 us 0 6 us 5 7 us 0 0 us 5 7 us 0 0 us 2 ao FOR V K 32 us 16 4us 85 8us 58us 85 8us 5 8us NEXT None 19 us O us 10 2us 0 0us 10 2us 0 0us GTS K 37 us 11 4us 10 9us 5 5us 10 9us 5 5us SBR K 0 6 us O us 0 5 us 0 0 us 0 5 us 0 0 us RT None 35 us Ous 9 9 us 0 0 us 9 9 us 0 0 us RTC None 11 4 us 5 9 us MLS K 1 7 12 us 12us 115us 11 5us 3 7
74. 8 V Bit Reg 247us 1 0us 24 7us 1 0us K Constant 23 3 us 1 0 us 23 3 us 1 0 us E P Indir Data 50 6 us 1 0us 50 6us 1 0us S P Indir Bit 50 6us 1 0us 50 6us 1 0 us 35 SUBBD V Data Reg 242us 1 0us 59 V Bit Reg 24 2us 1 0us a K Constant 20 2us 1 0us lt P Indir Data E 50 2 us 1 0 us 2 P Indir Bit 50 2us 1 0us E MULB V Data Reg 10 8us 1 0us 10 8us 1 0 us V Bit Reg 10 8 us 1 0 us 10 8 us 1 0 us K Constant 8 2 us 1 0 us 8 2 us 1 0 us P Indir Data E 37 1 us 1 0 us 37 1 us 1 0 us P Indir Bit 37 1 us 1 0us 37 1 us 1 0 us DIVB V Data Reg 28 7 us 1 0 us 28 7 us 1 0 us V Bit Reg G un 28 7 us 1 0 us 28 7 us 1 0 us K Constant 26 1 us 1 0 us 26 1 us 1 0 us P Indir Data 54 9 us 1 0 us 54 9 us 1 0 us P Indir Bit 54 9us 1 0us 54 9us 1 0us ADDR V Data Reg 48 1 us 1 0 us 48 1 us 1 0 us V Bit Reg 48 1 us 1 0 us 48 1 us 1 0 us K Constant 41 7 us 10us 41 7 us 1 0 us P Indir Data 74 3 us 10us 74 3 us 1 0 us P Indir Bit 74 3 us 10us 74 3 us 1 0 us SUBR V Data Reg 50 1 us 1 0us 50 1 us 1 0 us V Bit Reg LL 50 1 us 1 0 us 50 1 us 1 0 us K Constant NN a 58 7 us 1 0 us 58
75. Assignment 230 240 250 1 260 Timebase Output Mask Word Start MDRMW CT aaa ae Fit 0 Control Jog Step Preset K bb Inputs 0 01 sec Count K cccc 15 Ggggg 0 Reset Step Counts Event 1 Kdddd Eeeee O OO OO OO OO OO OO OO O Ag Eeeee O O O OO OO OO OO OO oooO Esc ON O OLO OLO Olo Olo OLO OLO O Step Number s l O OLO Olo O OLO OLO O Eeeee OOO OO OO OO OC O OO OO O Counts per Step Eeeee O OO OO OO OOOO OO OO O l Ol O OLO O S l O ROMO O Event per step 9 Kdddd Eeeee O OO O0 OC O OC O OO OO OO 10 Kdddd Eeeee O OO OO OO OO OC CO OC CO OC OC O Output Pattern 11 Kdddd Esesel O O OO O G O G OO O O O O O O Off On 12 Kkiki sece O1 ADS OO OLO OIO 13 Kdddd Eeeee O OO OO OO OO OO OC CO OC OC O 14 Kdddd Eeeee O OO OO OO OO OC CO OC CO OC OC O ls kkk Eco O O O O O 16 Kerr Esc O OO 010 OO OO Olo OO Olo O The Masked Event Drum with Word Output features sixteen steps and sixteen outputs Drum outputs are logically ANDed bit by bit with an output mask word for each step The Ggggg field specifies the beginning location of the 16 mask words creating the final output Fffff field Step transitions occur on timed and or event basis The jog input also advances the step on each off to on transition Time is specified in counts per step
76. CT S SP 3 9 us 3 9 us 1 6 us 1 6 us 67 us 0 us 67 us 0 us OR X Y C T CT S SP 2 7 us 2 7 us 1 0 us 1 0 us 51 us 51 us 51 us 51 us ORN X Y C T CT S SP 3 3 us 3 3 us 1 4 us 1 4 us 55 us 55 us 55 us 55 us AND X Y C T CT S SP 2 1 us 2 1 us 0 8 us 0 8 us 42 us 42 us 42 us 42 us ANDN X Y C T CT S SP 2 7 us 2 7 us 1 2 us 1 2 us 51 us 51 us 51 us 51 us ANDSTR None 1 2 us 1 2 us 0 7 us 0 7 us 37 US 37 US 37 US 37 US ORSTR None 1 2 us 1 2 us 0 7 us 0 7 us 37 US 37 US 37 us 37 US OUT X Y C 3 4us 3 4us 7 95us 7 65us 1 82us 182us 1 82us 1 82 us OROUT X Y C 8 6 us 8 6us 8 25us 84us 2 09us 209us 2 09us 2 09 us NOT 1 04us 1 04us 1 04us 1 04us SET 1st X Y C S 174us 68us 11 4us 84us 92us 1 0us 92us 1 0us 2nd X Y C S N 12 0us 68us 11 0us 8 4us 9 6 ust 1 1 us 9 6 us 1 1 us pt 5 4usxN 7 0usxN 0 9usxN 0 9usxN RST 1st X Y C S 17 7us 68us 11 4us 84us 92us 10us 92us 1 0us 2nd X Y C S N 10 5us 6 8us 11 0us 8 4 us 9 6 us 1 1 us 9 6 us 1 1 us pt 5 2usxN 7 0usxN 0 9usxN 0 9usxN 1ist T CT 31 6 us 6 8 us 29 0 us 8 4 us 25 7 us 1 1 us 25 7 us 1 1 us 2nd T CT N pt 17us 6 8us 24 3us 8 4us 16 8us 1 4us 16 8us 1 4 us 14 6usx 4 7usxN 2 7usxN 2 7usxN N PAUSE 1wd Y 190us 19 0us 13 0us 13 0us 5 6 us 5 4 us 5 6 us 5 4 us 2wd Y N points 15us 15us 4u 11us 3u 11us 3u 9 2 us 4 8 us 9 2 us 4 8 us 4us x
77. D DL D amp ep Garage Door Opener Example Draw the Block Diagram In this next stage programming example we will create a garage door opener controller Hopefully most readers are familiar with this application and we can have fun besides The first step we must take is to describe how the door opener works We will start by achieving the basic operation waiting to add extra features later stage programs are very easy to modify Our garage door controller has a motor which raises or lowers the door on command The garage owner pushes and releases a momentary pushbutton once to raise the door After the door is up another push release cycle will lower the door In order to identify the inputs and outputs of the system it s sometimes helpful to sketch its main components as shown in the door side view to the right The door has an up limit and a down limit switch Each limit switch closes only when the door has reached the end of travel in the corresponding direction In the middle of travel neither limit switch is closed The motor has two command inputs raise and lower When neither input is active the motor is stopped The door command is a simple pushbutton Whether wall mounted as shown or a radio remote control all door control commands logically OR together as one pair of switch contacts The block diagram of the controller is shown to the right Input XO is from the pushbutton door
78. Not tion Execute Execute Execute Execute ORN 1st 2nd T CT V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 139us 48us 4 8 us 4 8 us 4 8 us P Indir Data 140us 110 0 us 30 2 us 30 2 us 30 2us 30 2 us P Indir Bit 234us 1140us 30 2us 30 2us 30 2us 30 2 us ist 2nd V Data Reg V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 141 us 110 0 us 30 2 us 30 2 us 30 2us 30 2 us P Indir Bit 234us 1140us 30 2us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 158us 120us 134us 13 9us 7 6us 7 6 us 7 6 us 7 6 us V Bit Reg 240us 120us 223us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 137us 12 0us 133us 139us 4 8us 4 8 us 4 8 us 4 8 us P Indir Data 230 us 110 0 us 30 2 us 30 2us 30 2 us 30 2 us P Indir Bit 324us 114 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 29 9us 29 9us 29 9 us V Bit Reg 29 9us 29 9us 29 9us 29 9 us K Constant er l 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit
79. SP value represents a safe no alarm condition The yellow zones lie outside the green zone and the red zones are beyond those DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only 8 57 The PV Deviation Alarms are reported in PID Mode and Alarm Status V 06 the two bits in the PID Mode and Alarm Status word in the loop table as shown to Bit 15 14 13 12 11 10 9 8 76543210 the right We highly recommend using o 4 ladder logic to monitor these bits The Red Deviation bit of word instructions make this easy to Yellow Deviation do Additionally you can monitor PID alarms using DirectSOFT32 The PV Deviation Alarm can be independently enabled and disabled from the other PV alarms using bit 13 of the PID Mode 1 Setting V 00 word Remember the alarm hysteresis feature works in conjunction with both the deviation and absolute value alarms and is discussed at the end of this section PV Rate of Change One powerful way to get an early warning of a process fault is to monitor the Alarm rate of change of the PV Most batch processes have large masses and slowly changing PV values A relatively fast changing PV will result from a broken signal wire for either the PV or control output a SP value error or other causes If the operator responds to a PV Rate of Change Alarm quickly and effectively the PV absolute value will not reach the point where the
80. Slot 3 32 SP51 Watchdog timeout SP127 Communication error Slot 3 Sg SP52 Syntax error SP130 Module busy Slot 4 DD SP39 Cannot Olve MMe 9 SP131 Communication error Slot 4 2 8 SP54 Intelligent module communication error SP132 Module busy Slot 5 SP133 Communication error Slot 5 SP134 Module busy Slot 6 SP135 Communication error Slot 6 SP136 Module busy Slot 7 SP137 Communication error Slot 7 DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 1 0 Module Codes Each system component has a code identifier This code identifier is used in some of the error messages related to the I O modules The following table shows these codes Code Component Type Code Component Type Hex Hex 04 CPU 36 Analog Input 03 I O Base 2B 16 pt Input 20 8 pt Output 37 Analog Output 21 8 pt Input 3D Analog I O Combo 24 4input output 4A Counter Interface combination AG 28 12 pt Output ES 16 pt Output FF No module detected 3F 32 pt Input 30 32 pt Output EE cae O 52 H2 ERM F2 CP128 51 H2 CTRIO BE D2 RMSM The following diagram shows an example of how the I O module codes are used el V7752 0020 Desired module ID code V7753 0026 Current module ID code V7754 0002 Location of conflict V7755 0252 Fatal error code
81. Ts so smaller numbers produce more gain and larger numbers produce less gain This is very important to know during loop tuning Each of the P I and D gains allows a setting to eliminate that term from the PID equation Many applications actually work best by using a subset of PID control The figure below shows the various combinations of PID control offered on the DL250 1 and DL260 CPUs We do not recommend using any other combination of control because most of them are inherently unstable P gt Laas DL205 User Manual 3rd Ed Rev A 08 03 8 37 PID Loop Operation DL250 1 DL260 only Derivative Gain The derivative term is unique in that it has an optional gain limiting feature This is Limiting provided because the derivative term reacts badly to PV signal noise or other causes of sudden PV fluctuations The function of the gain limiting is shown in the diagram below Use bit 9 of PID Mode 1 Setting V 00 word to enable the gain limit Loop Calculation A Proportional Control Setpoint Error Term Integral Output p c ntegra gt 4 Derivative lt Process Variable Derivative gain limited Aiia Dooa a Loop Table v PID Mode 1 Setting V 00 V 25 00XX Derivative Gain Limit
82. a smooth analog signal as the control output A loop in which the PV increases in response to a control output increase In other words the process has a positive gain The difference in value between the SP and PV Error SP PV An optional feature which makes the loop insensitive to errors when they are small You can specify the size of the deadband An optional feature which multiplies the error by itself but retains the original algebraic sign It reduces the effect of small errors while magnifying the effect of large errors A method of optimizing the control response of a loop when a change in setpoint or disturbance offset is known and has a quantifiable effect on the bias term The numerical result of a PID equation which is sent by the loop with the intention of nulling out the current error A constant that determines the magnitude of the PID derivative term in response to the current error A constant that determines the magnitude of the PID integral term in response to the current error In cascade control it is the loop that generates a setpoint for the cascaded loop An operational mode of a loop it which the PID calculations are stopped The operator must manually control the loop by writing to the control output value directly In cascade control the minor loop is the subordinate loop that receives its SP from the major loop A simple method of controlling a process through on off application of energy
83. amount The PV Alarm threshold values must have pin Mode and Alarm Status V 06 certain mathematical relationships to be valid The requirements are listed below If 1008764321 not met the Alarm Programming Error bit will be set as indicated to the right E Alarm Programming Error e PV Absolute Alarm value requirements Low low lt Low lt High lt High high e PV Deviation Alarm requirements Yellow lt Red DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Ramp Soak Generator Introduction Our discussion of basic loop operation noted the setpoint for a loop will be generated in various ways depending on the loop operating mode and programming preferences In the figure below the ramp soak generator is one of the ways the SP may be generated t is the responsibility of your ladder program to ensure only one source attempts to write the SP value at V 02 at any particular time Setpoint Sources S Setpoint V 02 gt Loop Control Output amp soak generator Calculation Ladder Program _ Another loop s output cascade Process Variable If the SP for your process rarely changes or can tolerate step changes you probably will not need to use the ramp soak generator However some processes require precisely controlled SP value changes The ramp soak generator can greatly reduce the amount of programming
84. cause control oscillations etc The DL250 1 and DL260 provides 12 bit 15 bit and 16 bit unipolar and bipolar data format options This selection affects SP PV Control Output and Integrator sum After deciding the number of loops PV variables to measure and SP values we can choose the appropriate I O modules Refer to the figure on the next page In many cases you will be able to share input or output modules among several control loops The example shown sends the PV and Control Output signals for two loops through the same set of modules Remember that AutomationDirect offers DL205 analog modules with 2 4 and 8 channels per module in different signal types and ranges Refer to the sales catalog for further information on specific modules The analog modules have their own manual which will be essential during most installations DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only DL250 CPU Input V memory Output Module Module Loop 1 Data m Channel 1 gt PV SP OUT Channel 1 gt Process 1 gt Loop 2 Data R Channel 2 gt PV SP OUT Channel 2 Process 2 gt Channel 3 Channel 4 Step 5 After selection and procurement of all loop components and I O modules we can Wiring and perform the wiring and installation Refer to the wiring guideli
85. check the program syntax For example you can use AUX 21 CHECK PROGRAM to check the program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT32 This check will find a wide variety of programming errors The following example shows how to use the syntax check with a Handheld Programmer Use AUX 21 to perform syntax check C B AUX 21 CHECK PRO CLR 2 4 AUX ENT 1 SYN 2 DUP REF Select syntax check default selection You may not get the busy display BUSY if the program is not very long One of two displays will appear Error Display example 00050 E401 MISSING END shows location in question Syntax OK display NO SYNTAX ERROR See the Error Codes Section for a complete listing of programming error codes If you get an error press CLR and the Handheld will display the instruction where the error occurred Correct the problem and continue running the Syntax check until the NO SYNTAX ERROR message appears DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 9 19 Duplicate You can also check for multiple uses of the same output coil Both programming Reference Check devices offer a way to check for this condition For example you can AUX 21 CHECK PROGRAM to check for duplicate references from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT32 The f
86. control Input X1 energizes when the door reaches the full up position Input X2 energizes when the door reaches the full down position When the door is positioned between fully up or down both limit switches are open The controller has two outputs to drive the motor Y1 is the up raise the door command and Y2 is the down lower the door command DL205 User Manual 3rd Ed 06 02 Stage Program Example A Garage Door Opener s Up limit switch a Motor Raise lt Lower CE 61 Door ER Command Down limit switch RS ime Inputs Outputs Toggle o QO Ladder To motor Up limit xi Program y1 O O m Raise Down limit oo X2 LYS Lower RLLPLUS Stage Programming Draw the State Now we are ready to draw the state transition diagram Like the previous light bulb Diagram controller example this application also has only one switch for the command input Refer to the figure below s When the door is down DOWN state nothing happens until XO energizes Its push and release brings us to the RAISE state where output Y1 turns on and causes the motor to raise the door e We transition to the UP state when the up limit switch X1 energizes and turns off the motor e Then nothing happens until another XO press relea
87. during off line operation This will allow you to develop a program in the Handheld Programmer and include password protection e AUX 81 Modify Password e AUX 82 Unlock CPU e AUX 83 Lock CPU You can use AUX 81 to provide an extra measure of protection by entering a password that prevents unauthorized machine operations The password must be an eight character numeric 0 9 code Once you ve entered a password you can remove it by entering all zeros 00000000 This is the default from the factory Once you ve entered a password you can lock the CPU against access There are two ways to lock the CPU with the Handheld Programmer e The CPU is always locked after a power cycle if a password is present e You can use AUX 83 and AUX 84 to lock and unlock the CPU You can also enter or modify a password from within DirectSOFT32 by using the PLC Password sub menu This feature works slightly differently in DirectSOFT32 Once you ve entered a password the CPU is automatically locked when you exit the software package It will also be locked if the CPU is power cycled WARNING Make sure you remember the password before you lock the CPU Once the CPU is locked you cannot view change or erase the password If you do not remember the password you have to return the CPU to the factory for password removal NOTE The D2 240 DL250 1 and D2 260 CPUs support multi level password protection of the ladder program This allows passw
88. for the ramp soak control bits is all zeros Ladder logic must set only one control bit at a time e Start a 0 to 1 transition will start the ramp soak profile The CPU must be in Run Mode and the loop can be in Manual or Auto Mode If the profile is not interrupted by a Hold or Jog commana it finishes normally s Hold a 0 to 1 transition will stop the ramp soak profile in its current state and the SP value will be frozen e Resume a 0 to 1 transition cause the ramp soak generator to resume operation if it is in the hold state The SP values will resume from their previous value e Jog a 0 to 1 transition will cause the ramp soak generator to truncate the current segment step and go to the next segment Ramp Soak Profile You can monitor the Ramp Soak profile Ramp Soak Settings V 33 Monitoring status using other bits in the Ramp Soak Settings V 33 word shown to the right a STT s R S Profile Complete 1 when the ae A f R S Profile in Hold last prograrnmad step is done Soak PV Deviation e Soak PV Deviation 1 when the R S Profile Complete error SP PV exceeds the specified deviation in the R S table e R S Profile in Hold 1 when the profile was active but is now in hold The number of the current step is available Ramp Soak Settings V 33 in the upper 8 bits of the Ramp Soak Settings V 33 word The bits represent a 2 digit hex number ranging from
89. in the CPU automatically calculate the gains auto tuning Most experienced process engineers will have a favorite method and the CPU will accommodate either preference The use of the auto tuning can eliminate much of the trial and error of the manual tuning approach especially if you do not have a lot of loop tuning experience However note that performing the auto tuning procedure will get the gains close to optimal values but additional manual tuning changes can take the gain values to their optimal values Improper loop parameters will result if your PV fluctuates rapidly during auto tuning The built in PV analog filter see page 8 46 or ladder logic PV filter see example on page 8 48 must be used during auto tuning to prevent noise from giving a false indication of loop characteristics to the tuning algorithm Once the loop s are properly tuned the PV filter can be disabled WARNING Only authorized personnel fully familiar with all aspects of the process should make changes that affect the loop tuning constants Using the loop auto tune procedures will affect the process including inducing large changes in the control output value Make sure you thoroughly consider the impact of any changes to desa O TENN minimize the risk of injury to personnel or damage to equipment The auto tune in the DL250 1 and DL260 is not intended to perform as a replacement for your process knowledge AE doo did Open Lo
90. in the local I O system The problem could be in the COMMUNICATION FAILURE IN THE I O CHAIN base I O bus or the base power supply SP45 will be on and the error code will be stored in V7755 Run AUX42 to determine the base location reporting the error E252 This error occurs when the auto configuration check is turned on in the CPU NEW I O CFG and the actual I O configuration has changed either by moving modules in a base or changing types of modules in a base You can return the modules to the original position types or run AUX45 to accept the new configuration SP47 will be on and the error code will be stored in V7755 E262 An out of range I O address has been encountered in the application UO OUT OF RANGE program Correct the invalid address in the program SP45 will be on and the error code will be stored in V7755 DL205 User Manual 3rd Ed Rev A 08 03 DL205 Error Codes B 3 DL205 Error Code Description E312 A data error was encountered during communications with the CPU Clear HP COMM the error and retry the request If the error continues check the cabling ERROR 2 between the two devices replace the handheld programmer then if necessary replace the CPU SP46 will be on and the error code will be stored in V7756 E313 An address error was encountered during communications with the CPU HP COMM Clear the error and retry the request If the error continues
91. in the previous table AUX 73 compares the program in the Handheld programmer EEPROM with the CPU program You can compare different types of information as shown previously There is also an option called etc that allows you to check all of the areas sequentially without re executing the AUX function every time AUX 74 allows you to check the EEPROM in the handheld programmer to make sure it is blank It s a good idea to use this function anytime you start to copy an entire program to an EEPROM in the handheld programmer AUX 75 allows you to clear all data in the EEPROM in the handheld programmer You should use this AUX function before you copy a program from the CPU You can use AUX 76 to quickly determine what size EEPROM is installed in the CPU and Handheld Programmer The DL230 and DL240 use different size EEPROMs See Chapter 3 for additional information gt S gt oO lt 0 da Jx 2 gt Le ao DL205 User Manual 3rd Ed Rev A 08 03 ES Auxiliary Functions AUX 8 Password Operations U ZS 2 xe 2r 2 gt E E AUX 81 83 AUX 81 Modify Password A D a as AUX 82 Unlock CPU AUX 83 Lock CPU There are several AUX functions available that you can use to modify or enable the CPU password You can use these features during on line communications with the CPU or you can also use them with an EEPROM installed in the Handheld Programmer
92. into the system The mass of the process averages the on off effect for a relatively smooth PV A simple ladder program can convert the DL250 s continuous loop output to on off control A mathematical method of closed loop control involving the sum of three terms based on proportional integral and derivative error values The three terms have independent gain constants allowing one to optimize tune the loop for a particular physical system The control output is calculated so it responds to the displacement position of the PV from the SP error term A manufacturing procedure which adds value to raw materials Process control particularly refers to inducing chemical changes to the material in process A quantitative measurement of a physical property of the material in process which affects final product quality and is important to monitor and control DL205 User Manual 3rd Ed Rev A 08 03 Proportional Gain PV Absolute Alarm PV Deviation Alarm Ramp Soak Profile Rate Remote Setpoint Reset Reset Windup Reverse Acting Loop Sampling time Setpoint SP Soak Deviation Step Response Transfer Velocity Algorithm 8 67 PID Loop Operation DL250 1 DL260 only A constant that determines the magnitude of the PID proportional term in response to the current error A programmable alarm that compares the PV value to alarm threshold values A programmable alarm that compares the difference betwee
93. is feedforward The benefits from using feedforward are e The SP PV error is reduced during predictable setpoint changes or loop offset disturbances e Proper use of feedforward will allow us to reduce the integrator gain Reducing integrator gain gives us an even more stable control system g C D O1 L ms g C o O G El AE doo did Feedforward is very easy to use in the DL250 1 and DL260 loop controller as shown below The bias term has been made available to the user in a special read write location at PID Parameter Table location V 04 gt Loop Calculation P Kp l V 04 Setpoint gt Error Term D l XXXX Bias Term gt Control Output_ d Process Variable gt D DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation GO ro N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Feedforward Example To change the bias operating point ladder logic only has to write the desired value to V 04 The PID loop calculation first reads the bias value from V 04 and modifies the value based on the current integrator calculation Then it writes the result back to location V 04 This arrangement creates a sort of transparent bias term All you have to do to implement feed forward control is write the correct value to the bias term at the right time the example bel
94. is not preceded by the CV instruction ACVJMP must immediately MISSING CV follow the CV instruction INSTRUCTION E485 A CVJMP instruction is not placed between the CV and the SG ISG BLK NO CVJMP BEND END instruction E486 A BCALL is used in a subroutine or a program interrupt routine The INVALID BCALL BCALL instruction may only be used in the main program area before the ADDRESS END statement E487 The BCALL instruction is not followed by a BLK instruction MISSING BLK INSTRUCTION E488 The BLK instruction is used in a subroutine or a program interrupt Another INVALID BLK BLK instruction is used between the BCALL and the BEND instructions ADDRESS E489 The control relay used for the BLK instruction is being used as an output DUPLICATED CR elsewhere REFERENCE DL205 User Manual 3rd Ed Rev A 08 03 DL205 Error Codes B 7 ups 35 ojo 03 Sa Qx Du DL205 Error Code Description E490 The BLK instruction is not immediately followed by the SG instruction MISSING SG INSTRUCTION E491 There is an ISG instruction between the BLK and BEND instructions INVALID ISG INSTRUCTION ADDRESS E492 The BEND instruction is used in a subroutine or a program interrupt routine INVALID BEND The BEND instruction is not followed by a BLK instruction ADDRESS E493 A CV SG ISG BLK BEND instruction must immediately follow the BEND MISSING REQUIRED instr
95. it is good practice it is not required that s good because our two locations for the Set S6 instruction make that impossible Stage numbers and how they are used determines the transition paths In stage S6 we turn on the safety light by energizing Y3 Special relay contact SP1 is always on Timer TO times at 0 1 second per count To achieve 3 minutes time period we calculate 3 min x 60 sec min 0 1 sec count K 1800 counts The timer has power flow whenever stage S6 is active The corresponding timer bit TO is set when the timer expires So three minutes later TO 1 and the instruction Reset S6 causes the stage to be inactive While Stage S6 is active and the light is on stage transitions in the primary path continue normally and independently of Stage 6 That is the door can go up down or whatever but the light will be on for precisely 3 minutes K RLLPLUS Stage Programming 58 DOWN State Xo S1 IMP se Push UP State XO S2 V4 IMP S6 SET se RAISE State SP1 Y1 OUT x1 S3 CAMP SG 33 UP State XO S4 MP a Push DOWN State XO S5 V4 CAMP S6 E SET SG D S5 LOWER State SP1 Y2 OUT X2 So IMP SG S6 LIGHT State SP1 Y3 our TMR TO K1800 TO S6 ART DL205 User Manual 3rd Ed 06 02 a D Q D D e Q S 3 2 gt a SM1d T14
96. main process The counter inside the supervisor stage uses the stage bit S1 of the S1 main process as its count input Stage bits SGCNT CTO used as a contact let us monitor a process K5000 Note that both the Supervisor stage and the OFF stage are initial stages The supervisor stage remains active indefinitely Stage Counter The counter in the above example is a special Stage Counter Note that it does not have a reset input The count is reset by executing a Reset instruction naming the counter bit CTO in this case The Stage Counter has the benefit that its count may be globally reset from other stages The standard Counter instruction does not have this global reset capability You may still use a regular Counter instruction inside a stage however the reset input to the counter is the only way to reset it DL205 User Manual 3rd Ed 06 02 7 18 RLL PLUS D E D DL D amp ep RLLPLUS Stage Programming Unconditional Outputs Power Flow Transition Technique As in most example programs in this SG chapter and Stage 0 to the right your So application may require a particular output spi va to be ON unconditionally when a particular Z stage is active Until now the examples I OUT always use the SP1 special relay contact Unconditional always on in series with the output coils ec Output It s possible to omit the c
97. missing from the SR instruction BAD SR E461 More than nine levels of logic have been stored on the stack Check the use STACK OVERFLOW of OR STR and AND STR instructions E462 An unmatched number of logic levels have been stored on the stack Insure STACK the number of AND STR and OR STR instructions match the number of STR UNDERFLOW instructions E463 A STR instruction was not used to begin a rung of ladder logic LOGIC ERROR E464 A rung of ladder logic is not terminated properly MISSING CKT E471 Two or more OUT instructions reference the same l O point DUPLICATE COIL REFERENCE E472 Two or more TMR instructions reference the same number DUPLICATE TMR REFERENCE m gt 35 ojo 03 Oa ax Du DL205 User Manual 3rd Ed Rev A 08 03 ET DL205 Error Codes DL205 Error Code Description ng XD Ke se Ou 20 ii E473 Two or more CNT instructions reference the same number DUPLICATE CNT REFERENCE E480 The CV instruction is used in a subroutine or program interrupt routine The INVALID CV CV instruction may only be used in the main program area before the END ADDRESS statement E481 An instruction exists between convergence stages CONFLICTING INSTRUCTIONS E482 Number of CV instructions exceeds 17 MAX CV INSTRUCTIONS EXCEEDED E483 CVJMP has been used in a subroutine or a program interrupt routine INVALID CVJMP ADDRESS E484 CVJMP
98. no programming errors Establishing the On a program to run mode transition the CPU reads the loop setup parameters as Loop Table Size pictured below At that moment the CPU learns the location of the loop table and the and Location number of loops it configures Then during the ladder program scan the PID Loop task uses the loop data to perform calculations generate alarms and so on There are some loop table parameters the CPU will read or write on every loop calculation CPU Tasks V Memory Space User Data pa READ Ladder Program WRITE LOOP gt a DATA eR EE doo did Jg C D O1 L g C o O G gt CONFIGURE MONITOR a ee PID Loop ae Setup Parameters READ V7640 V7641 at powerup DirectSOFT32 Programming Soft ware The Loop Parameter table contains data for V Memory User Data only as many loops selected by the value you have programmed in V7641 Each loop configured occupies 32 words 0 to 37 octal in the loop table yas de For example suppose we have an V2040 LOOP 2 application with 4 loops Arbitrarily we V2077 32 words choose V2000 as the starting location The LOOP 3 Loop Parameter will occupy V2000 V2037 i 32 words for loop 1 V2040 V2077 for loop 2 and so LOOP 4 on Loop 4 occupies V2140 V2177 32 words DL205 User Manual 3rd Ed Rev A 08 03 8 8 PID Loop Operation DL250 1
99. of this section Below is the instruction in chart form as displayed by DirectSOFT32 Counter Number Step Preset Timebase ea Discrete Output Assignment The Event Drum with Discrete Outputs features 16 steps and 16 outputs Step transitions occur on timed and or event basis The jog input also advances the step on each off to on transition Time is specified in counts per step and events are specified as discrete contacts Unused steps and events can be left blank this is the default entry The discrete output points may be individually assigned The output pattern may be edited graphically with DirectSOFT32 Whenever the Start input is energized the drum s timer is enabled As long as the event is true for the current step the timer runs during that step When the step count equals the counts per step the drum transitions to the next step This process stops when the last step is complete or when the Reset input is energized The drum enters the preset step chosen upon a CPU program to run mode transition and whenever the Reset input is energized Drum Parameters Field Data Types Ranges Counter Number aaa 0 177 DL250 1 0 377 DL260 Preset Step bb K 1 16 Timer base CEGC 0 99 99 seconds Counts per step dddd K 0 9999 Event eeee X Y C S T ST GX GY see page 3 52 or Discrete Outputs Fffff X Y C GX GY pag
100. one display If you want to see Programmer the complete description press the arrow keys to scroll left and right Also depending on the current display you may have to press CLR more than once AUX FUNCTION SELECTION AUX 2 RLL OPERATIONS Use NXT or PREV to cycle through the menus AUX FUNCTION SELECTION AUX 3 V OPERATIONS NEXT Press ENT to select sub menus AUX 3 V OPERATIONS AUX 31 CLR V MEMORY ENT You can also enter the exact AUX number to go straight to the sub menu Enter the AUX number directly D fe a AUX 3 V OPERATIONS AUX 31 CLR V MEMORY CLR DL205 User Manual 3rd Ed Rev A 08 03 A4 Auxiliary Functions AUX 2 RLL Operations U BE 2 xe Ein 2 gt E x AUX 21 22 23 and 24 AUX 21 Check Program AUX 22 Change Reference AUX 23 Clear Ladder Range AUX 24 Clear Ladders There are four AUX functions available that you can use to perform various operations on the control program e AUX 21 Check Program e AUX 22 Change Reference e AUX 23 Clear Ladder Range e AUX 24 Clear Ladders Both the Handheld and DirectSOFT32 automatically check for errors during program entry However there may be occasions when you want to check a program that has already been in the CPU There are two types of checks available e Syntax e Duplicate
101. or possibly a faulty NO HPP EEPROM EEPROM installed in the handheld programmer E623 A function was requested with an EEPROM which contains system SYSTEM EEPROM information only E624 A function was requested with an EEPROM which contains V memory data V MEMORY ONLY only E625 A function was requested with an EEPROM which contains program data PROGRAM ONLY only DL205 User Manual 3rd Ed Rev A 08 03 DL205 Error Codes B 9 DL205 Error Code Description E627 An attempt to write to a write protected or faulty EEPROM was made Check BAD WRITE the write protect jumper and replace the EEPROM if necessary E628 The wrong size EEPROM is being used The DL230 and DL240 CPUs use EEPROM TYPE ERROR different size EEPROMs E640 A compare between the EEPROM and the CPU was found to be in error COMPARE ERROR E650 A system error has occurred in the handheld programmer Power cycle the HPP SYSTEM handheld programmer If the error returns replace the handheld programmer ERROR E651 A ROM error has occurred in the handheld programmer Power cycle the HPP ROM ERROR handheld programmer If the error returns replace the handheld programmer E652 A RAM error has occurred in the handheld programmer Power cycle the HPP RAM ERROR handheld programmer If the error returns replace the handheld programmer m gt 35 ojo 03 2a Qx Du DL205 User Manual 3rd Ed Rev A 08 03 In
102. points Ladder Program Drum pattern Output Mask oe gt CPU Image Register 00 000 T 00000 00 000600 060000000 00000000 00006000 Final Write Outputs gt Other rungs Practical applications for drum output masking include e Nested Sequence a particular output can perform a specialized sequence inside a particular step while the other drum outputs remain static Rather than consume additional steps we mask off the output and control it elsewhere in ladder logic during the step duration s Manual Override occasionally we need to do manual control of some output s in a particular step Masking the appropriate drum outputs will allow manual inputs to take over the control through ladder logic Each step has ts own mask word Each bit Ocal V memory of the word masks the corresponding address s output point A 16 register table in V memory will contain the mask values as VXXXX shown to the right In the drum instruction Mask you specify the starting location of the Boers table For example a table which begins Vico IO at V2000 will extend to V2017 Multiple 17 MDRMD or MDRMW drums must have separate mask tables When a mask bit 1 the drum controls the output point when the mask bit 0 the drum cannot write to the image regi
103. process variable After selecting the data format for these variables you can set limits on the range of SP values which the loop calculation will use Many loops have two or more possible sources writing the Setpoint at various times and the limits you set will help safeguard the process from the effects of a bad SP value In the figure below the SP has a selectable limit function enabled by PID Mode 2 Setting V 01 word bit 3 If enabled then locations V 26 and V 27 determine the lower and upper SP limits respectively The loop calculation applies this limit internally so it is always possible to write any value to V 02 No L Limits 0 L 8 Control Setpoint E Loop Output With Calculation C Z _ Limits a PEN P Variable PV L rocess Variable PV Loop Table V 26 XXXX SP Lower Limit PID Mode 2 Setting V 01 V 27 XXXX SP Upper Limit Bit 15 14 13 12 11 10 9 8 7 6 5 hr 0 SP Limits enable The loop calculation checks these SP upper and lower limits before each calculation This means ladder logic can change the limit settings while a process is in progress allowing you to keep a tighter guard band on the SP input value DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Remote Setpoint You may recall there are generally several p
104. request bits and the actual loop mode is indicated elsewhere The following figure shows an operator s panel using momentary push buttons to request PID mode changes The panel s mode indicators do not connect to the switches but interface to the corresponding data locations Operator s Panel TL Manual L J iL Auto LOL Mode Request ie Mode Monitoring L Cascade Le LA PID Mode 1 Setting V 00 Loop Mode and Alarm Status V 06 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit 15 14 13 12 1110 9 8 7 6 5 4 3 210 PLC Modes Effect If you have selected the option for the loops to follow the PLC mode the PLC modes on Loop Modes Program Run interact with the loops as a group The following summarizes this interaction e When the PLC is in Program Mode all loops are placed in Manual Mode and no loop calculations occur However note that output modules including analog outputs turn off in PLC Program Mode So actual manual control is not possible when the PLC is in Program Mode e The only time the CPU will allow a loop mode change is during PLC run Mode operation As such the CPU records the modes of all 16 loops as the desired mode of operation If power failure and restoration occurs during PLC Run Mode the CPU returns all loops to their prior mode which could be Manual Auto or
105. response of the PV to a step change in the output The instructions on how to so this are in the section on the manual tuning procedure located prior to this section on auto tuning Auto tuning error if the auto tune error bit bit 13 of Loop Mode and Alarm status word V 06 is on please verify the PV and SP values are within 5 of full scale difference as required by the auto tune function The bit will also turn on if the closed loop method is in use and the output goes to the limits of the range DL205 User Manual 3rd Ed Rev A 08 03 8 44 PID Loop Operation gt GO ro N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Closed Loop Auto Tuning During a closed loop auto tuning cycle the loop controller operates as shown in the diagram below PLC System Process Variable ALO Response Limit cycle wave Closed Loop Auto Tuning Control Setpoint Value 5 Error Term Loop Output Manufacturing N Calculation Process Process Variable When auto tuning the loop controller imposes a square wave on the output Each transition of the output occurs when the PV value crosses over or under the SP value Therefore the frequency of the limit cycle is roughly proportional to the mass of the process From the PV response the auto tune function calculates the gains and the sample t
106. see on the PID trend view The critically damped response shown gives the fastest PV response without oscillating DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Ea e Over damped response the gains are too small so gradually increase them concentrating on the proportional gain first e Under damped response the gains are too large Reduce the integral gain first and then the proportional gain if necessary e Critically damped response this is the the optimal gain setting You can verify that this is the best response by increasing the proportional gain slightly the loop then should make one or two small oscillations NAL 10 of l SP range over damped response critically damped response SP PV under damped response Now you may want to add a little derivative gain to further improve the run continuously during operation this would be adaptive control Whenever a substantial change in loop dynamics occurs mass of process size of actuator etc you will need to repeat the tuning procedure to derive the new gains that are required for optimal control critically damped response above Note the proportional and integral gains will be 5 very close to their final values at this point Adding some derivative action will allow Ea you to increase the proportional gain slightly without causing loop oscillations The ao derivative action tends to t
107. that the following publications be purchased and used as guidelines e BSI publication TH 42073 February 1996 covers the safety and electrical aspects of the Machinery Directive s EN 60204 1 1992 General electrical requirements for machinery including Low Voltage and EMC considerations DL205 User Manual 3rd Ed Rev A 08 03 G 4 European Union Directives s IEC 1000 5 2 EMC earthing and cabling requirements s IEC 1000 5 1 EMC general considerations It may be possible for you to obtain this information locally however the official source of applicable Directives and related standards is The Office for Official Publications of the European Communities L 2985 Luxembourg quickest contact is via the World Wide Web at www euro op eu int Another source is Global Engineering Documents www global ihs com OS x 2 58 co Oo 2 gt LU Basic EMC Installation Guidelines Enclosures The following diagram illustrates good engineering practices supporting the requirements of the Machinery and Low Voltage Directives House all control equipment in an industry standard lockable steel enclosure and use metallic conduit for wire runs and cables may be required for CE compliance see Declaration of Conformity for specific product requirements Mains fused rete isolation transformer Ferrite choke on Communications keyed lockout An switch communications cables Metallic conduit for com
108. us 1st 2nd V Data Reg V Data Reg 78 us 13 8 us 46 us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 159us 13 8us 135us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 57 us 13 8 us 46 us 162us 48us 4 8 us 4 8 us 4 8 us P Indir Data 141 us 111 0 us 302us 30 2 us 30 2us 30 2 us P Indir Bit 235us 115 0 us 30 2 us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 159us 138us 135us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 241 us 13 8us 225us 16 2us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 139 us 138us 135us 16 2us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 231 us 111 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Bit 324 us 115 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 299us 299us 29 9 us a V Bit Reg 29 9 us 29 9us 29 9us 29 9 us B K Constant 27 4us 27 4us 27 4us 27 4us E P Indir Data 51 0us 510us 510us 51 0 us o H P Indir Bit our 510us 510us 51 0us 51 0 us x5 P Indir Bit V Data Reg 29 9us 29 9us 29 9us 29 9 us DT 5 V Bit Reg 29 9us 29 9us 29 9us 29 9 us 5 S K Constant 27 4us 27 4us 27 4us 27 4 us Em P Indir Data 51 0us 510us 51 0us 51 0us P Indir Bit 51 0us 51 0us 51 0us 51 0 us no Cc DL205 User Manual 3rd Ed Rev A 08 03 C 9
109. value CT n 1 not used CTA n 2 3 176 3 376 Preset Step CT n 2 not used CTA n 3 4 177 4 377 Current Step CT n 1 not used The following ladder program shows the MDRMD instruction in a typical ladder program as shown by DirectSOFT32 Steps 1 through 11 are used and all 16 output points are used The output mask word is at V2000 The final drum outputs are shown above the mask word as individual bits The data bits in V2000 are logically ANDed with the output pattern of the current step in the drum If you want all drum outputs to be off after powerup write zeros to V2000 on the first scan Ladder logic may update the output mask at any time to enable or disable the drum outputs The preset step is step 1 The timebase runs at K10 x 0 01 0 1 second per count Therefore the duration of step 1 is 5 x 0 1 0 5 seconds Note that step 1 is time based only event is left blank In the last rung the Drum Complete bit CT10 turns on output YO upon completion of the last step step 10 A drum reset also resets CT10 DirectSOFT32 Display 1 Start MDRMD CT10 C34 Y32 C14 Y10 C4 YB Y13 C7 i Jog Step Preset K1 1 72 c30 20 c2 e v42 c10 x2 0 01 sec Count K 10 15 V2000 0 Reset Step Counts Event 1 KO005 O 06 00668068 00 068 000 2 k0
110. value in V3710 SP571 Current target value on when the counter current value equals the value in V3712 SP572 Current target value on when the counter current value equals the value in V3714 SP573 Current target value on when the counter current value equals the value in V3716 SP574 Current target value on when the counter current value equals the value in V3720 SP575 Current target value on when the counter current value equals the value in V3722 SP576 Current target value on when the counter current value equals the value in V3724 SP577 Current target value on when the counter current value equals the value in V3726 SP600 Current target value on when the counter current value equals the value in V3730 SP601 Current target value on when the counter current value equals the value in V3732 SP602 Current target value on when the counter current value equals the value in V3734 SP603 Current target value on when the counter current value equals the value in V3736 SP604 Current target value on when the counter current value equals the value in V3740 SP605 Current target value on when the counter current value equals the value in V3742 SP606 Current target value on when the counter current value equals the value in V3744 SP607 Current target value on when the co
111. will occur SP52 will be on and the error code will be stored in MEMORY V7755 Reduce the size of the application program EXCEEDED E104 A write to the CPU was not successful Disconnect the power remove the WRITE FAILED CPU and make sure the EEPROM is not write protected If the EEPROM is not write protected make sure the EEPROM is installed correctly If both conditions are OK replace the CPU E151 A parity error has occurred in the application program SP44 will be on and BAD COMMAND the error code will be stored in V7755 This problem may possibly be due to electrical noise Clear the memory and download the program again Correct any grounding problems If the error returns replace the EEPROM or the CPU E155 A checksum error has occurred in the system RAM SP44 will be on and the RAM FAILURE error code will be stored in V7755 This problem may possibly be due to a low battery electrical noise or a CPU RAM failure Clear the memory and download the program again Correct any grounding problems If the error returns replace the CPU E202 An I O module has failed to communicate with the CPU or is missing from the MISSING I O base SP45 will be on and the error code will be stored in V7756 Run AUX42 MODULE to determine the slot and base location of the module reporting the error E210 A short duration power drop out occurred on the main power line supplying POWER FAULT power to the base E250 A failure has occurred
112. 0 1 T o a s 1 8 0 1 9 9 1 10 0 1 11 0 1 12 0 1 A 13 0 1 14 0 1 15 0 g Ue fo CE o gt 32 3c 52 WO O 5 DL205 User Manual 3rd Ed Rev A 08 03 6 4 Drum Instruction Programming Step Transitions Programming c Q O 5 pun D C 5 _ a Drum Instruction Types Timer Only Transitions There are four types of Drum instructions in the DL250 1 and DL260 CPUs e Timed Drum with Discrete Outputs DRUM e Time and Event Drum with Discrete Outputs EDRUM e Masked Event Drum with Discrete Outputs MDRMD e Masked Event Drum with Word Output MDRMW The four drum instructions all include time based step transitions and three include event based transitions as well Other options include outputs defined as a single word or as individual bits and an output mask individual output disable enable Each drum has 16 steps and each step has 16 outputs Refer to the figure below Each output can be either an X Y or C coil offering programming flexibility We assign Step 1 an arbitrary unique output pattern o Off On as shown When programming a drum instruction you also determine both the output assignment and the On Off state pattern at that time All steps use the same output assignment but each step may have its own unique output pattern Drums move from step to step based on time and or an external event input All four drum types offer timer ste
113. 0 cc On 52 Faj ES5 52 gt Le oO gra D mu where you need the capability to force an I O point to be either on or off Before you use a programming device to force any data type it is important to understand how the DL205 CPUs process the forcing requests WARNING Only authorized personnel fully familiar with all aspects of the application should make changes to the program Make sure you thoroughly consider the impact of any changes to minimize the risk of personal injury or damage to equipment There are two types of forcing available with the DL205 CPUs Chapter 3 provides a detailed description of how the CPU processes each type of forcing request e Regular Forcing This type of forcing can temporarily change the status of a discrete bit For example you may want to force an input on even though it is really off This allows you to change the point status that was stored in the image register This value will be valid until the image register location is written to during the next scan This is primarily useful during testing situations when you need to force a bit on to trigger another event s Bit Override DL240 DL250 1 or DL260 Bit override can be enabled on a point by point basis by using AUX 59 from the Handheld Programmer or by a menu option in DirectSOFT32 You can use Bit Override with X Y C T CT and S data types Bit override basically disables any changes to the discrete point
114. 0 DL250 1 DL260 CPU Special Relays Special Relays DL230 CPU Special Relays on for the first scan after a power cycle or program to run transition only The relay is reset to off on the second scan It is useful where a function needs to be performed only on program startup provides a contact to insure an instruction is executed every scan provides a contact that is always off on for 30 seconds and off for 30 seconds on for 0 5 second and off for 0 5 second on for 50 ms and off for 50 ms on for 25 ms and off for 25 ms on every other scan on when the CPU is in the run mode on when the CPU is in the program mode on when the STOP instruction is executed on when interrupts have been enabled using the ENI instruction on when a critical error such as I O communication loss has occurred on when anon critical error such as a low battery has occurred on when the CPU battery voltage is low on when a memory error such as a memory parity error has occurred on when an I O error occurs For example an I O module is withdrawn from the base or an I O bus error is detected on if an I O configuration error has occurred The CPU power up I O configuration check must be enabled before this relay will be functional on when a Fault Instruction is executed on if the CPU Watch Dog timer times out on if a grammatical error has oc
115. 0000 SHFT Ls o NExT DEF K0000 3 P o NEXT Y C E A A DEF 0000 SHFT Yu gt NEXT DEF K0000 a n o NExT DEF 0000 sHFT lt 7 P E 4 NEXT DEF K0000 NEXT DEF 0000 SHET 3 p o next DEF K0000 NEXT Y G DEF 0000 SHFT ls o NEXT DEF K0000 NEXT shinier DEF 0000 SHFT ES H z NEXT DEF K0000 NEXT unused steps DEF 0000 sHFT gt p E a NEXT DEF K0000 NEXT 16 DEF 0000 SHFT YIS B 4 NEXT 16 DEF K0000 NEXT Continued on next page DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming Handheld Programmer Keystrokes cont d Handheld Programmer Keystrokes cont d ki 1 Q 1 DEF 0000 NExT skip over unused event DEF K0000 NEXT d step 1 pattern 0000 Ue 8 amp 3 DEF 0000 suer Y E NEXT pas A MLS 4 DEF K0000 d l B y NEXT S 5 9 8 1 2 2 SHFT X B NEXT C l J E 23 DEF 0000 SET 1 DEF K0000 5 8 9 a NEXT 3 S D X C SF DEF 0000 SHFT er gt NEXT CBR aana E a E E H G ES 9 DEF 0000 sHFT f A o NEXT DEF Ko000 F B G J MET 5 1 6 9 DEF 0000 sHFT A Le NEXT CBee nanl D E D ae 9 3 4 3 x
116. 020Y40 0 OO 6 OO OO CO 60 O0 68 3 KO150 X21 O CIR 068 0006 00 60 6 4 k0048 X2 O 0 OO 60 00666 0 6 08 5 K0180 CO O 06860 00680668 Oe O 0e 6 K0923 C1 600680 06868 0 08 0 O0 6e 7 K0120 X30 O 0O OO OOOO OO 0066 8 K0864 X35 OO O 068 0060608 0 Ce 9 K0120 X33 O O O OO OR 668 OO 068 oO 10 K4000 Y17 O 0000 CO 00668 00 68 11 c20 0 0006000600 066 12 O Olo 0O OO OO ooo olo olo Q 13 O OO OO OO CO CO OO CO CO OO 14 O OO CO O OO OO OO OO OO O 15 CHO Cl C e OC 16 OCHO Ol Cl O CIO CIO CIO CO O gT Drum Complete Rs ai Set Mask Registers LD K fff NOTE The ladder program must load constants in V2000 through V2012 to cover all mask registers for the eleven steps used in this drum RL g Ue fo 82 o 32 3c 52 WO O 5 DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Masked Event Drum with Word Output Drum Instruction Programming The Masked Event Drum with Word Output features outputs organized as bits of a single word rather than discrete points It operates according to the general principles of drum operation covered in the beginning of this section Below is the MDRMW instruction in chart form as displayed by DirectSOFT32 C Si AS Counter Number Step Preset Word Output
117. 1 to 10 Ladder logic can monitor these to synchronize other parts of the program Current Profile Step 2 digit hex with the ramp soak profile Load this word E to the accumulator and shift right 8 bits bic ire and you have the step number Bit 15 14 13 12 11 10 9 8 76543210 AE doo did Jg C D O1 L g C o O G Ramp Soak The starting address for the ramp soak Ramp Soak Table Error V 35 Programming table must be a valid location If the Errors address points outside the range of user es V memory one of the bits to the right will turn on when the ramp soak generator is Starting Address set in i started We recommend using reserved system V memory DirectSOFT32 to configure the Starting Address set out of ramp soak table It automatically range V memory upper range checks the addresses for you y Starting Address set out of V memory lower range Testing Your It s a good idea to test your ramp soak profile before using it to control the process Ramp Soak Profile This is easy to do because the ramp soak generator will run even when the loop is in Manual Mode Using DirectSOFT32 s PID View will be a real time saver because it will draw the profile on screen for you Be sure to set the trending timebase slow enough to display completed ramp soak segment pairs in the waveform window DL205 Us
118. 2 240 2 8 oz 80g 809 D2 08TD1 2 3 oz 65 D2 250 1 2 5 oz 70g 659 D2 08TD2 4 2 oz 118 D2 260 2 5 oz 70g 1189 D2 16TD1 2 2 1 oz 60 1 0 Bases 6 921009 D2 16TD2 2 2 0 oz 56g D2 03B 1 12 30z 350g D2 32TD1 2 102 60g D2 03BDC1 1 11 40z 322g D2 32TD2 3 50z 100g D2 03BDC 2 10 10z 285 E 92168991 AC Output D2 04B 1 13 4 oz 381g Modules D2 04BDC1 1 12 5 oz 354g D2 08TA 2 8 oz 80g D2 04BDC 2 11 2 oz 317g F2 08TA 3 0 oz 869 D2 06B 1 14 4 oz 4109 D2 12TA 3 8 oz 110g D2 06BDC1 1 13 8 0z 3929 Relay Output D2 06BDC2 1 13 8 oz 3929 Modules D2 09B 1 18 6 oz 5309 D2 04TRS 2 8 oz 809 D2 09BDC1 1 18 3 oz 522g D2 08TR 3 8 oz 110g D2 09BDC2 1 19 oz 530g D2 12TR 4 6 oz 130g DC Input Modules F2 08TR 5 5 oz 156g E CPU Slot D2 32ND3 2 10z 60g Haas D2 32ND3 2 109 S 3 eee eee H2 EBC 1 6 oz 45g AC Input Modules Weight H2 EBC F 2 1 oz 60g D2 08NA 1 2 5 oz 70g F2 SDS 1 2 8 oz 80g D2 08NA 2 2 5 oz 70g H2 PBC 2 1 oz 80g D2 16NA 2 4 oz 689 F2 DEVNETS 1 3 0 oz 86g DC Input Relay Output Module Analog Modules Weight F2 04AD 1 3 0 oz 86g F2 04AD 2 3 0 oz 86g F2 08AD 1 3 0 oz 86g F2 08AD 2 4 2 oz 118g F2 02DA 1 2 8 oz 80g F2 02DA 2 2 8 oz 80g F2 08DA 1 2 8 oz 80g F2 08DA 2 3 8 oz 109g F2 02DAS 1 3 8 oz 109g F2 02DAS 2 3 8 oz 109g F2 4AD2DA 4 2 oz 118g F2 04RTD 3 0 oz 86g F2 04THM 3 0 oz 86g Special
119. 2 location for the SP This does reduce the resolution of the SP but most flow control loops do not require a lot of precision the recipient of the flow is integrating the errors Use one of the following formulas for the SP according to the data format you are using It s a good idea to set the SP upper limit to the top of the allowed range Data Format SP Scaling SP Range PV range 12 bit SP PV input 64 0 64 0 4095 15 bit SP PV input 181 0 181 0 32767 16 bit SP PV input 256 0 256 0 65535 Control Output The Control Output is the numerical result of the PID calculation All of the other Configuration parameter choices ultimately influence the value of a loop s Control Output for each calculation Some final processing selections dedicated to the Control Output are available shown below At the far right of the figure the final output may be restricted by lower and upper limits that you program The values for V 30 and V 31 may be set once using DirectSOFT32 s PID Setup dialog box c The Control Output lower and upper limits can help guard against commanding an O excessive correction to an error when a loop fault occurs Such as PV sensor signal DP loss However do not use these limits to restrict mechanical motion that might Og otherwise damage a machine use hard wired limit switches instead S gt
120. 205 User Manual 3rd Ed Rev A 08 03 A2 Auxiliary Functions AUX 6 Handheld Programmer Configuration U BE 2 xe Ein 2 gt E x AUX 61 62 and 65 There are several AUX functions available that you can use to setup view or change AUX 61 Show Revision Numbers AUX 62 Beeper On Off AUX 65 Run Self Diagnostics the Handheld Programmer configuration e AUX 61 Show Revision Numbers e AUX 62 Beeper On Off e AUX 65 Run Self Diagnostics As with most industrial control products there are cases when additional features and enhancements are made Sometimes these new features only work with certain releases of firmware By using AUX 61 you can quickly view the CPU and Handheld Programmer firmware revision numbers This information for the CPU is also available from within DirectSOFT32 from the PLC Diagnostics sub menu The Handheld has a beeper that provides confirmation of keystrokes You can use Auxiliary AUX Function 62 to turn off the beeper If you think the Handheld Programmer is not operating correctly you can use AUX 65 to run a self diagnostics program You can check the following items e Keypad e Display e LEDs and Backlight e Handheld Programmer EEPROM check DL205 User Manual 3rd Ed Rev A 08 03 Auxiliary Functions EE AUX 7 EEPROM Operations AUX 71 76 Transferrable Memory Areas AUX 71 CPU to HPP EEPROM AUX 72 HPP EEPROM to CPU AUX
121. 205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only EA The built in filter uses the following algorithm yi k Xi Yi Yi y is the current output of the filter x is the current input to the filter y is the previous output of the filter k is the PV Analog Input Filter Factor PV Auto Transfer The diagrams below show how the auto transfer function address 36 and PV Functions with filtering address 01 bit 2 interact The options are Filtering Options e Auto transfer directly from an analog I O module channnel with the filter enabled or disabled When this function is used the analog pointer method cannot be used to read the module s channel values e Auto transfer directly from a V mermory location with the filter enabled or disabled When this function is used either the analog pointer method or program logic must be used to write a value to the V memory location specified Direct Access to Analog 1 0 with filtering enabled SS ee Se 7 Ov DO ir nalog Auto Transfer PV Loop or gt gt Filter gt gt E module from analog I O Address 3 Calculation 29 me a ge Oo S 93 Direct Access to V memory with filtering enabled lt ME a T 7 L
122. 29 Table of Contents RU Chapter 8 PID Loop Operation DL250 1 and DL260 only DL250 1 and DL260 PID Loop Features 8 2 M in Features PS RS 8 2 Getting Acquainted with PID Loops aaneen rnanan 8 4 Loop Setup Parameters sin siens A A A ee eee ey 8 6 Loop Table and Number of hoops vii e E a oh Yara Lees 8 6 PID Error Flags eco il E A A A A AAA weeks 8 6 Establishing the Loop Table Size and Location 8 7 Loop Table Word Definitions ss one on Cad eet tad ee cerise AAA eee ew tee 8 8 PID Mode Setting 1 Bit Descriptions Addr 00 8 9 PID Mode Setting 2 Bit Descriptions Addr 01 8 10 Mode Alarm Monitoring Word Addr 06 8 11 Ramp Soak Table Flags Addr 33 8 11 Ramp Soak Table Location Addr 34 8 12 Ramp Soak Table Programming Error Flags Addr 35 8 12 PV Auto Transfer Addr 36 from I O Module Base Slot Channel Option 8 13 PV Auto Transfer Addr 36 from V memory Option 8 13 Control Output Auto Transfer Addr 37 8 13 Loop Sample Rate and Scheduling
123. 3 uS Now adding the summation terms plus the original scan time value we have Avg Scan Time with PID loops 50 uS 0 42 uS 1 25 uS 8 3 uS DL205 User Manual 3rd Ed Rev A 08 03 50mS 50 06 mS 8 17 PID Loop Operation DL250 1 DL260 only The DL250 1 and DL260 CPUs only do PID calculation on a particular scan for the loop s which have sample time periods that are due for an update calculation The built in loop scheduler applies the following rules e Loops with sample rates lt 2 seconds are processed at the rate of as many loops per scan as is required to maintain each loop s sample rate Specifying loops with fast sample rates will increase the PLC scan time So use this capability only if you need it e Loops with sample rates gt 2 seconds are processed at the rate of one or less loops per scan at the minimum rate required to maintain each loop s sample rate The implementation of loop calculation scheduling is shown in the flow chart below This is a more detailed look at the contents of the Calculate PID Loops task in the CPU scan activities flow chart The pointers I and J correspond to the slow gt 2 sec and fast lt 2 sec loops respectively The flow chart allows the J pointer to increment from loop 1 to the last loop if there are any fast loops specified The pointer increments only once per scan and then only when the next slow loop is due for an u
124. 320 Time out E321 Communications error E625 Program only E499 Invalid Text entry for Print Instruction E627 Bad write operation F501 Bad entry E628 Memory type error should be EEPROM E502 Bad address E640 Miscompare E503 Bad command E650 Handheld Programmer system error E504 Bad reference value E651 Handheld Programmer ROM error E505 Invalid instruction E652 Handheld Programmer RAM error DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting Program Error The following list shows the errors that can occur when there are problems with the Codes program These errors will be detected when you try to place the CPU into Run Mode or when you use AUX 21 Check Program The CPU will also turn on SP52 and store the error code in V7755 Appendix B provides a more complete description of the error codes Error Code Description Error Code Description E4 No Program in CPU E461 Stack Overflow E401 Missing END statement E462 Stack Underflow E402 Missing LBL E463 Logic Error E403 Missing RET E464 Missing Circuit E404 Missing FOR E471 Duplicate coil reference E405 Missing NEXT E472 Duplicate TMR reference E406 Missing IRT E473 Duplicate CNT reference E412 SBR LBL gt 64 E480 CV position error E413 FOR NEXT gt 64 E481 CV not connected E421 Dupli
125. 41140 V 41157 Stages V41000 V41017 V41000 V41037 V41000 V41077 V41000 V41077 DL205 User Manual 3rd Ed Rev A 08 03 C 3 Instruction Execution Times How to Read the Tables Some of the instructions can have more than one parameter so the table shows execution times that depend on the amount and type of parameters For example the SET instruction can be used to set a single point or a range of points If you examine the execution table you ll notice the available data types and execution times for both situations The following diagram shows an example Two Locations Available XO x1 YO Y7 A SET Co Execution depends on numbers of locations and types SET ist X Y C S 17 4 us of data used 2nd X Y C S N pt 12 0us 5 4usxN RST ist X Y C S 19 5 us 2nd X Y C S N pt 10 5us 5 2usxN 9 xipueddy 5 a GR m x lt QO CC O 5 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 4 i Er Oc x 55 ED B XI U Instruction Execution Times Boolean Instructions Boolean Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute STR X Y C T CT S SP 3 3 us 3 3 us 1 4 us 1 4 us 67 us 0 us 67 us U us STRN X Y C T
126. 5 User Manual 3rd Ed Rev A 08 03 Analog and RS232 Cables Multidrop Cables Shielded Cables within Enclosures G 7 European Union Directives To date it has been a common practice to only provide an earth ground for one end of the cable shield in order to minimize the risk of noise caused by earth ground loop currents between apparatus The procedure of only grounding one end which primarily originated as a result of trying to reduce hum in audio systems is no longer applicable to the complex industrial environment Shielded cables are also efficient emitters of RF noise from the PLC system and can interact in a parasitic manner in networks and between multiple sources of interference The recommendation is to use shielded cables as electrostatic pipes between apparatus and systems and to run heavy gauge equi potential bond wires alongside all shielded cables When a shielded cable runs through the metallic wall of an enclosure or machine it is recommended in IEC 1000 5 2 that the shield should be connected over its full perimeter to the wall preferably using a conducting adapter and not via a pigtail wire connection to an earth ground bolt Shields must be connected to every enclosure wall or machine cover that they pass through NOTE Cables whether shielded or not MUST be enclosed within earthed metal conduit or other metallic trunking when outside the PLC enclosure Providing an earth ground for bo
127. 73 Compare HPP EEPROM to CPU AUX 74 HPP EEPROM Blank Check AUX 75 Erase HPP EEPROM AUX 76 Show EEPROM Type There are several AUX functions available you can use to move programs between the CPU memory and an optional EEPROM installed in the Handheld Programmer e AUX 71 Read from CPU memory to HPP EEPROM s AUX 72 Write HPP EEPROM to CPU s AUX 73 Compare CPU to HPP EEPROM s AUX 74 Blank Check HPP EEPROM e AUX 75 Erase HPP EEPROM e AUX 76 Show EEPROM Type CPU and HPP Many of these AUX functions allow you to copy different areas of memory to and from the CPU and handheld programmer The following table shows the areas that may be mentioned Option and Memory Type DL240 Default Range DL230 Default Range 1 PGM Program 00000 02559 00000 02047 2 V V memory 00000 4777 00000 04777 3 SYS System Non selectable copies system parameters 4 etc Program System Non selectable Non selectable and non volatile V memory AUX 71 copies information from the CPU memory to an EEPROM installed in the Handheld Programmer You can copy different portions of EEPROM HP memory to the CPU memory as shown in the previous table The amount of data you can copy depends on the CPU AUX 72 copies information from an EEPROM installed in the Handheld Programmer to the CPU You can copy different types of information from CPU memory as shown
128. 777 The Not Jump instruction allows the program to transition from an active stage which contains the jump instruction to another which is specified in the instruction The jump will occur when the input logic is off The active stage that contains the Not Jump will be deactivated 1 scan after the Not Jump instruction is executed aaa aaa aaa aaa Stage S 0 377 0 777 0 1777 0 1777 DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming In the following example when the CPU begins program execution only ISG 0 will be active When X1 is on the program execution will jump from Initial Stage 0 to Stage 1 In Stage 1 if X2 is on output Y5 will be turned on If X7 is on program execution will jump from Stage 1 to Stage 2 If X7 is off program execution will jump from Stage 1 to Stage 3 DirectSOFT32 Display Handheld Programmer Keystrokes ISG gt s sc 0 ENT ENT SG S0 STR gt xan 1 JMP gt see 1 ENT xi S1 SG gt S SG 1 ENT L Ll JMP STR gt F xn 2 ENT OUT vour 5 ENT S ENT SG S1 STR gt X IN 7 oy JMP gt S SG 2 ENT r x2 Y5 SHFT N JMP gt QU OUT SG 3 ENT Ta 2 9 3 2 3 X7 JMP Q S3 NJMP
129. 8 normally As the drum enters step 14 the Start input turns off Two more Jog signals moves the drum to step 16 However note that a third Jog signal is required to move the drum through step 16 to drum complete Finally a Reset input signal arrives which forces the drum into the preset step and turns off the drum complete bit Jog Reset Jog Jog Drum drum drum drum drum Complete Inputs Start i 1h 1 Jog 0 J4 1 Reset 0 J4 Drum Status Step 1 2 3 3 3 4 5 6 7 8 re 14 15 16 16 16 1 Drum 7 Complete CTO o Outputs x16 5 gi Applications often require drums that x0 Start automatically start over once they Setup Outputs complete a cycle This is easily X1 Reset Info Mask accomplished using the drum complete La Steps 2 Fe JO 0 bit In the figure to the right the drum SECHE ROME instruction setup is for CTO so we logically eeo oeo OR the drum complete bit CTO with the ba Ee Reset input When the last step is done O 09e the drum turns on CTO which resets itself nn to the preset step also resetting CTO Contact X1 still works as a manual reset The outputs of a drum are enabled any time the CPU is in run mode On program to run mode transitions the drum goes to the preset step and the outputs energize according to the pattern of that step If your app
130. A DEF 0000 SHFT o NEXT DEF koo00 E E ME a S Next x F sin DEF 0000 SHFT Er 5 NEXT Output DEF Ko000 2 R E a F J o Next vents Ix Pattern DEF 0000 ES SET 3 DEF K0000 p 3 l 8 SHFT 0 NEXT Y H DEF 0000 SHFT ys 7 NEXT BEF kooo i E l S G o E ES G C A DEF 0000 SHFT NEXT l E E H 2 2 0 DEF K0000 g 4 4 7 NEXT DEF 0000 NEXT DEF ko000 NEXT DEF 0000 NEXT DEF K0000 NEXT DEF 0000 NEXT DEF K0000 NEXT lt unused steps DEF 0000 NEXT DEF K0000 NEXT 16 DEF 0000 NEXT 6 DEF Ko000 NEXT GY A STR CNT o ei Last rung Y A SHFT Yus o NEXT NOTE You may use the NXT and PREV keys to skip past entries for unused outputs or steps DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Masked Event Drum with Discrete Outputs Drum Instruction Programming The Masked Event Drum with Discrete Outputs has all the features of the basic Event Drum plus final output control for each step It operates according to the general principles of drum operation covered in the beginning of this section Below MDRMD is the instruction in chart form as displayed by DirectSOFT32 XIX dI d Counter Number Step Preset Discrete Output Assignment 230 240 250 1 260 Timebase Outpu
131. AR ERE Geer Beet ae ek 7 18 Power Flow Transition Technique 00 00 cece eee eee eee 7 18 Parallel Processing Concepts 4 ssssssssss 7 19 Parallel Processes sat ii eats ge wages MER eee eee TRE eke eee 7 19 Converging Processes cater ele eat ORG Chee pees eh tee eee Outs 7 19 Convergence Stages OV rien vhs oe Pelee ie Gale Gs Ahh Glee Swe gone GS ee ases 7 19 Convergence Jump CVJMP 2 cece eee eee eee eee eens 7 20 Convergence Stage Guidelines 7 20 Managing Large Programs lt ireren ir esse eben a 9 R te beeen a ee 7 21 Stage Blocks BLK BENDI 7 21 Block Call BCALL ostias oes eee te ta ole ie rene fe sieves eek is 7 22 RELPLUS InstructiOns 00 o See cies ea eae Dee eee Du ee eee 7 23 Stage SG NN 7 23 Hal Stage ISG lt A la Tl D ne et 7 24 dump MRI ue RE Te eyesore esters abet Sola A Near vets 7 24 MOU JUMPING ME EE ed on TT 7 24 Converge Stage CV and Converge Jump CVUMP 7 25 Block Gall BCALL gcc cent rs beds ans ad who ne vad its ta fhe see eke dats oe 7 27 Block BUK estra dace ct baled eS Dale ete ed amo Meee ee ad aca eo pates 7 27 Block Eng BEND taa eR edhe Meters ae ade arse reac oe att Soe re 7 27 Stage View in DirectSOFT32 22 84 7 28 Questions and Answers about Stage Programming 7
132. Best For any particular control loop there is no single perfect sample rate to use A good Sample Rate sample rate is a compromise that simultaneously satisfies various guidelines e The desired sample rate is proportional to the response time of the PV to a change in control output Usually a process with a large mass will have a slow sample rate but a small mass needs a faster sample rate e Faster sample rates provide a smoother control output and accurate PV performance but use more CPU processing time Sample rates much faster than necessary serve only to waste CPU processing power e Slower sample rates provide a rougher control output and less accurate PV performance but use less CPU processing time e A sample rate which is too slow will cause system instability particularly when a change in the setpoint or a disturbance occurs As a starting point we can determine a sample rate for any particular rate which will be fast enough to avoid control instability which is extremely important Do the following procedure to find a starting sample rate PID Loop Operation GO Q N a m _ T O Ye A S DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only ET 1 Operate the process open loop the loop does not even need to be configured yet Place the CPU in run mode and the loop in Manual mode if you have already configured it Manually set the control output value so
133. Cascade e Ona Program to Run mode transition the CPU forces each loop to return to its prior mode recorded during the last PLC Run Mode e You can add and configure new loops only when the PLC is in Program Mode New loops automatically begin in Manual Mode AE doo Aid g C D O1 L g C o O G Loop Mode In normal conditions the mode of a loop is determined by the request to V 00 bits 0 Override 1 and 2 However some conditions exist which will prevent a requested mode change from occurring e A loop that is not set independent of PLC mode cannot change modes when the PLC is in Program mode s A major loop of a cascaded pair of loops cannot go from Manual to Auto until its minor loop is in Cascade mode In other situations the PID loop controller will automatically change the mode of the loop to ensure safe operation e A loop which develops an error condition automatically goes to Manual e If the minor loop of a cascaded pair of loops leaves Cascade Mode for any reason its major loop automatically goes to Manual Mode DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation GO Q N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Bumpless Transfers In process control the word transfer has a particular meaning A loop transfer occurs when we change its mode of operation as shown below When we change loop modes what we are really
134. Constant 79us 8 4 us 14 6 us 1 0 us 14 6 us 1 0 us LDX V Data Reg 10 8us 1 0us 10 8us 1 0us V Bit Reg _ EE 10 8 us 1 0 us 10 8 us 1 0 us P Indir Data 45 2 us 1 0 us 45 2 us 1 0 us P Indir Bit 45 2 us 1 0 us 45 2 us 1 0 us OUT V Data Reg 60 us 8 4 us 21 us 8 4 us 9 3 us 1 0 us 9 3 us 1 0 us V Bit Reg 132 us 8 4 us 126 us 8 4 us 9 3 us 1 0 us 9 3 us 1 0 us P Indir Data 162 us 8 4 us 112 us 8 4 us 35 2 us 0 9 us 35 2 us 0 9 us P Indir Bit 239 us 8 4 us 222 us 8 4us 35 2us 0 9us 35 2us 0 9us OUTD V Data Reg 68 us 8 4 us 26 us 8 4 us 10 2 us 1 0 us 10 2 us 1 0 us V Bit Reg 276 us 8 4 us 235 us 8 4 us 10 2us 1 0 us 10 2us 1 0 us P Indir Data 196 us 8 4 us 116 us 8 4 us 35 8 us 0 9 us 35 8 us 0 9 us P Indir Bit 384 us 8 4 us 331 us 84us 35 8us 0 9us 35 8us 0 9 us DL205 User Manual 3rd Ed Rev A 08 03 C 18 Ls E H Oc x D 5 ED S L A U Instruction Execution Times Accumulator Stack Load DL230 DL240 DL250 1 DL260 and Output Data Instructions Continued Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute OUTF 1st 2nd X Y C K Constant 53us 8 4 us 54us 0 9 us 54us 0 9 us 7us x N 1 0us x 1 0us x N N OUTL V Data Reg 13 5 us 1 0 us V Bit Reg a 2 _ R 13 5 us 1 0 us OUTM V Data Reg 13 7 us 1 0 us V Bit Reg a Le
135. Current Step V1003 XXXX The drum instruction accepts several inputs for step control the main control of the drum The inputs and their functions are Start The Start input is effective only when Reset is off When Start is on the drum timer runs if it is in a timed transition and the drum looks for the input event during event transitions When Start is off the drum freezes in its current state Reset must remain off and the drum outputs maintain their current on off pattern Jog The jog input is only effective when Reset is off Start may be either on or off The jog input increments the drum to the next step on each off to on transition Note that only the basic timer drum does not have a jog input Reset The Reset input has priority over the Start input When Reset is on the drum moves to its preset step When Reset is off then the Start input operates normally Preset Step A step number from 1 to 16 that you define typically is step 1 The drum moves to this step whenever Reset is on and whenever the CPU first enters run mode DL205 User Manual 3rd Ed Rev A 08 03 A OZD ZNN Powerup State of Drum Registers Drum Instruction Programming e Counts Step The number of timer counts the drum spends in each step Each step has its own counts parameter However programming the counts step is optional on Timer Event drums e Timer Value the current value of the counts step timer
136. DL205 User Manual Volume 2 of 2 D2 USER M Crt ea te TI aoe ceo oe HEF a Li jajaa eras aile aa AA O ee Er 89A EA Baa teehee e I Vol 2 Table of Contents Chapter 6 Drum Instruction Programming DL250 1 DL260 CPU only Introduction ae is ge i hee ANR A Pee eae Ee ae AA Pawnee 6 2 PUIPOSC is a o ie fe tle O A AA A 6 2 Drum ISTMO ee R Y 2 S id e aaa eee wa da el ela Seen as 6 2 Drum Chart Representation 200 as a oe Ree aoe bata Bees 6 3 Output S quences Lessard taie TR ne LRR en Rb Geet oe abe eee ete aoe 6 3 Step eT Ts Le T a mens as wah A ee ee O ee 6 4 Dr milnstruction Types ritos TR Sad aan A e A Ta 6 4 Timer Only Tasio US NS eme ie RO DS ANS ae 6 4 Timer and Event Transitions sustos ds 6 5 Event Only Transitions ss oso e teen aa a rs ra ete ede eee 6 6 COUNTErsASSIONINSM Sie A SE RP ER me 6 6 Last Step Completion 2 58 osent eine nf ne on De eu rs nr perd 6 7 Overview of Drum Operation sss x x x x 24 ede a Oe ee a de tite 6 8 Drum Instruction Block Diagram eaan sa nena nae ranere 6 8 Powerup State of Drum Registers 6 9 Output Mask Operation fab es ula o al A es we tela aa Men andl cee ane ihe 6 10 Drum Control TECHNIQUES A ee ee A eet has Seed 6 11 Drum Control Inputs estarias E tata reco Rate tie tee Pa Paie es 6 11 Self R s ting Drum 0 00 ai ai 6 12 Initializing Drum OURS 14 A Sre a eee eed atlas t are 6 12 Cas
137. END statement prior to the portion that should be disabled When the CPU encounters the END statement it assumes it is the end of the program The following diagram shows an example Normal Program New END disables X10 and Y1 XU X2 ae XO X2 YO L E x1 X3 X4 X1 X3 X4 L L X10 Y1 CD gt Eo 2 X10 Y1 Eno K 2 GD PAUSE Instruction This instruction provides a quick way to allow the inputs or other logic to operate while disabling selected outputs The output image register is still updated but the output status is not written to the modules For example you could make this conditional by adding an input contact or CR to control the instruction with a switch or a programming device Or you could add the instruction without any conditions so the selected outputs would be disabled at all times Normal Program PAUSE disables YO and Y1 a X0 X2 YO aai g a E mu Pause ee X1 X3 X4 XO x2 YO eo L ES ga Y L cD X10 x1 X3 X4 G D F XN vA po X10 Y1 5 eD CD GD DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 9 23 STOP Instruction Sometimes during machine startup you need a way to quickly turn off all the outputs and return to Program Mode In addition to using the Test Modes and AUX 58 to configure each individual point you can also us
138. L260 also provide Cascaded Mode NOTE Cascaded loops are an advanced process control technique Therefore we recommend their use only for experienced process control engineers When a manufacturing process is complex and contains a lag time from control input to process variable output even the most perfectly tuned single loop around the process may yield slow and inaccurate control It may be the actuator operates on one physical property which eventually affects the process variable measured by a different physical property Identifying the intermediate variable allows us to divide the process into two parts as shown in the following figure PROCESS Intermediate Process Control input gt Process A Variable Process B Variable PV The principle of cascaded loops is simply that we add another process loop to more precisely control the intermediate variable This separates the source of the control lag into two parts as well The diagram below shows a cascade control system showing that it is simply one loop nested inside another The inside loop is called the minor loop and the outside loop is called the major loop For overall stability the minor loop must be the fastest responding loop of the two We do have to add the additional sensor to measure the intermediate variable PV for process A Notice the setpoint for the minor loop is automatically generated for us by usi
139. LUS Stage Programming RLLPLUS Instructions Stage The Stage instructions are used to create SG structured RLLPLUS programs Stages are program segments which can be activated Y Y Y Y by transitional logic a jump or a set stage SG 230 240 250 1 260 that is executed from an active stage Sasa Stages are deactivated one scan after transitional logic a jump or a reset stage instruction is executed a D Ko OD DEL Stage Ss 0 377 0 777 0 1777 0 1777 O S gx z The following example is a simple RLLPLUS program This program utilizes the initial 3 o stage stage and jump instruction to create a structured program E DirectSOFT Display Handheld Programmer Keystrokes ISG gt asa 0 ENT ISG SO STR gt X IN 0 ENT OUT gt youn 1 0 ENT STR gt X IN 1 ENT XD Y10 SET gt asa 2 ENT OUT STR gt X IN 5 ENT x1 82 JMP gt S SG 1 ENT SET SG gt S SG 1 ENT X5 S1 STR gt X IN 2 ENT JMP OUT gt youn 1 1 SG gt S SG 2 ENT SG S1 STR gt X IN 6 ENT OUT your 1 2 ENT STR gt X IN 7 ENT X2 AND gt asa 1 ENT ouT I JMP gt sise 0 E
140. Major loop in Auto Mode We will be tuning the major loop with the minor loop treated as a series component its overall process Therefore do not go back and tune the minor loop again while tuning the major loop 5 Tune the major loop following the standard loop tuning procedure in this section The response of the major loop PV is actually the overall response of the cascaded loops together DL205 User Manual 3rd Ed Rev A 08 03 8 46 PID Loop Operation DL250 1 DL260 only PID Loop Operation GO Q N a m _ T O Ye A S Setpoint PV Analog Filter As you can see from the timing diagrams on the previous pages the zero crossing of the SP and PV difference is important Obviously a noisy PV signal can create extra zero crossings and give a false indication of loop characteristics to the loop controller The DL250 1 and DL260 provide a selectable first order low pass PV input filter specifically for you to use during auto tuning using the closed loop method Shown in the figure below we strongly recommend the use of this filter during auto tuning You may disable the filter after auto tuning is complete or continue to use it if the PV input signal is noisy Loop Control Output _ 2 Calculation Unfiltered NN 0 L SN j Process Variable Filtered PV TE AA PID Mode 2 Setting V 01
141. N sxN SX N SX N 0 3usxN 0 3usxN DL205 User Manual 3rd Ed Rev A 08 03 Comparative Boolean Instruction Execution Times C 5 Comparative Boolean DL230 DL240 DL250 1 DL260 Instructions Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute STRE 1st 2nd V Data Reg V Data Reg 77 us 13 8 us 46 us 16 2 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 13 8us 135 us 16 2 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 57 us 13 8 us 46 us 16 2 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 141 us 111 0us 30 2us 30 2us 30 2us 30 2 us P Indir Bit 235us 115 0 us 30 2us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 158us 13 8us 135us 16 2us 7 6us 7 6 us 7 6 us 7 6 us V Bit Reg 240us 138us 225us 16 2 us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 139us 138us 135us 16 2 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 231us 111 0us 30 2us 30 2us 30 2us 30 2 us P Indir Bit 324us 115 0us 30 2us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 29 9us 29 9us 29 9us 29 9 us V Bit Reg 299us 29 9us 29 9us 29 9 us K Constant 27 7 us 27 7us 27 7us 27 7 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0us P Indir Bit V Da
142. NEXT ENT GO TO T RUN MODE Press ENT to confirm TEST RUN Mode a Note the TEST LED on the DL205 MODE CHANGE Handheld indicates the CPU is in CPU T RUN TEST Mode You can return to Run Mode enter Program Mode or enter TEST PGM Mode by using the Mode Key MODE CHANGE CLR MODE NEXT NEXT ENT GO TO T PGM MODE Press ENT to confirm TEST PGM Mode enr Note the TEST LED on the DL205 MODE CHANGE Handheld indicates the CPU is in CPU T PGM TEST Mode DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 8 21 Test Displays With the Handheld Programmer you also have a more detailed display when you use TEST Mode For some instructions the TEST RUN mode display is more detailed than the status displays shown in RUN mode The following diagram shows an example of a Timer instruction display during TEST RUN mode RUN Mode TEST RUN Mode S TMR TO K1000 TMR TOA K1000 TO Contact S is off TO Contact S is off E is on Input to Timer Current Value E is on Holding Output States The ability to hold output states is very useful because it allows you to maintain key system I O points In some cases you may need to modify the program but you do not want certain operations to stop In normal Run Mode the outputs are turned off when you return to Program Mode In TEST RUN mode you can set each individual output
143. NT SG S2 X6 Y12 ouT X7 S1 so JMP gt DL205 User Manual 3rd Ed 06 02 7 24 RLL PLUS D E D 2 DL D amp ep RLLPLUS Stage Programming Initial Stage ISG Y Y Y Y 230 240 250 1 260 Jump JMP Y Y Y Y 230 240 250 1 260 Not Jump NJMP ARAKA Y 230 240 250 1 260 The Initial Stage instruction is normally used as the first segment of an RLLPLUS program Initial stages will be active when the CPU enters the run mode allowing for a starting point in the program Initial Stages are also activated by transitional logic a jump or a set stage executed from an active stage Initial Stages are deactivated one scan after transitional logic a jump or a reset stage instruction is executed Multiple Initial Stages are allowed in a program ISG Saaa aaa aaa aaa aaa Stage S 0 377 0 777 0 1777 0 1777 The Jump instruction allows the program to transition from an active stage which contains the jump instruction to another which stage is specified in the instruction The jump will occur when the input logic is true The active stage that contains the Jump will be deactivated 1 scan after the Jump instruction is executed S aaa amp aaa aaa aaa aaa Stage S 0 377 0 777 0 1777 0 1
144. O Q N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Direct Acting and Reverse Acting Loops The gain of a process determines in part how it must be controlled The process shown in the diagram below has a positive gain which we call direct acting This means that when the control output increases the process variable also eventually increases Of course a true process is usually a complex transfer function that includes time delays Here we are only interested in the direction of change of the process variable in response to a control output change Most process loops will be direct acting such as a temperature loop An increase in the heat applied increases the PV temperature Accordingly direct acting loops are sometimes called heating loops Direct Acting Loop Process Setpoint gt Loop Control Output K Calculation Process Variable A reverse acting loop is one in which the process has a negative gain as shown below An increase in the control output results in a decrease in the PV This is commonly found in refrigeration controls where an increase in the cooling input causes a decrease in the PV temperature Accordingly reverse acting loops are sometimes called cooling loops Reverse Acting Loop Process Setpoint gt Loop Control Output J D Calculation Process Variable It
145. OTE Technically both major and minor loops are cascaded in strict process control terminology Unfortunately we are unable to retain this convention when controlling loop modes Remember that all minor loops will be in Cascade Mode and only the outer most major loop will be in Auto Mode You can cascade together as many loops as necessary on the DL250 1 and DL260 and you may have multiple groups of cascaded loops For proper operation on cascaded loops you must use the same data range 12 15 bit and polar bipolar settings on the major and minor loop To prepare a loop for Cascade Mode operation as a minor loop you must program its remote Setpoint Pointer in its loop parameter table location V 32 as shown below The pointer must be the address of the V 05 location control output of the major loop In Cascade Mode the minor loop will ignore the its local SP register V 02 and read the major loop s control output as its SP instead c2 Major Loop Auto mode Minor Loop Cascade Mode oS ZO Loop Table Loop Table O 38 V 02 XXXX SP v 02 XXxX lt SP_ ae V 03 XXXX PV V 03 XXXX PV Sd V 05 XXXX Control Output V 05 XXXX Control Output o a V 32 XXXX Remote SP Pointer When using DirectSOFT32 s PID View to watch the SP value of the minor loop DirectSOFT32 automatically reads the major loop s control output and displays it for the minor loop
146. PV Deviation Specify alarms for two ranges of PV deviation from the setpoint value Rate of Change Detect when PV exceeds a rate of change limit you specify DL205 User Manual 3rd Ed Rev A 08 03 EE doo did Jg C D O1 L g C o O G gt PID Loop Operation GO Q N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Getting Acquainted As an introduction to key parts of a control loop refer to the block diagram shown with PID Loops below The closed path around the diagram is the loop referred to in closed loop control Loop Configuring External and Monitoring Disturbances PLC System 4 Setpoint Value Error Term Loop Control Output Manufacturing gt gt Calculation Process Process Variable Manufacturing Process the set of actions that adds value to raw materials The process can involve physical changes and or chemical changes to the material The changes render the material more useful for a particular purpose ultimately used in a final product Process Variable a measurement of some physical property of the raw materials Measurements are made using some type of sensor For example if the manufacturing process uses an oven you will most likely want to control temperature Temperature is a process variable Setpoint Value the theoretically per
147. PV and SP exceed the programmed alarm value s PV Rate of change Alarm computes the rate of change of the PV and alarms if it exceeds the programmed alarm amount s Alarm Hysteresis works in conjunction with the absolute value and deviation alarms to eliminate alarm chatter near alarm thresholds Qu The alarm thresholds are fully programmable and each type of alarm may be AO independently enabled and monitored The following diagram shows the PV IQ monitoring function Bits 12 13 and 14 of PID Mode 1 Setting V 00 word in the loop S parameter table to enable disable the alarms DirectSOFT32 s PID View setup 59 dialog screens allow easy programming enabling and monitoring of the alarms DO Ladder logic may monitor the alarm status by examining bits 3 through 9 of PID O Mode and alarm Status word V 06 in the loop table 23 Setpoint Error Term Loop Control Output 2 Calculation j Process Variable Alarm Generation 0 O A PV Value Q PV Deviation re PV Rate of change PID Mode 1 Setting PID Alarm Word Monitor Alarms Bit 15 14 13 12 11 10 9 8 76543210 Bit 15 14 13 12 11 10 9 8 76543210 A A Alarm Enable Bits Alarm Bits Unlike the PID calculations the alarms are always functioning any time the CPU is in Run Mode The loop may b
148. References The Syntax check will find a wide variety of programming errors such as missing END statements incomplete FOR NEXT loops etc If you perform this check and get an error see Appendix B for a complete listing of programming error codes Correct the problem and then continue running the Syntax check until the message NO SYNTAX ERROR appears Use the Duplicate Reference check to verify you have not used the same output coil reference more than once Note this AUX function will also find the same outputs even if they have been used with the OROUT instruction which is perfectly acceptable This AUX function is available on the PLC Diagnostics sub menu from within DirectSOFT32 There will be times when you need to change an I O address reference or control relay reference AUX 22 allows you to quickly and easily change all occurrences within an address range of a specific instruction For example you can replace every instance of X5 with X10 There have been many times when you take existing programs and add or remove certain portions to solve new application problems By using AUX 23 you can select and delete a portion of the program DirectSOFT32 does not have a menu option for this AUX function but you can select the appropriate portion of the program and cut it with the editing tools AUX 24 clears the entire program from CPU memory Before you enter a new program you should always clear ladder memory This AUX functio
149. Run Mode or when a Handheld Programmer key sequence results in an error or an illegal request Error Description Error Description Code Code E003 Software time out E506 Invalid operation E004 Invalid instruction E520 Bad operation CPU in Run RAM parity error in the CPU E041 CPU battery low E043 Memory cartridge battery low E521 Bad operation CPU in Test Run E523 Bad operation CPU in Test Program E524 Bad operation CPU in Program E525 Mode switch not in TERM E099 Program memory exceeded E101 CPU memory cartridge missing E104 Write fail E526 Unit is offline E151 Invalid command E527 _ Unit is online E155 RAM failure E528 CPU mode E201 Terminal block missing E540 CPU locked E202 Missing I O module E541 Wrong password E203 Blown fuse E542 Password reset E206 User 24V power supply failure E601 Memory full E210 Power fault E602 Instruction missing E250 Communication failure in the I O chain E604 Reference missing E251 I O parity error E610 Bad I O type E252 New I O configuration E262 I O out of range E312 Communications error 2 E611 Bad Communications ID E620 Out of memory E621 EEPROM Memory not blank E622 No Handheld Programmer EEPROM E624 V memory only D amp o 00 cc On 52 Faj ES 52 SF Le oO E313 Communications error 3 E316 Communications error 6 E
150. S S the reset input of all drums CT4 in Selects the example s OR a manual reset contact with the Drum 2 reset contact above if needed is X1 x0 GTO Start S in the example a ou utputs Reset Info Mask e Use the same V memory address for gy Steps the output mask of both drums if CTA ododoo your drum application requires a ana 4 mask o edeo O 6 e Use different control relay CR O0 ooe o output coils for each drum but OR Cee ace them together in ladder logic as aa output 4stoutput yo shown OUT Now YO is the final output from the Drum 2 output combined drums Note each drum must C20 have an idle step in which its CR outputs are off while the other drum s operate will typically be step 1 16th output Drum 1 output CO Y17 OUT Drum 2 output C37 DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Drum Instruction Programming Drum Instructions Timed Drum with Discrete Outputs DRUM X XIJ Y 230 240 250 1 260 0 Control Step Preset K bb F ERE ER EHW ER Pfff Ef Inputs Reset 0 01 sec Count K cccc O awd RAW Step Counts ER Kdddd O OO OO OO OO OO OO OO O 2 Kdddd O OO OO OO OO OO OO OO O Kdddd CHO OC O Cl ONO QO Step Number 4 Kdddd olo olo olo olo olo olo oo o
151. SP546 Current target value on when the counter current value equals the value in V3644 SP547 Current target value on when the counter current value equals the value in V3646 SP550 Current target value on when the counter current value equals the value in V3650 SP551 Current target value on when the counter current value equals the value in V3652 SP552 Current target value on when the counter current value equals the value in V3654 SP553 Current target value on when the counter current value equals the value in V3656 SP554 Current target value on when the counter current value equals the value in V3660 SP555 Current target value on when the counter current value equals the value in V3662 SP556 Current target value on when the counter current value equals the value in V3664 SP557 Current target value on when the counter current value equals the value in V3666 SP560 Current target value on when the counter current value equals the value in V3670 SP561 Current target value on when the counter current value equals the value in V3672 SP562 Current target value on when the counter current value equals the value in V3674 SP563 Current target value on when the counter current value equals the value in V3676 SP564 Current target value on when the counter current value equals the value in V3700 SP565 Current target value on when the counter current value equals t
152. SW1 failed 1993 04 28 03 25 14 31 Saw Jam Detect You can access the error code table and the message table through DirectSOFT32 s PLC Diagnostic sub menus or from the Handheld Programmer Details on how to access these logs are provided in the DL205 DirectSOFT32 manual The following examples show you how to use the Handheld and AUX Function 5C to show the error codes The most recent error or message is always displayed You can use the PREV and NXT keys to scroll through the messages Use AUX 5C to view the tables AUX 5C HISTORY D ERROR MESAGE sHFT AUX ENT CLR Sunooysa qno pue ODUPUSJUIE NA gt ENT AUX 5C HISTORY D ERROR MESAGE Example of an error display E252NEW I O CFG 93 09 21 10 11 15 Year Month Day Time DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting System Error The System error log contains 32 of the most recent errors that have been detected Codes The errors that are trapped in the error log are a subset of all the error messages VA WIV Iv which the DL205 systems generate These errors can be generated by the CPU or by the Handheld Programmer depending on the actual error Appendix B provides a 230 240 250 1 260 more complete description of the error codes The errors can be detected at various times However most of them are detected at power up on entry to
153. Step CT n 2 not used CTA n 3 4 177 4 377 Current Step CT n 1 not used The following ladder program shows the DRUM instruction in a typical ladder program as shown by DirectSOFT32 Steps 1 through 10 are used and twelve of the sixteen output points are used The preset step is step 1 The timebase runs at K10 x 0 01 0 1 second per count Therefore the duration of step 1 is 25 x 0 1 2 5 seconds In the last rung the Drum Complete bit CTO turns on output YO upon completion of the last step step 10 A drum reset also resets CTO DirectSOFT32 Display xo gtat DRUM CTO 15 0 Step Preset K1 C14 Y10 C4 Y5 Y13 C7 X1 Reset 0 01sec Count K 10 7 C30 09 C2 DRI v42 C10 Step Counts 1 K0025 O OO CR 000000000096 2 K0020 O OO CR O6 DIO 8 0 OO OR o 3 K1500 O OO 0068006060 0 68 0 0e 4 K0045 O OO Oi G CO 00 0060 0 06 5 Ko180 OO0OO00O00000600000 6 K0923 O OO OR 000000000096 7 K1200 O O O 068 068 0 68 06 00 O0 6 8 K8643 O OO 00 0 068 06 0 0 0 06 9 K1200 O 0006 66 00 0 0 0 0 0 10 K4000 O OO OO 0 60 60 60 BOO 11 O CO OQO 12 O1 C1 OC O1 O 13 O OO OO OO OO OO OF O OO O 14 O OO OO OO OO OO OO OO O 15 ON ON O 16 CHO OC
154. TrUCtONS wos 2 5 54208 mr ie auto coe eee KR teas eee eae eee ee ee eG AA C 32 Clock Calander Instructions ccc x x x x x x iene A n C 32 MODBUS INSTFUCUONS sierra ran ora C 32 ASCI Instructions a R E SR REER A an C 33 Appendix D Special Relays DL230 CPU Special Relays viii sss s x x x rene A a eee eS D 2 Startup and Real Time Relays vache ee oan sede ts see sue do weeny Rabe oe ed ie D 2 CPU Status BG us COS tas e tr le a AE est et fae site ee ein UNS D 2 System Montong lt wae cee ea Shook ae whe Gad Pad aoe Poe ed ede Hae ORs el oe ae hate oe D 2 ACCUMULATION SAWS eses sus ae ae ed ald och ae clara tes anti ee ed gee eae D 3 Counter Interface Module Relays D 3 Equal Relays for Multi step Presets with Up Down Counter 1 for Counter Interface Module D 3 DL240 DL250 1 DL260 CPU Special Relays D 4 Startup and Real Time Relays rr D 4 GPU Status Relays lat it Ar Es D 4 System Monitoring Relays 42 a AS ia te PO A D 5 Accumulator Status Relays ed ere e Ad cid e ed D 5 Counter Interface Module Relays nunnana annann D 5 Communications Monitoring Relays D 6 Equal Relays for Multi step Presets with Up Down Counter 1 for Counter Interface Module D 7 Equal Relays for Multi st
155. UX 5C Display Error Message History The DL205 products can use a program name for the CPU program or a program stored on EEPROM in the Handheld Programmer Note you cannot have multiple programs stored on the EEPROM The program name can be up to eight characters in length and can use any of the available characters A Z 0 9 AUX 51 allows you to enter a program name You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu Once you ve entered a program name you can only clear the name by using AUX 54 to reset the system memory Make sure you understand the possible ramifications of AUX 54 before you use it The DL240 DL250 1and the DL260 CPUs have a clock and calendar feature If you are using this you can use the Handheld and AUX 52 to set the time and date The following format is used e Date Year Month Date Day of week 0 6 Sunday thru Saturday e Time 24 hour format Hours Minutes Seconds You can use the AUX function to change any component of the date or time However the CPU will not automatically correct any discrepancy between the date and the day of the week For example if you change the date to the 15th of the month and the 15th is on a Thursday you will also have to change the day of the week unless the CPU already shows the date as Thursday You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu AUX 53 displays the cu
156. V can shut down the power supply This 5V can be coming from the base or from the CPU communication ports To test for a device causing this problem 1 Turn off power to the CPU 2 Disconnect all external devices i e communication cables from the CPU 3 Reapply power to the system If the power supply operates normally you may have either a shorted device or a shorted cable If the power supply does not operate normally then test for a module causing the problem by following the steps below If the PWR LED operates normally the problem could be in one of the modules To isolate which module is causing the problem disconnect the system power and remove one module at a time until the PWR LED operates normally Follow the procedure below s Turn off power to the base e Remove a module from the base e Reapply power to the base Bent base connector pins on the module can cause this problem Check to see the connector is not the problem If the machine had been operating correctly for a considerable amount of time prior to the indicator going off the power budget is not likely to be the problem Power budgeting problems usually occur during system start up when the PLC is under operation and the inputs outputs are requiring more current than the base power supply can provide WARNING The PLC may reset if the power budget is exceeded If there is any doubt about the system power budget please check it at this time Exceeding the pow
157. a carry 23 SP70 Sign on anytime the value in the accumulator is negative De SP71 Invalid octal on when an Invalid octal number was entered This also occurs when ve number the V memory specified by a pointer P is not valid 20 SP72 on anytime accumulator has an invalid floating point number n SP73 Overflow on if overflow occurs in the accumulator when a signed addition or subtraction results in a incorrect sign bit SP74 on when a floating point math operation results in an overflow error SP75 Data error on if a BCD number is expected and a non BCD number is encountered SP76 Load zero on when any instruction loads a value of zero into the accumulator Counter Interface SP100 XO is on X0 on when corresponding input is on Module Relays SP101 X1 is on X1 on when corresponding input is on SP102 X2 is on X2 on when corresponding input is on SP103 X3 is on X3 on when corresponding input is on DL205 User Manual 3rd Ed Rev A 08 03 Special Relays Communications Monitoring Relays fp oz ESO DT Co D 28 to 09 SP116 DL240 CPU on when the CPU is communicating with another device communication SP116 DL250 1 260 on when port 2 is communicating with another device communication SP117 Comm error on when Port 2 has encountered a communication error Port 2 DL250 1 260 SP120 Module busy on when the communication modul
158. a communications error has occurred on any of the CPU error ports SP47 1 O configuration on if an I O configuration error has occurred The CPU power up I O error configuration check must be enabled before this relay will be functional SP50 Fault instruction on when a Fault Instruction is executed SP51 Watch Dog on if the CPU Watch Dog timer times out timeout SP52 Grammatical on if a grammatical error has occurred either while the CPU is error running or if the syntax check is run V7755 contains the exact error code SP53 Solve logic error on if CPU cannot solve the logic SP54 Intelligent I O on when communications with an intelligent module has occurred error Accumulator SP60 Value less than on when the accumulator value is less than the instruction value Status Relays SP61 Value equal to on when the accumulator value is equal to the instruction value SP62 Greater than on when the accumulator value is greater than the instruction value SP63 Zero on when the result of the instruction is zero in the accumulator SP64 Half borrow on when the 16 bit subtraction instruction results in a borrow SP65 Borrow on when the 32 bit subtraction instruction results in a borrow SP66 Half carry on when the 16 bit addition instruction results in a carry Mm SP67 Carry when the 32 bit addition instruction results in
159. able V 03 Loop Table V2002 XXXX Setpoint V2003 XXXX Process Variable V2005 XXXX Control Output The data for the SP PV and Control Output must interface with real word sources and devices In the figure below the sources or destinations are shown for each loop variable The Control Output and Process Variable values move through the appropriate analog module to interface with the process itself A small amount of ladder logic is required to copy data from the loop table to the analog I O module s memory address and vise versa Remember that most analog modules have multiplexed data with two or three channel address decode bits Refer to the analog module manual for ladder examples that show how to move analog data between DL205 analog modules and an arbitrary V memory location Loop Control Output V 05 1 2 Calculation Setpoint Sources Operator Input Ramp soak generator Ladder Program Another loop s output cascade Process Process Variable V 03 The Setpoint has several possible sources listed in the figure above Many applications will use two or more of the sources at various times depending on the loop mode In addition the loop control topology and programming method also determine how the setpoint is generated When using the built in Ramp Soak generator or when cascading a loop the PID controller automatically writes the setpoint data in locat
160. ables have a primarily linear response curve Most temperature sensors are mostly linear across their sensing range However flow sensing using an orifice plate technique gives a signal representing approximately the square of the flow Therefore a square root extract function is necessary before using the signal in a linear control system such as PID Some flow transducers are available which will do the square root extract but they add cost to the sensor package The PID loop PV input has a selectable square root extract function pictured below You can select between normal linear PV data and data needing a square root extract by using PID Mode setting V 00 word bit 6 AE doo Aid g C D O1 L g C o O G Setpoint gt Loop Control Output _ Calculation Linear PV IL 0 L Process Variable Square root PV L PID Mode 1 Setting V 00 Bit 15 14 13 12 11 10 9 8 Li 4 3 2 1 0 L Linear Square root PV select DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only IMPORTANT The scaling of the SP must be adjusted if you use PV square root extract because the loop drives the output so the square root of the PV is equal to the PV input Divide the desired SP value by the square root of the analog span and use the result in the V 0
161. again Start Reset Hold Resume Drum Reset drum drum drum drum Complete drum l t Y T T nputs r 7 Start o 7 1 Jog 0 JH Reset A H Drum Status Step 1 1 2 1 1 2 3 3 4 des 15 16 16 16 1 1 Drum i Complete CTO o L Outputs x 16 S L When the drum completes the last step Step 16 in this example the Drum Complete bit CTO turns on and the step number remains at 16 When the Reset input turns on it turns off the Drum Complete bit CTO and forces the drum to enter the preset step NOTE The timing diagram shows all steps using equal time durations Step times can vary greatly depending on the counts step programmed DL205 User Manual 3rd Ed Rev A 08 03 en 200 LE Q DE gE U g EO 20 le Self Resetting Drum Initializing Drum Outputs Drum Instruction Programming In the figure below we focus on how the Jog input works on event drums To the left of the diagram note the off to on transitions of the Jog input increments the step Start may be either on or off however Reset must be off Two jogs takes the drum to step three Next the Start input turns on and the drum begins running normally During step 6 another Jog input signal occurs This increments the drum to step 7 setting the timer to 0 The drum begins running immediately in step 7 because Start is already on The drum advances to step
162. ame the proportional response slightly so adjust these Le gains together SS RS Auto Tuning The auto tuning feature in the DL250 1 and DL260 CPU loop controllers run only at oe Procedure the command of the process control engineer The auto tuning therefore does not OF 5 lt WARNING Only authorized personnel fully familiar with all aspects of the process should make changes that affect the loop tuning constants Using the loop auto tuning procedures will affect the process including inducing large changes in the control output value Make sure you thoroughly consider the impact of any changes to minimize the risk of injury to personnel or damage to equipment The auto tune in the DL250 1 and DL260 is not intended to perform as a replacement for your process knowledge A mD PENR The loop controller offers both closed loop and open loop methods If you intend to use the auto tune feature we recommend you use the open loop method first This will permit you to use the closed loop method of auto tuning when the loop is operational Auto Mode and cannot be shut down Manual Mode The following sections describe how to use the auto tuning feature and what occurs in open and closed loop auto tuning DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only The controls for the auto tuning function use three bits in the PID Mode 2 word V 01 as shown below DirectSOFT32 will manipu
163. ammer or DirectSOFT32 to communicate online to the PLC 2 Change to Program Mode Go to address 0 Insert an END statement at address 0 This will cause program 4 execution to occur only at address O and prevent the application pro gram from turning the I O points on or off 5 Change to Run Mode 6 Use the programming device to set turn on or off the points you wish to test 7 When you finish testing I O points delete the END statement at address 0 WARNING Depending on your application forcing I O points may cause unpredictable machine operation that can result in a risk of personal injury or equipment damage Make sure you have taken all appropriate safety precautions prior to testing any I O points GD XO X2 be Insert an END statement Ne D at the beginning of the X1 X3 X4 program This disables L the remainder of the program Gs From a clear display use the following keystrokes 16P STATUS STAT ENT BIT REF Use the PREV or NEXT keys to select the Y data type NEXT ENT Use arrow keys to select point then use ON and OFF to change the status ON E lt lt SHFT INS
164. and events are specified as discrete contacts Unused steps and events can be left blank this is the default entry Whenever the Start input is energized the drum s timer is enabled As long as the event is true for the current step the timer runs during that step When the step count equals the counts per step the drum transitions to the next step This process stops when the last step is complete or when the Reset input is energized The drum enters the preset step chosen upon a CPU program to run mode transition and whenever the Reset input is energized Drum Parameters Field Data Types Ranges Counter Number aaa 0 177 DL250 1 0 377 DL260 Preset Step bb K 1 16 Timer base cccc K 0 99 99 seconds Counts per step dddd K 0 9999 Event eeee X Y C S T ST GX GY see p 3 52 3 53 Word Output Fffff V see p 3 52 3 53 Output Mask Ggggg V see p 3 52 3 53 DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming Drum instructions use four counters in the CPU The ladder program can read the counter values for the drum s status The ladder program may write a new preset step number to CTA n 2 or a new current step number to CTA n 3 at any time However the other counters are for monitoring purposes only Counter Ranges of n Ranges of n Function Counter Bit Function Number DL250 1 CTA n 0 174 0 374 Counts in step
165. and optimize the performance of a control loop The loop calculation function uses the configuration parameters in real time to adjust gains offsets etc Loop Monitoring the function which allows an operator to observe the status and performance of a control loop This is used in conjunction with the loop configuring to optimize the performance of a loop minimize the error term DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only ES The diagram below shows each loop element in the form of its real world physical component The example manufacturing process involves a liquid in a reactor vessel sensor probe measures a process variable which may be pressure temperature or another parameter The sensor signal is amplified through a transducer and is sent through the wire in analog form to the PLC input module The PLC reads the PV from an analog input The CPU executes the loop calculation and writes to the analog output module location The CPU executes the loop calculation and writes to the analog output The control output signal may be analog proportional or digital on off depending on loop setup This signal goes to a device in the manufacturing process such as a heater valve pump etc Over time the liquid begins to change enough to be measured on the sensor probe The process variable changes accordingly The next loop calculation occurs and the loop cycle repeats in this manner con
166. andheld programmer status Indicators display Below are the keystrokes to call the status display for Y10 Y20 From a clear display use the following keystrokes to display the status of Y10 Y20 STAT ENT NEXT B i A ENT Override bit is on Point is on fad o 35 CO c3 To D 3 nD D O Q Cp J O DL205 User Manual 3rd Ed Rev A 08 03 Auxiliary Functions In This Appendix Introduction AUX 2 RLL Operations AUX 3 V memory Operations AUX 4 I O Configuration AUX 5 CPU Configuration AUX 6 Handheld Programmer Configuration AUX 7 EEPROM Operations AUX 8 Password Operations U BE E xe er 2 gt E x Introduction What are Auxiliary Functions Auxiliary Functions Many CPU setup tasks involve the use of Auxiliary AUX Functions The AUX Functions perform many different operations ranging from clearing ladder memory displaying the scan time copying programs to EEPROM in the handheld programmer etc They are divided into categories that affect different system parameters You can access the AUX Functions from DirectSOFT32 or from the DL205 Handheld Programmer The manuals for those products provide step by step procedures for accessing the AUX Functions Some of
167. ant because it shows us why the integrator term must respond more slowly to errors than either the proportional or derivative terms DL205 User Manual 3rd Ed Rev A 08 03 8 38 PID Loop Operation DL250 1 DL260 only PID Loop Operation GO Q N a m _ T O Ye A S Bias Freeze The term reset windup refers to an undesirable characteristic of integrator behavior which occurs naturally under certain conditions Refer to the figure below Suppose the PV signal becomes disconnected and the PV value goes to zero While this is a serious loop fault it is made worse by reset windup Notice the bias reset term keeps integrating normally during the PV disconnect until its upper limit is reached When the PV signal returns the bias value is saturated windup and takes a long time to return to normal The loop output consequently has an extended recovery time Until recovery the output level is wrong and causes further problems PV PV loss PV loss Reset windup Freeze bias enabled S Bias coma tt eer PS Recovery time Recovery time In the second PV signal loss episode in the figure the freeze bias feature is enabled It causes the bias value to freeze when the control output goes out of bounds Much of the reset windup is thus avoided and the output recovery time is much less
168. anual 3rd Ed Rev A 08 03 Equal Relays for Multi step Presets with Up Down Counter 1 for use with a Counter Interface Module Special Relays D 7 SP540 Current target value on when the counter current value equals the value in V3630 SP541 Current target value on when the counter current value equals the value in V3632 SP542 Current target value on when the counter current value equals the value in V3634 SP543 Current target value on when the counter current value equals the value in V3636 SP544 Current target value on when the counter current value equals the value in V3640 SP545 Current target value on when the counter current value equals the value in V3642 SP546 Current target value on when the counter current value equals the value in V3644 SP547 Current target value on when the counter current value equals the value in V3646 SP550 Current target value on when the counter current value equals the value in V3650 SP551 Current target value on when the counter current value equals the value in V3652 SP552 Current target value on when the counter current value equals the value in V3654 SP553 Current target value on when the counter current value equals the value in V3656 SP554 Current target value on when the counter current value equals the value in V3660
169. ar format must be used Unipolar Bipolar DL205 User Manual 3rd Ed Rev A 08 03 8 28 PID Loop Operation DL250 1 DL260 only PID Loop Operation gt GO ro N a m _ T O Ye A S Handling Data Offsets Setpoint SP Limits In many batch process applications sensors or actuators interface to DL205 analog modules using 4 20 mA signals This signal type has a built in 20 offset because the zero point is a 4 mA instead of 0 mA However remember the analog modules convert the signals into data and remove the offset at the same time For example a 4 20 mA signal is often converted to 0000 OFFF hex or 0 to 4095 decimal In this case all you need to do is choose 12 bit unipolar data format and make sure the ladder program copies the data appropriately between the loop table and the analog modules e PV Offset In the event you have a PV value with a 20 offset convert it to zero offset by subtracting 20 of the top of its range and multiply by1 25 s Control Output In the event the Control Output is going to a device with 20 offset all you need to do is have the ladder program write a value equivalent to the offset to the integrator register V 04 before transitioning from Manual to Auto mode The loop will then see this offset as a part of the process taking care of it for you automatically The Setpoint in loop table location V 02 represents the desired value of the
170. arate table of 32 words with appropriate values A DirectSOFT32 dialog box makes this easy to do In the basic loop table the Ramp Soak Table Pointer at Addr 34 must point to the start of the ramp soak data for that loop This may be anywhere in user memory and does not have to be adjoining to the Loop Parameter table as shown to the left Each R S table requires 32 words regardless of the number of segments programmed The ramp soak table parameters are defined in the table below Further details are in the section on Ramp Soak Operation in this chapter V Memory Space Addr Step Description Addr Step Description Offset Offset User Data 00 1 Ramp End SP Value 20 9 Ramp End SP Value V2000 LOOP 1 01 1 Ramp Slope 21 9 Ramp Slope 2037 32 words EN 02 2 Soak Duration 22 10 Soak Duration LOOP 2 03 2 Soak PV Deviation 23 10 Soak PV Deviation 32 words ue 04 3 Ramp End SP Value 24 11 Ramp End SP Value ES S6 Z 05 3 Ramp Slope 25 11 Ramp Slope BS D O V3000 Ramp Soak 1 C 06 4 Soak Duration 26 12 Soak Duration OZ 32 words 07 4 Soak PV Deviation 27 12 Soak PV Deviation gr 10 5 Ramp End SP Value 30 13 Ramp End SP Value S 11 5 Ramp Slope 31 13 Ramp Slope La 12 6 Soak Duration 32 14 Soak Duration x V2034 3000 octal 13 6 Soak PV Deviation 33 14 Soak PV Deviation Pointer to R S table
171. are issued by other parties and in some cases Governmental agencies the requirements can change over time without advance warning or notice Changes or additions to the standards can possibly invalidate any part of the information provided in this section This area of certification and approval is absolutely vital to anyone who wants to do business in Europe One of the key tasks that faced the EU member countries and the European Economic Area EEA was the requirement to harmonize several similar yet distinct standards together into one common standard for all members The primary purpose of a harmonized standard was to make it easier to sell and transport goods between the various countries and to maintain a safe working and living environment The Directives that resulted from this merging of standards are now legal requirements for doing business in Europe Products that meet these Directives are required to have a CE mark to signify compliance Currently the members of the EU are Austria Belgium Denmark Finland France Germany Greece Ireland Italy Luxembourg The Netherlands Portugal Spain Sweden and the United Kingdom Iceland Liechtenstein and Norway together with the EU members make up the European Economic Area EEA and all are covered by the Directives There are several Directives that apply to our products Directives may be amended or added as required s Electromagnetic Compatibility Directive EMC this Di
172. at caused the problem You will find this problem is sometimes caused by high frequency electrical noise introduced into the CPU from an outside source Check your system grounding and install electrical noise filters if the grounding is suspected If power cycling the system does not reset the error or if the problem returns you should replace the CPU BATT Indicator If the BATT indicator is on the CPU battery is either disconnected or needs replacing The battery voltage is continuously monitored while the system voltage is being supplied Communications Problems If you cannot establish communications with the CPU check these items e The cable is disconnected e The cable has a broken wire or has been wired incorrectly e The cable is improperly terminated or grounded e The device connected is not operating at the correct baud rate 9600 baud for the top port Use AUX 56 to select the baud rate for the bottom port on a DL240 DL250 1 and DL260 e The device connected to the port is sending data incorrectly s A grounding difference exists between the two devices e Electrical noise is causing intermittent errors e The CPU has a bad communication port and the CPU should be replaced If an error occurs the indicator will come on and stay on until a successful communication has been completed 20UBUAJUIEIA E a re Cc S D A gt 5 O DL205 User Manual 3rd Ed Rev A 08 03 9 10 Maintena
173. at from the menu Setpoint V 02 5 Loop Control Output V 05 Calculation PID Mode 2 Setting V 01 Process Variable V 03 Bit 15 14 13 12 11109876543210 Data formats LSB Bit 15 14 13 12 11 10 9 8 76543210 00 12 bit unipolar to OFFF 0 to 4095 Ox Select data NO S 01 12 bit bipolar 0 to OFFF 8FFF to 8001 O1 ee S j 0 to 4095 4095 to 1 Te 10 15 bit unipolar 0 to 32767 yA NS 11 m 15 bit bipolar 0 to 7FFF FFF to 8001 DO 1 0 to 32767 32767 to 1 S S sign bit OS T7 The data format is a very powerful setting because it determines the numerical interface between the PID loop and the PV sensor and the Control Output device The Setpoint must also be in the same data format Normally the data format is chosen during the initial loop configuration and is not changed again Choosing Unipolar Choosing the data format involves deciding whether to use unipolar or bipolar or Bipolar Format numbers Most applications such as temperature control will use only positive numbers and therefore need unipolar format Usually it is the Control Output which determines bipolar unipolar selection For example velocity control may include control of forward and reverse directions At a zero velocity setpoint the desired control output is also zero In that case bipol
174. atory use s Product Specific Standard for PLCs EN61131 2 Programmable controllers equipment requirements and tests This standard replaces the above generic standards for immunity and safety However the generic emissions standards must still be used in conjunction with the following standards EN 61000 3 2 Harmonics EN 61000 3 2 Fluctuations Automationdirect com is currently in the process of changing their testing procedures from the generic standards to the product specific standard so that all new products will be tested to standard EN61131 2 Check our catalog or website for updated information Special Installation The installation requirements to comply with the requirements of the Machinery Manual Directive EMC Directive and Low Voltage Directive are slightly more complex than the normal installation requirements found in the United States To help with this we have published a special manual which you can download from our website www automationdirect com e DA EU M EU Installation Manual that covers special installation requirements to meet the EU Directive requirements Download this manual to obtain the most up to date information Other Sources of Although the EMC Directive gets the most attention other basic Directives such as Information the Machinery Directive and the Low Voltage Directive also place restrictions on the control panel builder Because of these additional requirements it is recommended
175. ave to be active before the last stage has power flow e The last convergence stage of a group may have ladder logic within the stage However this logic will not execute until all convergence stages of the group are active e The convergence jump CVJMP is the intended method to be used to transition from the convergence group of stages to the next stage The CVJMP resets all convergence stages of the group and energizes the stage named in the jump e The CVJMP instruction must only be used in a convergence stage as it is invalid in regular or initial stages e Convergence Stages or CVJMP instructions may not be used in subroutines or interrupt routines DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming Managing Large Programs A stage may contain a lot of ladder rungs or only one or two program rungs For most applications good program design will ensure the average number of rungs per stage will be small However large application programs will still create a large number of stages We introduce a new construct which will help us organize related stages into groups called blocks So program organization is the main benefit of the use of stage blocks Stage Blocks A block is a section of ladder program which contains stages In the figure below BLK BEND each block has its own reference number Like stages a stage block may be active or inactive Stages inside a block are not limited in how they may transiti
176. bled because the bit override is enabled For example if you enabled the Bit Override for YO and it was off at the time then the CPU would not change the state of YO However you can still use a programming device to change the status Now if you use the programming device to force YO on it will remain on and the CPU will not change the state of YO If you then force YO off the CPU will maintain YO as off The CPU will never update the point with the results from the application program or from the I O update until the bit override is removed from the point The following diagram shows a brief overview of the bit override feature Notice the CPU does not update the Image Register when bit override is enabled Bit Override OFF Bit Override ON Input Update Inputgpdate ee Xi28 x2 x1 xo OFF on ON OFF Force from Y128 Y2 Y1 vo Force from Programmer p LOFF ON ON OFF Programmer ca77 c2 c1 co D oFF ON OFF OFF Result of Pro Image Register example Resultof TU gramSolution gramSot tion AUX 5B is used with the DL205 Counter Interface module to select the module configuration You can choose the type of counter set the counter parameters etc See the DL205 Counter Interface Module manual for a complete description of how to select the various counter features DL205 User Manual 3rd Ed Re
177. by even smaller increments percentage wise Also note the drum instruction executes once per CPU scan Therefore it is pointless to specify a drum timebase that is much faster than the CPU scan time Timer and Event Time and Event Drums move from step to step based on time and or external events Transitions The figure below shows how step transitions work for these drums Step1 Outputs O 00000000000000 Is Step event true Yes Increment count timer Has step counts expired Step2 Outputs O0 00000000000000 Use next transition criteria When the drum enters Step 1 the output pattern shown is set It begins polling the external input programmed for that step You can define event inputs as X Y or C discrete point types Suppose we select XO for the Step 1 event input If XO is off then the drum remains in Step 1 When XO0 is On the event criteria is met and the timer increments The timer increments as long as the event remains true When the counts for Step 1 have expired the drum moves to Step 2 The outputs change immediately to match the new pattern for Step 2 DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Event Only Transitions Counter Assignments Drum Instruction Programming Time and Event drums do not have to possess both the event and the timer criteria programmed for each step You have th
178. by the CPU For example if you enable bit override for X1 and X1 is off at the time the CPU will not change the state of X1 This means that even if X1 comes on the CPU will not acknowledge the change Therefore if you used X1 in the program it would always be evaluated as off in this case If X1 was on when the bit override was enabled then X1 would always be evaluated as on There is an advantage available when you use the bit override feature The regular forcing is not disabled because the bit override is enabled For example if you enabled the Bit Override for YO and it was off at the time the CPU would not change the state of YO However you can still use a programming device to change the status If you use the programming device to force YO on it will remain on and the CPU will not change the state of YO If you then force YO off the CPU will maintain YO as off The CPU will never update the point with the results from the application program or from the I O update until the bit override is removed from the point DL205 User Manual 3rd Ed Rev A 08 03 9 27 Maintenance and Troubleshooting The following diagrams show how the bit override works for both input and output points The example uses a simple rung but the concepts are similar for any type of bit memory Program Rung Override holds XU YU previous state and disables A y
179. c So S8 is not valid ij c s Total Stages The maximum number of stages is CPU dependent SG e No duplicates Each stage number S2 is unique and can be used once c Any order You can skip numbers 1 c and sequence the stage numbers in any order ES s Last Stage the last stage in the ladder program includes all rungs from its stage box until the end coil DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming 1 7 Using the Stage Jump Instruction for State Transitions Stage Jump Set The Stage JMP instruction we have used deactivates the stage in which the and Reset instruction occurs while activating the stage in the JMP instruction Refer to the Instructions state transition shown below When contact X0 energizes the state transition from SO to S1 occurs The two stage examples shown below are equivalent So the Stage Jump instruction is equal to a Stage Reset of the current stage plus a Stage Set instruction for the stage to which we want to transition X0 SG SG SO SO Equivalent R Ps UMP S jab Q OD UE eo Sc So 3 no RST S Q S1 SET Please Read Carefully The jump instruction is easily misunderstood The jump does not occur immediately like a GOTO or GOSUB program control instruction when executed Here s how it works e The jump instruction resets the stage bit of the stage in which it occ
180. caded Drums Provide More Than 16 Steps 6 13 Drum Instructions lt v r A A a etant dura 6 14 Timed Drum with Discrete Outputs DRUM 6 14 Event Drum with Discrete Outputs EDRUM 6 16 Masked Event Drum with Discrete Outputs MDRMD 6 20 Masked Event Drum with Word Output MDRMW 6 22 Chapter 7 RLLPLUS Stage Programming Introduction to Stage Programming sss x x x x c c e e e x x K K K K eee eens 7 2 Overcoming Stage Fright 2 sin sat dome ste chee sopesar te ee esa etes des 7 2 Learning to Draw State Transition Diagrams 7 3 Introduction to Process States 2356 es ren eme en enter eur bete in 7 3 The Need for State Diagrams 4 04 sees beetle GERS a a oa 7 3 A P Stdle POCOS us sua am an nee adie ae aa bee ak toh te de ass hiela meee edie aes 7 3 RLE Equivalent saree 0 R ET o R els LE A eee NRT 7 4 Stage EQUIVAIGIN gc Bi E re e la eae A TE Meter NR Le ce 7 4 H Table of Contents tets Compare S RAE EEN Ss 7 5 Initial STAgBS iener re ee wend eves Pre re a dE a OO TR a RE ne wees 7 5 War Stage DNS Dons med tent abide ab ttt aed Sa ee bane se tee eee 7 6 Stage Instruction Characteristics 7 6 Using the Stage Jump Instruction for State Transitio
181. cans Test Mode also allows you to maintain output status while you switch between Test Program and Test Run Modes You can select Test Modes from either the Handheld Programmer by using the MODE key or from DirectSOFT32 via a PLC Modes menu option The primary benefit of using the TEST mode is to maintain certain outputs and other parameters when the CPU transitions back to Test program mode For example you can use AUX 58 from the DL205 Handheld Programmer to configure the individual outputs CRs etc to hold their output state Also the CPU will maintain timer and counter current values when it switches to TEST PGM mode NOTE You can only use DirectSOFT32 to specify the number of scans This feature is not supported on the Handheld Programmer However you can use the Handheld to switch between Test Program and Test Run Modes With the Handheld the actual mode entered when you first select Test Mode depends on the mode of operation at the time you make the request If the CPU is in Run Mode mode then TEST RUN is available If the mode is Program then TEST PGM is available Once you ve selected TEST Mode you can easily switch between TEST RUN and TEST PGM DirectSOFT32 provides more flexibility in selecting the various modes with different menu options The following example shows how you can use the Handheld to select the Test Modes Use the MODE key to select TEST Modes example assumes Run Mode MODE CHANGE MODE
182. case ladder logic will need to be used to perform the math and transfer the data to or from the analog modules as required NOTE If the auto transfer to from I O function is used the analog data for all of the channels on the analog modules being used with this feature cannot be accessed by any other method i e pointer or multiplex DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Loop Modes In PID Loop applications we have control situations that frequently occur throughout the industry In each scenario we slightly modify the source of data for the basic three variables SP PV and control output creating a mode name for each scenario The modes featured in the DL250 1 and DL260 CPUs are Manual Automatic and Cascade After this introduction to the modes we will study how to request mode changes In Manual Mode the loop is not executing PID calculations however loop alarms are still active With regard to the loop table the CPU stops writing values to location V 05 for that loop It is expected that an operator or other intelligent source is manually controlling the output by observing the PV and writing data to V 05 as necessary to keep the process under control The drawing below shows the equivalent schematic diagram of manual mode operation Input from Operator Manual D Control Output V 05 Loop a Calculation p In Automatic Mode the l
183. cate stage reference E482 CV exceeded E422 Duplicate SBR LBL reference E483 CVJMP placement error E423 Nested loops E484 No CV E431 Invalid ISG SG address E485 No CVJMP E432 Invalid jump GOTO address E486 BCALL placement error E433 Invalid SBR address E487 No Block defined E434 Invalid RTC address E488 Block position error E435 Invalid RT address E489 Block CR identifier error E436 Invalid INT address E490 No Block stage E437 Invalid IRTC address E491 ISG position error E438 Invalid IRT address E492 BEND position error a E440 Invalid Data Address E493 BEND error 32 E441 ACON NCON E494 No BEND Se E451 Bad MLS MLR 33 E452 X input used as output coil oo E453 Missing T C a E454 Bad TMRA E455 Bad CNT E456 Bad SR DL205 User Manual 3rd Ed Rev A 08 03 9 10 Maintenance and Troubleshooting CPU Indicators The DL205 CPUs have indicators on the front to help you diagnose problems with the system The table below gives a quick reference of potential problems associated with each status indicator Following the table will be a detailed analysis of each of these indicator problems Indicator Status Potential Problems PWR off 1 System voltage incorrect 2 Power supply CPU is faulty 3 Other component such an I O module has power supply shorted 4 Power budget exceeded for the base being used RUN 1 CPU programming error will not come on 2 Switch in TERM position 3 Switch in STOP position
184. check the cabling ERROR 3 between the two devices replace the handheld programmer then if necessary replace the CPU SP46 will be on and the error code will be stored in V7756 E316 A mode error was encountered during communications with the CPU Clear HP COMM the error and retry the request If the error continues replace the handheld ERROR 6 programmer then if necessary replace the CPU SP46 will be on and the error code will be stored in V7756 E320 The CPU did not respond to the handheld programmer communication HP COMM request Check to insure cabling is correct and not defective Power cycle the TIME OUT system if the error continues replace the CPU first and then the handheld programmer if necessary E321 A data error was encountered during communication with the CPU Check to COMM ERROR insure cabling is correct and not defective Power cycle the system and if the error continues replace the CPU first and then the handheld programmer if necessary E4 A syntax error exists in the application program The most common is a NO PROGRAM missing END statement Run AUX21 to determine which one of the E4 series of errors is being flagged SP52 will be on and the error code will be stored in V7755 E401 All application programs must terminate with an END statement Enter the MISSING END END statement in appropriate location in your program SP52 will be on and STATEMENT the error code will be stored in V7755 E402 A GOTO GTS MOVMC
185. ck Calander DL230 DL240 DL250 1 DL260 Y Instructions E DATE V Data Reg 24 0us 1 2us 24 0us 1 2us F V Bit Reg Oc x2 ES TIME V Data Reg 50 8us 1 2us 50 8us 1 2us ol V Bit Reg S lt US L MODBUS Instructions Clock Calander DL230 DL240 DL250 1 DL260 Instructions MRX Input Input Register 120 2 us 1 3 us Coil Holding Register MWX Input Input Register 21 3 us 1 3 us Coil Holding Register DL205 User Manual 3rd Ed Rev A 08 03 C 33 Instruction Execution Times ASCII Instructions ASCII Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute AIN V 13 9 us 12 0 us AFIND V 111 5us 1 3 us AEX V 111 7 us 1 3 us CMPV V 12 2 us 1 3 us SWAPB V 109 8 us 1 3 us VPRINT Text Data DE 161 6 us 1 3 us PRINTV V 163 3 us 1 3 us ACRB V 3 9 us 1 1 us 9 xipueddy 5 a ast m x lt QO CC O 5 3 D B DL205 User Manual 3rd Ed Rev A 08 03 Special Relays In This Appendix DL230 CPU Special Relays DL24
186. closure which also contains susceptible electronic equipment from other manufacturers remember that these cables may be a source of RF emissions There are ways to minimize this risk Standard data cables connecting PLCs and or operator interfaces should be routed well away from other equipment and their associated cabling You can make special serial cables where the cable shield is connected to the enclosure s earth ground at both ends the same way as external cables are connected 9 xpusddy DL205 User Manual 3rd Ed Rev A 08 03 G8 European Union Directives OS x 2 58 co Oo 2 gt LU Network Isolation Items Specific to the DL205 For safety reasons it is a specific requirement of the Machinery Directive that a keyswitch must be provided that isolates any network input signal during maintenance so that remote commands cannot be received that could result in the operation of the machinery The FA ISONET does not have a keyswitch Use a keylock and switch on your enclosure which when open removes power from the FA ISONET To avoid the introduction of noise into the system any keyswitch assembly should be housed in its own earth grounded steel box and the integrity of the shielded cable must be maintained Again for further information on EU directives we recommend that you get a copy of our EU Installation Manual DA EU M Also if you are connected to the World Wide Web you can check the EU Commision s off
187. ction such as SET SO Q How does a stage become inactive A There are three ways e Standard Stages SG are automatically inactive at powerup e A stage can execute a Stage JMP instruction resetting its Stage Bit to 0 e Any rung in the program can execute a Reset Stage Bit instruction such as RST SO Q What about the power flow technique of stage transitions A The power flow method of connecting adjacent stages directly above or below in the program actually is the same as the Stage Jump instruction executed in the stage above naming the stage below Power flow transitions are more difficult to edit in DirectSOFT32 we list them separately from two preceding questions DL205 User Manual 3rd Ed 06 02 7 30 RLL PLUS D E D DL D amp ep RLLPLUS Stage Programming Q Can I have a stage which is active for only one scan A Yes but this is not the intended use for a stage Instead make a ladder rung active for 1 scan by including a stage Jump instruction at the bottom of the rung Then the ladder will execute on the last scan before its stage jumps to a new one Q Isn t a Stage JMP like a regular GOTO instruction used in software A No it is very different A GOTO instruction sends the program execution immediately to the code location named by the GOTO A Stage JMP simply resets the Stage Bit of the current stage while setting the Stage Bit of the stage named in the JMP instr
188. curred either while the CPU is running or if the syntax check is run V7755 will hold the exact error code Startup and SPO First scan Real Time Relays SP1 Always ON SP2 Always OFF SP3 1 minute clock SP4 1 second clock SP5 100 ms clock SP6 50 ms clock SP7 Alternate scan CPU Status Relays SP12 Terminal run mode SP16 Terminal program mode SP20 Forced stop mode SP22 Interrupt enabled System Monitoring sp40 Critical error SP41 Warning SP43 Battery low SP44 Program 172 memory error as xT SP45 UO error TTC em D SP47 1 O 23 configuration Q a error SP50 Fault instruction SP51 Watch Dog timeout SP52 Grammatical error SP53 Solve logic error on if CPU cannot solve the logic DL205 User Manual 3rd Ed Rev A 08 03 Accumulator Status Counter Interface Module Relays Equal Relays for Multi step Presets with Up Down Counter 1 for use with a Counter Interface Module Special Relays 0 D O L D D D lt n SP60 Value less than on when the accumulator value is less than the instruction value SP61 Value equal to on when the accumulator value is equal to the instruction value SP62 Greater than on when the accumulator value is greater than the instruction value SP63 Zero on when the result of the instructio
189. d Cascade With this selection you automatically affect the modes of the loops by changing the CPU mode CPU Modes fs Loop Mode Linking O N O1 CG2 L g e e La GC AE doo Aid 0 loop follows PLC mode 1 PID Mode 1 Setting V 00 1 loop is independent from PLC mode Bit 15 14 13 12 11 10 9 8 76543210 Loop Modes Mode 2am Gama Mode change If Bit 15 is set to one then the loops will run independently of the CPU mode It is like having two independent processors in the CPU one is running ladders and the other is running the process loops NOTE If you choose for the loops to operate independently of the CPU mode then you must take special steps in order to change any loop table parameter values The procedure is to temporarily make the loops follow the CPU mode Then your programming device such as DirectSOFT32 will be able to place the loop you want to change into Manual Mode After you change the loop s parameter setting be sure to restore the loop independent operation setting DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only How to Change The first three bits of the PID Mode 1 word PID Mode 1 Setting V 00 Loop Modes V 00 requests the operating mode of the corresponding loop Note these bits are a
190. d OUT wwe SS instructions However these memory locations are part of the retentive system parameters so writing them from RLL is not required The CPU reports any programming errors of the setup parameters in V7640 and V7641 It does this by setting the PID Error Flags V7642 appropriate bits in V7642 on program to run mode transitions If you use the DirectSOFT32 loop setup dialog box its automatic range checking prohibits possible setup errors However the setup parameters may be written using other methods such as RLL so the error flag register may be helpful in those cases Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only The following table lists the errors reported in V7642 Bit Error Description 0 no error 1 error The starting address in V7640 is out of the lower V memory range The starting address in V7640 is out of the upper V memory range The number of loops selected in V7641 is greater than 4 WO D The loop table extends past straddles the boundary at V7377 Use an address closer to V1400 4 The loop table extends past straddles the boundary at V17777 DL250 1 or V35777 DL260 Use an address closer to V10000 As a quick check if the CPU is in Run mode and V7642 0000 then we know there are
191. dir Data 160 us 8 4us 33 8us 09us 33 8us 0 9us 32 P Indir Bit 239 us 8 4us 33 8us O9us 33 8us 0 9us 5 ORD V Data Reg 9 0 us 1 0 us 9 0 us 1 0 us 3 V Bit Reg a 9 0 us 1 0 us 9 0 us 1 0 us D K Constant 49 us 8 4 us 60 us 8 4 us 5 8 us 1 0 us 5 8 us 1 0 us mn P Indir Data 34 5 us 0 9 us 34 5 us 0 9 us P Indir Bit G s 345us O9us 345us 0 9 us ORF 1st 2nd X Y C S K Constant 20 9us 1 0 us 20 9us 1 0 us T CT SP 0 9us x 0 9us x GX GY N ORS None sE 10 2 us 1 0 us XOR V Data Reg 60 us 10 4 us 69 us 8 4 us 8 0 us 1 0 us 8 0 us 1 0 us V Bit Reg 257us 10 4us 144 us 8 4 us 8 0 us 1 0 us 8 0 us 1 0 us P Indir Data 160 us 8 4us 336us 09us 33 6us 0 9us P Indir Bit 239 us 8 4us 336us 09us 336us 0 9 us XORD V Data Reg 9 0 us 1 0 us 9 0 us 1 0 us V Bit Reg 9 0 us 1 0 us 9 0 us 1 0 us K Constant 49 us 8 4 us 62 us 8 4 us 5 4 us 1 0 us 5 4 us 1 0 us P Indir Data NN 34 4us 09us 344us 0 9us P Indir Bit 344us O9us 344us 0 9 us DL205 User Manual 3rd Ed Rev A 08 03 C 20 Instruction Execution Times Logical Accumulator DL230 DL240 DL250 1 DL260 Instructions Continued Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execut
192. doing is causing a transfer of control of some loop parameter from one source to another For example when a loop changes from Manual Mode to Automatic Mode control of the output changes from the operator to the loop controller When a loop changes from Automatic Mode to Cascade Mode control of the SP changes from its original source in Auto Mode to the output of another loop the major loop Mode change Mode change Operator PID Transfer generates loop output calculates loop output SP Transfer SP generated local to loop generated remotely by major loop The basic problem of loop transfers is the two different sources of the loop parameter being transferred will have different numerical values This causes the PID calculation to generate an undesirable step change or bump on the control output thereby upsetting the loop to some degree The bumpless transfer feature arbitrarily forces one parameter equal to another at the moment of loop mode change so the transfer is smooth no bump on the control output The bumpless transfer feature of the DL250 1 and DL260 loop controller is available in two types Bumpless I and Bumpless Il Use DirectSOFT32 s PID Setup dialog box to select transfer type Or you can use bit 3 of PID Mode 1 V 00 setting as shown PID Mode 1 Setting V 00 Bit 15 14 13 12 11 10 9 8 76543210 Bumpless Transfer II se
193. e check the troubleshooting tips at the end of this chapter CAUTION If the PV and Control Output values begin to oscillate reduce the gain values immediately If the loop does not stabilize immediately then transfer the loop back to Manual Mode and manually write a safe value to the control output During the loop tuning procedure always be near the Emergency Stop switch which controls power to the loop actuator in case a shutdown Is necessary e At this point the SP should PV because of the bumpless transfer feature Increase the SP a little in order to develop an error value With only the proportional gain active and the bias term 0 we can easily check the control output value Control Output SP PV x proportional gain e Ifthe control output value changed the loop should be getting more energy from the actuator heater or other device Soon the PV should move in the direction of the SP If the PV does not change then increase the proportional gain until it moves slightly s Now add a small amount of integral gain Remember that large numbers are small integrator gains and small numbers are large integrator gains After this step the PV should SP or be very close Until this point we have only used proportional and integrator gains Now we can pump the process change the SP by 10 and adjust the gains so the PV has an optimal response Refer to the figure below Adjust the gains according to what you
194. e Execute Execute Execute XORF 1st 2nd X Y C S K Constant 20 9us 1 0 us 20 9us 1 0 us T CT SP 0 9us x 0 9us x GX GY N XORS None 10 1 us 1 0 us CMP V Data Reg 59 us 10 4 us 69 us 8 4 us 9 4 us 1 0 us 9 4 us 1 0 us V Bit Reg 259us 10 4us 115us 8 4 us 9 4 us 1 0 us 9 4 us 1 0 us P Indir Data 130 us 8 4us 349us 09us 349us 0 9us P Indir Bit 211 us 84us 349us 09us 349us 0 9us CMPD V Data Reg 63 us 8 4 us 47 us 8 4 us 9 9 us 1 0 us 9 9 us 1 0 us V Bit Reg 257 us 8 4 us 206 us 8 4 us 9 9 us 1 0 us 9 9 us 1 0 us K Constant 54 us 8 4 us 49 us 8 4 us 6 7 us 1 0 us 6 7 us 1 0 us P Indir Data 133 us 84us 354us 10us 35 4us 1 0us P Indir Bit 303 us 84us 354us 10us 35 4us 1 0us Z CMPF list 2nd E X Y C S K Constant 29 2us 10us 29 2us 1 0 us Oc T CT SP 1 0us x G xX x 2 N 5E GX GY AA CMPR V Data Reg 42 8 us 1 0us 42 8us 1 0 us Sii V Bit Reg y 42 8us 1 0us 42 8us 1 0 us lt K Constant 38 4 us 1 0us 38 4 us 1 0 us D P Indir Data 69 0 us 1 0us 69 0us 1 0 us P Indir Bit 69 0 us 1 0us 69 0us 1 0 us CMPS None e 11 2us 1 0 us DL205 User Manual 3rd Ed Rev A 08 03 C 21 Instruction Execution Times Math Instructions Math Instructions DL230 DL240 DL250 1 DL260 Accumulator
195. e Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ISG S 31 us 32 us 28 us 27 us 20 9us 92us 209us 9 2 us SG S 31 us 32 us 28 us 27 us 20 9us 92us 20 9us 9 2 us JMP S 14 us 8 us 143us 84us 20 9us 3 7us 209us 3 7 us NJMP S 14 us 8 us 13 3 us 8 4 us 21 0 us 4 0 us 210us 4 0us CV S 43 us 27 us 20 us 20 us 121us 121us 12 1us 12 1 us CVJMP S N stages 1 to 16 33us 23us 229us 10us 11 0us 11 0us 11 0us 11 0 us 14 5us 6 1 xN xN BCALL C 18 us 17 us 17 us 18 us 22 1 us 22 6 us 22 1 us 22 6 us BLK C 32 us 30 us 17 us 13 us 17 1 us 14 6 us 17 1 us 14 6 us BEND None 17 us 17 us 9 us 9 us 8 7 us 0 0 us 8 7 us 0 0 us 9 xipueddy 5 a ost m x lt QO CC O 5 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 32 Instruction Execution Times DRUM Instructions DRUM Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute DRUM CT 265 2 us 48 8 us 265 2 us 48 8 us EDRUM CT 189 5 us 78 0us 189 5 us 78 0 us MDRMD CT 411 3 us 216 4 us 411 3 us 216 4 us MDRMW CT 378 6 us 147 0 us 378 6 us 147 0 us Clock Calander Instructions Clo
196. e ON state we add special relay contact SP1 which is always on Note that even as our programs grow more complex it is still easy to correlate the state transition diagram with the stage program DL205 User Manual 3rd Ed 06 02 68 OFF State XO S1 CMP s Push On State XO 2 V4 CAMP ec ON State Output SP1 YO OUT XO S3 ump SG 33 Push Off State X0 SO V4 CAMP 7 9 RLLPLUS Stage Programming Four Steps to Writing a Stage Program By now you ve probably noticed that we follow the same steps to solve each example problem The steps will probably come to you automatically if you work through all the examples in this chapter It s helpful to have a checklist to guide us through the problem solving The following steps summarize the stage program design procedure 1 Write a Word Description of the application Describe all functions of the process in your own words Start by listing what happens first then next etc If you find there are too many things happening at once try dividing the problem into more than one process Remember you can still have the processes communicate with each other to coordinate their overall activity 2 Draw the Block Diagram Inputs represent all the information the process needs for decisions and outputs connect to all devices controlled by the process e Make lists of inputs and outputs for the p
197. e an initial stage for ladder that must always be active or as a starting point Q Can place program ladder rungs outside of the stages so they are always on A It is possible but it s not good software design practice Place ladder that must always be active in an initial stage and do not reset that stage or use a Stage JMP instruction inside it lt can start other stage sequences at the proper time by setting the appropriate Stage Bit s Q Can I have more than one active stage at a time A Yes and this is a normal occurrence for many programs However it is important to organize your application into separate processes each made up of stages Anda good process design will be mostly sequential with only one stage on at a time However all the processes in the program may be active simultaneously DL205 User Manual 3rd Ed 06 02 PID Loop Operation DL250 1 and DL260 only In This Chapter DL250 1 DL260 PID Loop Features Loop Setup Parameters Loop Sample Rate and Scheduling Ten Steps to Successful Process Control Basic Loop Operation PID Loop Data Configuration PID Algorithms Loop Tuning Procedure PV Analog Filter Feedforward Control Time Proportioning Control Cascade Control Process Alarms Ramp Soak Generator Troubleshooting Tips Bibliography Glossary of PID Loop Terminology 8 2 PID Loop Operation DL250 1 DL260 only PID Lo
198. e at the inputs 2 Read Execute Write can affect the outputs in a few 3 Read ete sl milliseconds gt Most manufacturing processes consist of a series of activities or conditions each lasting for several seconds minutes or even hours We might call these process states which are either active or inactive at any particular time A challenge for RLL programs is that a particular input event may last for a brief instant We typically create latching relays in RLL to preserve the input event in order to maintain a process state for the required duration We can organize and divide ladder logic into sections called stages representing process states But before we describe stages in detail we will reveal the secret to understanding stage programming state transition diagrams Sometimes we need to forget about the scan nature of PLCs and focus our thinking toward the states of the process we need to identify Clear thinking and concise analysis of an application gives us the best chance at writing efficient bug free programs State diagrams are tools to help us draw a picture of our process You will discover that if we can get the picture right our program will also be right Consider the simple process shown to the Inputs Outputs right which controls an industrial motor ou We will use a green momentary SPST XO Motor pushbutton to turn the motor on and a red Ladder Yo one to turn it o
199. e connected to the protective earth ground terminal Equi potential Grounding A B C D K Serial Communication Cable ey Equi potential Bond Adequate site earth grounding must be provided for equipment containing modem electronic circuitry The use of isolated earth electrodes for electronic systems is forbidden in some countries Make sure you check any requirements for your particular destination IEC 1000 5 2 covers equi potential bonding of earth grids adequately but special attention should be given to apparatus and control cubicles that contain VO devices remote VO racks or have inter system communications with the primary PLC system enclosure An equi potential bond wire must be provided alongside all serial communications cables and to any separate items of the plant which contain I O devices connected to the PLC The diagram shows an example of four physical locations connected by a communications cable Communications red Conductive A lt Adapter and Shielded Cable SE Cables ES Si e D To Earth Block Equi potential Bond A Control Cubicle Ke Good quality 24 AWG minimum twisted pair shielded cables with overall foil and braid shields are recommended for analog cabling and communications cabling outside of the PLC enclosure DL20
200. e contacts Unused steps and events can be left blank this is the default entry Whenever the Start input is energized the drum s timer is enabled As long as the event is true for the current step the timer runs during that step When the step count equals the counts per step the drum transitions to the next step This process stops when the last step is complete or when the Reset input is energized The drum enters the preset step chosen upon a CPU program to run mode transition and whenever the Reset input is energized Drum Parameters Field Data Types Ranges Counter Number aaa 0 177 DL250 1 0 377 DL260 Preset Step bb 1 16 Timer base CCCC K 0 99 99 seconds Counts per step dddd 0 9999 Event eeee X Y C S T ST GX GY see page 3 52 or Discrete Outputs Fffff X Y C GX GY pagsa Output Mask Ggggg V DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming Drum instructions use four counters in the CPU The ladder program can read the counter values for the drum s status The ladder program may write a new preset step number to CTA n 2 or a new current step number to CTA n 3 at any time However the other counters are for monitoring purposes only Counter Ranges of n Ranges of n Function Counter Bit Function Number DL250 1 CTA n 0 174 0 374 Counts in step CTn Drum Complete CTA n 1 2 175 2 375 Timer
201. e fatal error occurs the CPU will switch to Program Mode Remember in Program Mode all outputs are turned off If the fatal error is detected while the CPU is in Program Mode the CPU will not enter Run Mode until the error has been corrected Here are some examples of fatal errors e Base power supply failure e Parity error or CPU malfunction s 1 0 configuration errors e Certain programming errors Non fatal Errors Non fatal errors are errors that are flagged by the CPU as requiring attention They can neither cause the CPU to change from Run Mode to Program Mode nor do they prevent the CPU from entering Run Mode There are special relays the application program can use to detect if a non fatal error has occurred The application program can then be used to take the system to an orderly shutdown or to switch the CPU to Program Mode if necessary Some examples of non fatal errors are e Backup battery voltage low s All I O module errors e Certain programming errors Finding Diagnostic Diagnostic information can be found in several places with varying levels of Information message detail e The CPU automatically logs error codes and any FAULT messages into two separate tables which can be viewed with the Handheld or DirectSOFT32 e The handheld programmer displays error numbers and short descriptions of the error e DirectSOFT32 provides the error number and an error message e Appendix B in this manual has a complete list of error m
202. e in Manual Auto or Cascade and the alarms will be functioning if the enable bit s as listed above are set 1 DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation GO ro N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only PV Absolute Value Alarms The PV absolute value alarms are organized as two upper and two lower alarms The alarm status is false as long as the PV value remains in the region between the upper and lower alarms as shown below The alarms nearest the safe zone are named High Alarm and Low Alarm If the loop loses control the PV will cross one of these thresholds first Therefore you can program the appropriate alarm threshold values in the loop table locations shown below to the right The data format is the same as the PV and SP 12 bit or 15 bit The threshold values for these alarms should be set to give an operator an early warning if the process loses control High high Alarm Loop Table High Alarm V 16 XXXX High high Alarm V 15 XXXX High Alarm PV Low Alarm pu V 14 XXXX Low Alarm Low low Alarm a V 13 XXXX Low low Alarm PV Deviation Alarms If the process remains out of control for some time the PV will eventually cross one of the outer alarm thresholds named High high alarm and Low low alarm Their threshold values are programmed using the loop table registers listed above A High hi
203. e in slot O is busy transmitting or Slot 0 receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP121 Com error on when the communication module in slot 0 of the local base has Slot 0 encountered a communication error SP122 Module busy on when the communication module in slot 1 of the local base is busy Slot 1 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP123 Com error on when the communication module in slot 1 of the local base has Slot 1 encountered a communication error SP124 Module busy on when the communication module in slot 2 of the local base is busy Slot 2 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP125 Com error on when the communication module in slot 2 of the local base has Slot 2 encountered a communication error SP126 Module busy on when the communication module in slot 3 of the local base is busy Slot 3 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP127 Com error on when the communication module in slot 3 of the local base has Slot 3 encountered a communication error SP130 Module busy on when the communication mod
204. e ne a iaa 8 40 Auto Tuning Procedure A AA A AAA 8 41 Tuning Cascaded L psS std a dci eee bl ace 8 45 PV Analog Filt r iwi aa da es et ua Sale wan te da nie Aa 8 46 PV Auto Transfer Functions with Filtering Options 8 47 Creating an Analog Filter in Ladder Logic 8 48 Feediorward Controla a cala 8 49 Fesdtorward Example usadas aia a a a as 8 50 Time Proportioning Control 20000 ne ne ee ee oe eh ne 8 51 On Off Control Program Example a annann earren eeaeee 8 52 Cascade Control it ale NA aia 8 53 INTO UC lo A A a Se AE aes Oe de ee es 8 53 Cascaded Loops in the DL250 1 DL260 CPUs 8 54 Process ALMAS A a nie 8 55 PV Absolute Value Alarms nannaa annen 8 56 PV Deviation Alarms A dG ee a da ee es 8 56 PV Rate of Change Alarm mt ere utece gh koe anes tees eawahtet ty 8 57 PV Alarm HystereSiS aa ue araia nn dee de See re mA a et NE eee ee Goes 8 58 Alarma Programming 2 s cora ps danos 8 58 Ramp Soak Generator En A it tints tire heard rane E A 8 59 Introducir Rd dust de Me land Reset en 8 59 Ramp Soak Table serat rue heu ee ta Et a st te 8 60 Ramp odas Table Te scream riadas 8 62 Ramp Soak Generator Enable rnrn eneee 8 62 Ramp Soak Controls rar ii A A weed A wee es 8 62 Ramp Soak Profile Monitoring 24 lt del ea 8 63 Ramp Soak Programming Errors c s esnees scar kee acer hehe erated eddies t
205. e of change alarm word binary No 19 Addr 22 PV Value alarm hysteresis setting word binary No 20 Addr 23 PV Value error deadband setting wordbinary Yes 21 Addr 24 PV low pass filter constant word BCD Yes 22 Addr 25 Loop derivative gain limiting factor setting word BCD No 23 Addr 26 SP value lower limit setting word binary Yes 24 Addr 27 SP value upper limit setting word binary Yes 25 Addr 30 Control output value lower limit setting word binary No 26 Addr 31 Control output value upper limit setting word binary No 27 Addr 32 Remote SP Value V Memory Address Pointer word hex Yes 28 Addr 33 Ramp Soak Setting Flag bit Yes 29 Addr 34 Ramp Soak Programming Table Starting Address word hex No 30 Addr 35 Ramp Soak Programming Table Error Flags bits No 31 Addr 36 PV auto transfer base slot channel option or word hex Yes V memory pointer option 32 Addr 37 Control output auto transfer base slot channel word hex Yes Read data only when alarm enable bit transitions 0 to1 DL205 User Manual 3rd Ed Rev A 08 03 Read data only on PLC Mode change PID Loop Operation DL250 1 DL260 only PID Mode Setting 1 The bit definitions for PID Mode Setting 1 word Addr 00 are listed in the following Bit Descriptions table More information about the use of this word is available later in this chapter Addr 00 Bit PID Mode Se
206. e option of programming one of the two and even mixing transition types among all the steps of the drum For example you might want Step 1 to transition on an event Step 2 to transition on time only and Step 3 to transition on both time and an event Furthermore you may elect to use only part of the 16 steps and only part of the 16 outputs Step 1 Outputs 0006806000066000 Is Step event true Step2 Outputs O0 00000000000000 Use next transition criteria Each drum instruction uses the resources of four counters in the CPU When programming the drum instruction you select the first counter number The drum also uses the next three counters automatically The counter bit associated with the first counter turns on when the drum has completed its cycle going off when the drum is reset These counter values and counter bit precisely indicate the progress of the drum instruction and can be monitored by your ladder program Suppose you program a timer drum to Counter Assignments have 8 steps and we select CT10 for the CTA10 Counts in step V1010 1528 counter number remember counter numbering is in octal Counter usage is CTA11 Timer Value V1011 0200 shown to the right The right column holds CTA12 Preset Step V1012 0001 typical values interpreted below CTA13 Current Step V1013 0004 CTA10 shows you are at the 1528th count in the current s
207. e the STOP instruction When this instruction is executed the CPU automatically exits Run Mode and enters Program Mode Remember all outputs are turned off during Program Mode The following diagram shows an example of a condition that returns the CPU to Program Mode Normal Program STOP puts CPU in Program Mode XU X2 a X20 L E ToP XI X3 nA XO x2 Yo X10 a Y1 K 2 x1 X3 X4 2 L X10 Y1 Eno Ey GD In the example shown above you could trigger X20 which would execute the STOP instruction The CPU would enter Program Mode and all outputs would be turned off fad o 5 O S c3 To D 3 nD O Q O 0 E O DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting Run Time Edits The DL205 CPUs allow you to make changes to the application program during Run Mode These edits are not bumpless Instead CPU scan is momentarily interrupted and the outputs are maintained in their current state until the program change is complete This means if the output is off it will remain off until the program change is complete If the output is on it will remain on WARNING Only authorized personnel fully familiar with all aspects of the application should make changes to the program Changes during Run Mode become effective immediately Make sure you thoroughly consider the impact of any changes to minimize the ri
208. e tres DL205 User Manual 3rd Ed Rev A 08 03 6 17 Drum Instruction Programming Drum instructions use four counters in the CPU The ladder program can read the counter values for the drum s status The ladder program may write a new preset E S step number to CTA n 2 or a new current step number to CTA n 3 at any time Ue However the other counters are for monitoring purposes only eS Counter Ranges of n Ranges of n Function Counter Bit Function 5 a Number DL250 1 CTA n 0 174 0 374 Counts in step CTn Drum Complete az CTA n 1 2 175 2 375 Timer value CT n 1 not used CTA n 2 3 176 3 376 Preset Step CT n 2 not used CTA n 3 4 177 4 377 Current Step CT n 1 not used The following ladder program shows the EDRUM instruction in a typical ladder program as shown by DirectSOFT32 Steps 1 through 11 are used and all sixteen output points are used The preset step is step 1 The timebase runs at K10 x 0 01 0 1 second per count Therefore the duration of step 1 is 1 x 0 1 0 1 second Note that step 1 is time based only event is left blank And the output pattern for step 1 programs all outputs off which is a typically desirable powerup condition In the last rung the Drum Complete bit CT4 turns on output YO upon completion of the last step step 11 A drum reset also resets CT4 DirectSOFT32 Display
209. eae Seiad OS ei Te wee eee ee A 4 AUX 23 Clear badder Bande nd a osha crested on eee eRe ele ee eta Sy A 4 AU 24 Clear Ladders y ude ki neue A Eat eel e a es RUES A 4 AUX 3 V memory Operations sx x x x x x K K cee KKK A 4 AOS Clear V Memo in ee ue ed s cuban Genes acre a ie A 4 AUX 4 VO Configuration is iri tein een cael EN Se Pts SA a eee be ke A 5 AUNAR Penn en mar nr AA da ne PAR re Le A 5 AUX 41 Show I O Configuration is Seed soe eed hoe ie au Co ae octane Oi A 5 AUX 42 1O DiaGnosucs 2 Sun ton cen eens ata meee REE EAR tes eee AA A 5 AUX 44 Power up Configuration Check A 5 AUX 45 Select Configuration vn te pri ii tts RS mute nu a Retake RENE A 5 AUX 46 I O Configuration ica es Sn Gates Ha ad Rasa Santora RS En en SHIRE A 6 AUX 5 CPU Contiguration sss se R 6 9 9 5 ita 5 R R 0 R A erase ves nee mens sus A 7 AUK ST 50 ve erst uct AA cee eee Ot nee ee rd A 7 Vi Table of Contents AUX 51 Modify Program Names te A A ted eee cies Soh yeh ee Lees AUX 52 Display Change Calendar nanne nrnna AUX S3 Display Scan TING eee mme ties ab TR or aida ue Or apie eee emits AUX 54 Initialize Scratchpad Le SE nee een ee il Mes AE menace ya alates AUX 55 Set Watchdog Timer cc 8eme nes av Ab eed adler rentree lanta en vie AUX 56 CPU Network Address i sia cence te e nee Dassault sondes t s bete AUX 57 Set Retentive Ranges
210. ect this install a resistor in parallel with the input or output of the circuit The value of this resistor will depend on the amount of leakage current and the voltage applied but usually a 10K to 20KQ resistor will work Insure the wattage rating of the resistor is correct for your application e The easiest method to determine if a module has failed is to replace it if you have a spare However if you suspect another device to have caused the failure in the module that device may cause the same failure in the replacement module as well As a point of caution you may want to check devices or power supplies connected to the failed module before replacing it with a spare module fad o 5 oO c3 To D 3 nD O Q O 0 E O DL205 User Manual 3rd Ed Rev A 08 03 9 18 Maintenance and Troubleshooting D lt o Q 00 cc On 52 Fa ES 52 gt D Kd Testing Output Points we ae TAR Handheld Programmer Keystrokes Used to Test an Output Point Output points can be set on or off in the DL205 series CPUs In the DL240 and DL250 you can use AUX 59 Bit Override to force a point even while the program is running However this is not a recommended method to test the output points If you want to do an I O check out independent of the application program for either the DL230 DL240 DL250 1 or DL260 follow the procedure below Step Action 4 Use a handheld progr
211. ecute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute TMR ist 2nd T V Data Reg 75 us 31 us 61 us 23 5us 26 8us 7 3us 268us 7 3us V Bit Reg 158 us 31 us 158us 23 5us 26 8us 7 3us 268us 7 3us K Constant 66 us 31 us 70 us 23 5 us 20 0 us 4 8 us 20 0 us 4 8 us P Indir Data 177 us 131 0 us 45 6us 30 2us 45 6us 30 2 us P Indir Bit 271us 136 0 us 45 6 us 30 2us 45 6us 30 2 us TMRF 1st 2nd T V Data Reg 75 us 31 us 61 us 23 5us 51 4 us 7 3 US 51 4 us 7 3 us V Bit Reg 158 us 31 us 158us 235us 514us 7 3us 51 4us 7 3us K Constant 66 us 31 us 70 us 23 5 us 48 4 us 4 6 us 48 4 us 4 6 us P Indir Data 177 us 131 0us 75 9us 30 2us 75 9us 30 2 us P Indir Bit 271us 136 0 us 75 9us 30 2us 75 9us 30 2 us TMRA tst 2nd oO T V Data Reg 94 us 56 us 75 us 41 us 48 9 us 7 3 US 48 9 us 7 3 US e V Bit Reg 304 us 264us 253us 219us 489us 7 3us 48 9us 7 3 us K Constant 95 us 45 us 79 us 49 us 45 0 us 4 6 us 45 0 us 4 6 us GE P Indir Data 193 us 159us 759us 30 2us 75 9us 30 2 us x P Indir Bit 366us 331us 75 9us 30 2us 75 9us 30 2 us E ER TMRAF list 2nd S o T V Data Reg 98us 54us 75us 42us 542us 7 3us 54 2us 7 3us Lu V Bit Reg 304us 264us 253us 218us 542us 7 3us 542us 7 3us XI D K Constant 95 us 49 us 80 us 50 us 50 3 us 4 6 us 50 3 us 4 6 us A
212. ee aS oh eed een eat a G 8 Items Specific to the DL205 5288 taa Peis wd a keen G 8 Drum Instruction Programming DL250 1 DL260 CPU only In This Chapter Introduction Step Transitions Overview of Drum Operation Drum Control Techniques Drum Instructions D E E D e DL Drum Instruction Introduction Purpose xT xlviv 230 240 250 1 260 Drum Terminology DL205 User Manual Drum Instruction Programming The four types of drum instructions available in the DL250 1 and DL260 CPUs electronically simulate an electro mechanical drum sequencer The instructions offer slight variations on the basic principle Drum instructions are best suited for repetitive processes consisting of a finite number of steps They can do the work of many rungs of ladder logic with simplicity Therefore drums can save programming and debugging time We introduce some terminology associated with drum instructions by describing the original electro mechanical drum pictured below The mechanical drum generally has pegs on its curved surface The pegs are populated in a particular pattern representing a set of desired actions for machine control A motor or solenoid rotates the drum a precise amount at specific times During rotation stationary wipers sense the presence of pegs present on absent off This interaction makes or breaks electrical contact with the wipers creating electrica
213. eg cual 51 1 us 1 0 us V Bit Reg 51 1 us 1 0 us ATT V Data Reg 0 53 5 us 1 0 us V Bit Reg 53 5 us 1 0 us K Constant 50 8 us 1 0 us TSHFL_ V Data Reg 134 0 us 1 0us V Bit Reg 134 0 us 1 0 us TSHFR V Data Reg 133 9 us 1 0 us V Bit Reg 133 9us 1 0us DL205 User Manual 3rd Ed Rev A 08 03 C 28 Ls Er Oc x D 5 ED S L U Instruction Execution Times Table Instructions DL230 DL240 DL250 1 DL260 Continued Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ANDMOV V Data Reg 80 2 us 1 0 us V Bit Reg 80 2 us 1 0 us ORMOV V Data Reg E 80 4 us 1 0 us V Bit Reg 80 4 us 1 0 us XORMOV V Data Reg 80 4 us 1 0 us V Bit Reg 80 4 us 1 0 us SWAP V Data Reg NN 84 1 us 1 0 us V Bit Reg 84 1 us 1 0 us SETBIT V Data Reg N bits on 59 5 us 1 0us V Bit Reg N bits 59 5 us 1 0us RSTBIT V Data Reg N bits 59 5 us 1 0 us V Bit Reg N bits 59 5us 1 0 us MOVMC Move V Data Reg to E 8 4us 33 5us 0 9us 33 5uS 0 9us Move V Bit Reg to E 8 4us 10 4xN 10 4xN Move from E to V Data Reg 250us 6 2us 392us 8 4us Move from E to V Bit Reg 201xN
214. eg 30 3us 30 3us 30 3us 30 3 us K Constant T 27 4us 27 4us 27 4 us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 510us 51 0us 51 0us 51 0 us 9 xipueddy 5 a G m x lt QO CC O 5 I 3 D B DL205 User Manual 3rd Ed Rev A 08 03 C 6 Instruction Execution Times Comparative Boolean cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ORE 1st 2nd V Data Reg V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6us 7 6 us 7 6us 7 6 us V Bit Reg 158us 120us 134us 13 9 us 7 6us 7 6 us 7 6us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 140 us 110 0 us 30 2 us 30 2 us 30 2 us 30 2 us P Indir Bit 234 us 114 0 us 30 2 us 30 2us 30 2 us 30 2 us V Bit Reg V Data Reg 158 us 12 0us 134us 13 9us 7 6us 7 6 us 7 6us 7 6us V Bit Reg 239 us 120us 223us 13 9 us 7 6us 7 6 us 7 6us 7 6 us K Constant 137us 12 0us 133us 139us 48us 4 8 us 48us 4 8 us P Indir Data 230 us 110 0 us 30 2 us 30 2 us 30 2 us 302 us P Indir Bit 324 us 114 0 us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 30 3 us 30 3 us 30 3 us 30 3 us V Bit Reg
215. ep Presets with Up Down Counter 2 for Counter Interface Module ses sat eange sagt aes oe Ge edges sews es D 8 Table of Contents Appendix E DL205 Product Weights Product Weight Table s s c c c apa Ai dad ea peed we ck ed ed E 2 Appendix F PLC Memory DL205 PLO Memory ses tear et estar ata vert E te rows a F 2 Appendix G European Union Directives CE European Union EU Directives sssssssss G 2 Member Countries os rese iis E EEE K Sr E N A wee ol Rl o Aa G 2 Special Installation Manual ses rare wed tees il dios G 3 Other Sources of Information ira rames nn Kes Rene eee Lee ee mul G 3 Basic EMC Installation Guidelines G 4 ENCIOSUTES ac Hra Z A Ee T eed A Ged we deh A bos G 4 Electrostatic Discharge ESD srr Ra Ya Re er R YS 0 da G 5 Suppression and FUSING vico done patie noes ae tt ee a Mae te ine Pate ee alee ae G 5 Internal Enclosure Gi undnor si pesada A de it bea Seen G 6 Egqui potential Grounding mime ria ey easels eee ae desert G 6 Communications and Shielded Cables G 6 Analog and RS232 Cables as O A A ES e G 7 Multicrop Gables SR ee gus sities boa int See Pia hw De ante ee ane See G 7 shielded Cables sue retenir dent E eee nn Er me tte G 7 within ENCIOSUTOS 2843 Cesta Rat L nt en nn AA PR aes G 7 Network Isolation n tess 2445 aod jane ees ee soigne ae etienne ans n
216. er budget can cause unpredictable results which can cause damage and injury Verify the modules in the base operate within the power budget for the chosen base You can find these tables in Chapter 4 Bases and I O Configuration DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 9 13 RUN Indicator If the CPU will not enter the Run mode the RUN indicator is off the problem is usually in the application program unless the CPU has a fatal error If a fatal error has occurred the CPU LED should be on You can use a programming device to determine the cause of the error If you are using a DL240 DL250 1 or DL260 and you are trying to change the modes with a programming device make sure the mode switch is in the TERM position Both of the programming devices Handheld Programmer and DirectSOFT32 will return a error message describing the problem Depending on the error there may also be an AUX function you can use to help diagnose the problem The most common programming error is Missing END Statement All application programs require an END statement for proper termination A complete list of error codes can be found in Appendix B CPU Indicator If the CPU indicator is on a fatal error has occurred in the CPU Generally this is not a programming problem but an actual hardware failure You can power cycle the system to clear the error If the error clears you should monitor the system and determine wh
217. er Manual 3rd Ed Rev A 08 03 8 64 PID Loop Operation DL250 1 DL260 only Troubleshooting Tips PID Loop Operation gt GO ro N a m _ T O Ye A S Q The loop will not go into Automatic Mode A Check the following for possible causes A PV alarm exists or a PV alarm programming error exists The loop is the major loop of a cascaded pair and the minor loop is not in Cascade Mode Q The Control Output stays at zero constantly when the loop is in Automatic Mode A Check the following for possible causes The Control Output upper limit in loop table location V 31 is zero The loop is driven into saturation because the error never goes to zero value and changes algebraic sign Q The Control Output value is not zero but it is incorrect A Check the following for possible causes The gain values are entered improperly Remember gains are entered in the loop table in BCD while the SP and PV are in binary If you are using DirectSOFT32 it displays the SP PV Bias and Control output in decimal BCD converting it to binary before updating the loop table Q The Ramp Soak Generator does not operate when activate the Start bit A Check the following for possible causes The Ramp Soak enable bit is off Check the status of bit 11 of loop parameter table location V 00 It must be set 1 The hold bit or other bits in the Ramp Soak control are on The beginning SP value and the
218. er as you might think Instead the block is identified with a Control Relay Caaa This control relay cannot be used as an output anywhere else in the program Must Remain Active The BCALL instruction actually controls all the stages between the BLK and the BEND instructions even after the stages inside the block have started executing The BCALL must remain active or all the stages in the block will automatically be turned off f either the BCALL instruction or the stage that contains the BCALL instruction goes off then the stages in the defined block will be turned off automatically Activates First Block Stage When the BCALL is executed it automatically activates the first stage following the BLK instructions SM1d T14 a D Q D D e a S 3 2 gt a Control Relay C 0 777 0 1777 0 3777 Block BLK The Block instruction is a label which marks the beginning of a block of stages x Y4 4 Y that can be activated as a group A Stage 230 240 250 1 260 instruction must immediately follow the BLK Start Block instruction Initial Stage C aaa instructions are not allowed in a block The control relay Caaa specified in Block instruction must not be used as an output any where else in the program Control Relay C 0 777 0 1777 0 3777 Block End BEND The Block End instruction is a label used
219. ery connector UL onto the circuit board connector DL230 2 Push the battery into the retaining and clip Don t use excessive force You DL240 may break the retaining clip 3 Make a note of the date the battery was installed To install the D2 BAT 1 CPU battery in the DL250 1 and DL260 CPUs CR2354 DL250 1 4 Press the retaining clip on the battery door DL260 down and swing the battery door open 2 Remove old battery and insert the new battery into the coin type slot with the larger side outwards 3 Close the battery door making sure that it locks securely in place 4 Make a note of the date the battery was installed 2501 05 WARNING Do not attempt to recharge the battery or dispose of an old battery by fire The battery may explode or release hazardous materials DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 9 3 Diagnostics Diagnostics Your DL205 system performs many pre defined diagnostic routines with every CPU scan The diagnostics have been designed to detect various types of failures for the CPU and I O modules There are two primary error classes fatal and non fatal Fatal Errors Fatal errors are errors the CPU has detected that offer a risk of the system not functioning safely or properly If the CPU is in Run Mode when th
220. es but 16 addresses will be assigned and 8 of them are unused U ZS 2 xe Sie 2S E G E WARNING If you manually configure an I O slot the I O addressing for the other modules will change This is because the DL205 products do not allow you to assign duplicate I O addresses You should always correct any I O configuration errors before you place the CPU into RUN mode Uncorrected errors can cause unpredictable machine operation that can result in a risk of personal injury or damage to equipment we OLD me Once you have manually configured the addresses for an I O slot the system will automatically retain these values even after a power cycle You can remove any manual configuration changes by simply performing an automatic configuration DL205 User Manual 3rd Ed Rev A 08 03 A 7 Auxiliary Functions AUX 5 CPU Configuration AUX 51 58 AUX 51 Modify Program Name AUX 52 Display Change Calendar AUX 53 Display Scan Time There are several AUX functions available that you can use to setup view or change the CPU configuration s AUX 51 Modify Program Name e AUX 52 Display Change Calendar e AUX 53 Display Scan Time e AUX 54 Initialize Scratchpad e AUX 55 Set Watchdog Timer e AUX 56 CPU Network Address e AUX 57 Set Retentive Ranges e AUX 58 Test Operations e AUX 59 Bit Override e AUX 5B Counter Interface Configuration e A
221. es require extra mains filtering to comply with the EMC Directive on conducted RF Statues emissions Applicable PLC Filter FN2010 equipment has been tested with E filters from Schaffner which reduce emissions levels if the filters are properly grounded earth ground A filter with a hee current rating suitable to supply _ Transient ciiir all PLC power supplies and AC Ca dA Suppressor input modules should be selected We suggest the Ean Ig Sie FN2010 for DL205 sytems Terminal L N 29999 NOTE Very few mains filters can reduce problem emissions to negligible levels In some cases filters may increase conducted emissions if not properly matched to the problem emissions The filters shown above are not the same as a power filter which is used to keep transients on the mains from entering the PLC power supply Suppression and In order to comply with the fire risk requirements of the Low Voltage and Machinery Fusing Directive electrical standards EN 61010 1 and EN 60204 1 by limiting the power into unlimited mains circuits with power leads reversed it is necessary to fuse both AC and DC supply inputs You should also install a transient voltage suppressor across the power input connections of the PLC Choose a suppressor such as a metal oxide varistor with a rating of 275VAC working v
222. essages sorted by error number 20UBUAJUIEIA E a re Cc S D A gt O Many of these messages point to supplemental memory locations which can be referenced for additional related information These memory references are in the form of V memory and SPs special relays The following two tables name the specific memory locations that correspond to certain types of error messages The special relay table also includes status indicators which can be used in programming For a more detailed description of each of these special relays refer to Appendix D DL205 User Manual 3rd Ed Rev A 08 03 D amp o Q 00 cc On 52 Faj ES 52 SF Le oO Maintenance and Troubleshooting V memory Locations Corresponding to Error Codes V memory Battery Voltage DL240 only Shows battery voltage to tenths 32 is 3 2V V7746 User Defined Error code used with FAULT instruction Always holds a 0 Grammatical Address where syntax error occurs V7763 Error Code found during syntax check V7764 CPU Scan Number of scans since last Program to Run V7765 Mode transition Minimum scan time ms V7776 Maximum scan time ms V7777 DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting Special Relays SP Corresponding to Error Codes
223. etes 8 63 Table of Contents Testing Your Ramp Soak Profile cai oa Ts aye ie nt te M ays 8 63 Troubleshooting TIOS i osc nee She a nee ee at terne a wae antenne 8 64 Bibli graphy A A a 8 65 Glossary of PID Loop Terminology 8 66 Chapter 9 Maintenance and Troubleshooting Hardware Maintenance 4 4 eee eee 9 2 Diagnostic a a a A de e 9 3 CPU I dicators EEE Len A A E AA AA 9 10 PWR Indicatof nii Taaa e a aa ad RE LE 9 11 RUN Indicator isi a A A Aa mt st oa 9 13 CPU Indicators Sr a enrol tao ease ea ina 9 13 BATT INQICATOr ii A ik ieee A ee ee ie er 9 13 Communications Problems vas arar RA as asa unease was 9 13 UO Module Troubleshooting xs sse e ess cc 9 14 NOISE TFOUDIeSRGOUN si ss ease A AS Me MPa ne ats tetes AR aE 9 17 Machine Startup and Program Troubleshooting 9 18 Appendix A Auxiliary Functions IMTOUUCIONM Sa ur tree cle sawed pr Ses Ge ees o Mee eee ENGT A 2 What are Auxiliary Functions cis ace Ovid dis tated A 2 Accessing AUX Functions via DirectSOFT32 A 3 Accessing AUX Functions via the Handheld Programmer A 3 AUX 2 RLL Operations eiii x ei eee tes eee ee eee la aie get A 4 AUX 222 MA soe ea ist as Sia ap ad tag ete Sad tases ud stay ad Stl AO A 4 AUX 21 Check Progr e eee bo da ae LE ne tl T A 4 AUX 22 Change ROTO E E
224. f any I O module error that has occurred This feature is also available within DirectSOFT32 under the PLC Diagnostics sub menu By selecting this feature you can quickly detect any changes that may have occurred while the power was disconnected For example if someone placed an output module in a slot that previously held an input module the configuration check would detect the change If the system detects a change in the I O configuration at power up an error code E252 NEW I O CONFIGURATION will be generated You can use AUX 42 to determine the exact base and slot location where the change occurred WARNING You should always correct any I O configuration errors before you place the CPU into RUN mode Uncorrected errors can cause unpredictable machine operation that can result in a risk of personal injury or damage to equipment This feature is also available within DirectSOFT32 under the PLC Setup sub menu Even though the CPU can automatically detect configuration changes you may actually want the new I O configuration to be used For example you may have intentionally changed a module to use with a new program You can use AUX 45 to select the new configuration or keep the existing configuration that is stored in memory This feature is also available within DirectSOFT32 from the PLC Setup sub menu WARNING Make sure the I O configuration being selected will work properly with the CPU program You should always correct any I O co
225. fect quantity of the process variable or the desired amount which yields the best product The machine operator knows this value and either sets it manually or programs it into the PLC for later automated use External Disturbances the unpredictable sources of error which the control system attempts to cancel by offsetting their effects For example if the fuel input is constant an oven will run hotter during warm weather than it does during cold weather An oven control system must counter act this effect to maintain a constant oven temperature during any season Thus the weather which is not very predictable is one source of disturbance to this process Error Term the algebraic difference between the process variable and the setpoint This is the control loop error and is equal to zero when the process variable is equal to the setpoint desired value A well behaved control loop is able to maintain a small error term magnitude Loop Calculation the real time application of a mathematical algorithm to the error term generating a control output command appropriate for minimizing the error magnitude Various control algorithms are available and the CPU uses the Proportional Derivative Integral PID algorithm more on this later Control Output the result of the loop calculation which becomes a command for the process such as the heater level in an oven Loop Configuring operator initiated selections which set up
226. ff The machine operator will Off Program press the appropriate pushbutton for a _5 5 X1 second or so The two states of our process are ON and OFF The next step is to draw a state transition Transition condition diagram as shown to the right It shows State XO the two states OFF and ON with two transition lines in between When the event XO is true we transition from OFF to X1 ON When X1 is true we transition from a le ON to OFF Output equation YO ON If you re following along you are very close to grasping the concept and the problem solving power of state transition diagrams The output of our controller is YO which is true any time we are in the ON state In a boolean sense YO ON state Next we will implement the state diagram first as RLL then as a stage program This will help you see the relationship between the two methods in problem solving DL205 User Manual 3rd Ed 06 02 D E E U E E LD Buiuwesboig 26e1s 7 4 RLLPLUS Stage Programming RLL Equivalent RLL PLUS D E D DL D Ky ep Stage Equivalent The state transition diagram to the right is a picture of the solution we need to create The beauty of it is this it expresses the problem independently of the programming language we may use to realize it In other words by drawing the diagram we have already solved the control problem XO X1 Output equation YO ON First we will translate t
227. ff On EE 13 Auto Tune error indication read Off On O 14 15 Reserved for future use TS 5 KO Ramp Soak Table The individual bit definitions of the Ramp Soak Table Flag word Addr 33 is listed Do Flags in the following table Further details are given in the Ramp Soak Operation section O Addr 33 23 Bit Ramp Soak Flag Bit Description Read Write Bit 0 Bit 1 Ed 0 Start Ramp Soak Profile write 0 1 Start 1 Hold Ramp Soak Profile write 0 1 Hold 2 Resume Ramp soak Profile write 0 1 Resume 3 Jog Ramp Soak Profile write 0 1 Jog 4 Ramp Soak Profile Complete read Complete 5 PV Input Ramp Soak Deviation read Off On 6 Ramp Soak Profile in Hold read Off On 7 Reserved read 8 15 Current Step in R S Profile read decode as byte hex Bits 8 15 must be read as a byte to indicate the current segment number of the Ramp Soak generator in the profile This byte will have the values 1 2 3 4 5 6 7 8 9 A B C D E F and 10 which represent segments 1 to 16 respectively If the byte 0 then the Ramp Soak table is not active DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Ramp Soak Each loop that you configure has the option of using a built in Ramp Soak generator Table Location dedicated to that loop This feature generates SP values in a continuous stream Addr 34 called a profile To use the Ramp Soak feature you must program a sep
228. first ramp ending SP value are the same so first ramp segment has no slope and consequently has no duration The ramp soak generator moves quickly to the soak segment giving the illusion the first ramp is not working The loop is in Cascade Mode and is trying to get the SP remotely The SP upper limit value in the loop table location V 27 is too low Check your ladder program to verify it is not writing to the SP location V 02 in the loop table A quick way to do this is to temporarily place an end coil at the beginning of your program then go to PLC Run Mode and manually start the ramp soak generator Q The PV value in the table is constant even though the analog module receives the PV signal A Your ladder program must read the analog value from the module successfully and write it into the loop table V 03 location Verify the analog module is generating the value and the ladder is working Q The Derivative gain doesn t seem to have any affect on the output A The derivative limit is probably enabled see section on derivative gain limiting DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Q The loop Setpoint appears to be changing by itself A Check the following for possible causes The Ramp Soak generator is enabled and is generating setpoints If this symptom occurs on loop Manual to Auto Mode changes the loop automatically sets the SP PV bumpless transfer feature Check yo
229. gh or Low low alarm indicates a serious condition exists and needs the immediate attention of the operator The PV Absolute Value Alarms are PID Mode and Alarm Status V 06 reported in the four bits in the PID Mode and Alarm Status word in the loop table as a ad shown to the right We highly recommend A using ladder logic to monitor these bits High high Alarm 1 The bit of word instructions make this High Alarm easy to do Additionally you can monitor Low Alarm PID alarms using DirectSOFT32 Low low Alarm The PV Deviation Alarms monitor the PV deviation with respect to the SP value The deviation alarm has two programmable thresholds and each threshold is applied equally above and below the current SP value In the figure below the smaller deviation alarm is called the Yellow Deviation indicating a cautionary condition for the loop The larger deviation alarm is called the Red Deviation indicating a strong error condition for the loop The threshold values use the loop parameter table locations V 17 and V 20 as shown Red Deviation Alarm Red Yellow Deviation Alarm Yellow Loop Table Green V 17 XXXX Yellow Deviation Alarm SP V 20 XXXX Red Deviation Alarm Yellow Deviation Alarm Yellow Red Deviation Alarm Red The thresholds define zones which fluctuate with the SP value The green zone which surrounds the
230. gorithm is very fundamental to control loop operation and is normally never changed after the initial configuration of a loop The Position Algorithm causes the PID equation to calculate the Control Output Mn n Mn Ko e amp n Ki Sek Kr en en 1 Mo i 1 In the formula above the sum of the integral terms and the initial output are combined into the Bias term Mx Using the bias term we define formulas for the Bias and Control Output as a function of sampling time Mxo Mo Mxn Ki en Mxn 1 n Mn Ki Se Mo i 1 Mn Kc en Kr en en 1 Mxn Output for sampling time n DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only 8 33 The position algorithm variables and related variables are Ts Sample rate Kc Proportional gain Ki Kc Ts Ti coefficient of integral term Kr Kc Td Ts coefficient of derivative term Ti Reset time integral time Td Rate time derivative time SPn Set Point for sampling time n SP value PVn Process variable for sampling time n PV en SPn PVn Error term for sampling time n Mo Control Output for sampling time O Mn Control Output for sampling time n Analysis of these equations will be found in most good text books on process control At a glance we can isolate the parts of the PID Position Algorithm which correspond to the P I and D terms and the Bias as shown below n
231. han a slow scan time will when adding the same PID loop calculation load in each case The formula for average scan time calculation is Scan time without loop Avg Scan Time with PID loop Sample rate of loop X PID calculation time Scan time without loop For example suppose the estimated scan time without loop calculations is 50 mS and the loop sample time is 3 seconds Now we calculate the new scan time 50 mS Average Scan time with PID loop Fa X 250uS sec 50mS 50 004 mS As the calculation shows the addition of only one loop with a slow sample rate has a very small effect on scan time Next we expand equation above to show the effect of adding any number of loops o naL l Scan time without loop _ Avg Scan Time with PID loops X PID calculation time Sample rate of nth loop n 1 Scan time without loops In the new equation above we must calculate the summation term inside the brackets for each loop from 1 to L last loop and add the right most term scan time without loops only once at the end Suppose we have a DL250 CPU controlling four loops The table below shows the data and summation term values for each loop Loop Number Description Sample Rate Summation Term 1 Steam Flow Inlet valve 0 25 sec 50 us 2 Water bath temperature 30 sec 0 42 uS 3 Dye level main tank 10 sec 1 25 uS 4 Steam Pressure Autoclave 1 5 sec 8
232. he loop Make sure the PV is relatively steady when the SP is not changing Fundamentals of Process Control Theory Second Edition Author Paul W Murrill Publisher Instrument Society of America ISBN 1 55617 297 4 Application Concepts of Process Control Author Paul W Murrill Publisher Instrument Society of America ISBN 1 55617 080 7 PID Controllers Theory Design and Tuning 2nd Edition Author K Astrom and T Hagglund Publisher Instrument Society of America ISBN 1 55617 516 7 Fundamentals of Temperature Pressure and Flow Measurements Third edition Author Robert P Benedict Publisher John Wiley and Sons ISBN 0 471 89383 8 Process Industrial Instruments amp Controls Handbook Fourth Edition Author Editor in Chief Douglas M Considine Publisher McGraw Hill Inc ISBN 0 07 012445 0 pH Measurement and Control Second Edition Author Gregory K McMillan Publisher Instrument Society of America ISBN 1 55617 483 7 Process Control Third Edition Instrument Engineer s Handbook Author Editor in Chief Bela G Liptak Publisher Chilton ISBN 0 8019 8242 1 Process Measurement and Analysis Third Edition Instrument Engineer s Handbook Author Editor in Chief Bela G Liptak Publisher Chilton ISBN 0 8019 8197 2 DL205 User Manual 3rd Ed Rev A 08 03 EE doo did Jg C D O1 L g C o O G gt 8 66 PID Loop Operati
233. he process variable in response to a step change in the SP in closed loop operation or a step change in the control output in open loop operation AE doo did Jg C D O1 L g C o O G gt To change from one loop operational mode to another between Manual Auto or Cascade The word transfer probably refers to the transfer of control of the control output or the SP depending on the particular mode change The control output is calculated to represent the rate of change velocity for the PV to become equal to the SP DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting In This Chapter Hardware Maintenance Diagnostics CPU Indicators PWR Indicator RUN Indicator CPU Indicator BATT Indicator Communications Problems I O Module Troubleshooting Noise Troubleshooting Machine Startup and Program Troubleshooting 9 2 Maintenance and Troubleshooting Hardware Maintenance D amp o Q 00 cc On 52 Faj 52 gt Le Kd Standard Maintenance Air Quality Maintenance Low Battery Indicator CPU Battery Replacement wee up 7 The DL205 is a low maintenance system requiring only a few periodic checks to help reduce the risks of problems Routine maintenance checks should be made regarding two key items e Air quality cabinet temperature airflow etc e CPU battery T
234. he quality of the air your system is exposed to can affect system performance If you have placed your system in an enclosure check to see that the ambient temperature is not exceeding the operating specifications If there are filters in the enclosure clean or replace them as necessary to ensure adequate airflow A good rule of thumb is to check your system environment every one to two months Make sure the DL205 is operating within the system operating specifications The CPU has a battery LED that indicates the battery voltage is low You should check this indicator periodically to determine if the battery needs replacing You can also detect low battery voltage from within the CPU program SP43 is a special relay that comes on when the battery needs to be replaced If you are using a DL240 CPU you can also use a programming device or operator interface to determine the battery voltage V7746 contains the battery voltage For example a value of 32 in V7746 would indicate a battery voltage of 3 2V The CPU battery is used to retain program V memory and the system parameters The life expectancy of this battery is five years NOTE Before installing or replacing your CPU battery back up your V memory and system parameters You can do this by using DirectSOFT32 to save the program V memory and system parameters to hard floppy disk on a personal computer To install the D2 BAT CPU battery in Ia A DL230 or DL240 CPUs 1 Gently push the batt
235. he state diagram to traditional RLL Then we will show how easy it is to translate the diagram into a stage programming solution The RLL solution is shown to the right It consists of a self latching control relay CO When the On momentary pushbutton X0 is pressed output coil CO turns on and the CO contact on the second row latches itself on So XO sets the latch CO on and it remains on after the XO contact opens The motor output YO also has power flow so the motor is now on When the Off pushbutton X1 is pressed it opens the normally closed X1 contact which resets the latch Motor output YO turns off when the latch coil CO goes off The stage program solution is shown to the right The two inline stage boxes SO and S1 correspond to the two states OFF and ON The ladder rung s below each stage box belong to each respective stage This means the PLC only has to scan those rungs when the corresponding stage is active For now let s assume we begin in the OFF State so stage SO is active When the On pushbutton X0 is pressed a stage transition occurs The JMP 1 instruction executes which simply turns off the Stage bit SO and turns on Stage bit S1 So on the next PLC scan the CPU will not execute Stage SO but will execute stage S1 In the On State Stage S1 we want the motor to always be on The special relay contact SP1 is defined as always on so YO turns the motor on
236. he value in V3702 SP566 Current target value on when the counter current value equals the value in V3704 SP567 Current target value on when the counter current value equals the value in V3706 DL205 User Manual 3rd Ed Rev A 08 03 q xipueddy Special Relays DL240 DL250 1 DL260 CPU Special Relays Startup and Real Time Relays CPU Status Relays fp oz ESO DT a a 28 La 09 SPO First scan on for the first scan after a power cycle or program to run transition only The relay is reset to off on the second scan It is useful where a function needs to be performed only on program startup SP1 Always ON provides a contact to insure an instruction is executed every scan SP2 Always OFF provides a contact that is always off SP3 1 minute clock on for 30 seconds and off for 30 seconds SP4 1 second clock on for 0 5 second and off for 0 5 second SP5 100 ms clock on for 50 ms and off for 50 ms SP6 50 ms clock on for 25 ms and off for 25 ms SP7 Alternate scan on every other scan SP11 Forced run mode on anytime the CPU switch is in the RUN position SP12 Terminal on when the CPU switch is in the TERM position and the CPU is in run mode the RUN mode SP13 Test run mode on when the CPU switch is in the TERM position and the CPU is in the test RUN mode SP14 Break Relay 1 on when the BREAK instructions is executed
237. hich will be set if V7640 or V7641 are programmed improperly Address Setup Parameter Data type Ranges Read Write V7640 Loop Parameter Octal V1400 V7340 write Table Pointer V10000 V17740 DL250 1 V10000 V35740 DL260 V7641 Number of Loops BCD 0 4 DL250 1 write 0 16 DL260 V7642 Loop Error Flags Binary Oori read PID Error Flags If the number of loops is 0 the loop controller task is turned off during the ladder program scan The loop controller will allow use of loops in ascending order beginning with 1 For example you cannot use loop 1 and 4 while skipping 2 and 3 The loop controller attempts to control the full number of loops specified in V7641 The Loop Parameter table may occupy a V Memory Space block of memory in the lower user data space V1400 V7377 or in the upper V1400 User Data user memory data space V10000 V17777 for the 250 1 and V10000 LOOP V35740 for the DL260 as shown to the TABLE T right Be sure to choose an available space V7377 in the memory map for you application The value in V7641 tells the CPU how big V7640 Loop Table Pointer the loop table is there are 32 locations for VIORI S OR each loop The DirectSOFT32 PID Setup dialog box v10000 User Data contd offers you one way to program these parameters It s also possible to use ladder LOOP k commands such a LDA or LD an
238. icial site at http eur op eu int e This equipment must be properly installed while adhering to the guidelines of the PLC installation manual DA EU M and is suitable for EN 61010 1 installation categories 1 or 2 e The rating between all circuits in this product are rated as basic insulation only as appropriate for single fault conditions e The protection provided by the equipment may be impaired if the equipment is used in a manner not specified by the manufacturer e tis the responsibility of the system designer to earth one side of all control and power circuits and to earth the braid of screened cables e Input power cables must be externally fused and have an externally mounted switch or circuit breaker preferably mounted near the PLC Note The DL205 internal base power supply has a 2A 250V slow blow fuse however it is not replaceable so external fusing is required e When needed carefully clean the outside plastic case of PLC components using a dry cloth e For hardware maintenance instructions see the Maintenance and Troubleshooting section in this manual This section also includes battery replacement information Also only replacement parts supplied by Automationdirect com or its agents should be used s Cables whether shielded or not MUST be enclosed within earthed metal conduit or other metallic trunking when outside the PLC enclosure e This is a Class A product and it may cause radio interference in cer
239. ily calculate it by subtracting Error SP PV If the PV square root extract is enabled then Error SP sqrt PV In any case the size of the error and algebraic sign determine the next change of the control output for each PID calculation Now we will superimpose some special effects on to the error term as described Refer to the diagram below Bit 7 of the PID Mode Setting 1 V 00 word lets you select a linear or squared error term and bit 8 enables or disables the error deadband NOTE When first configuring a loop it s best to use the standard error term After the loop is tuned then you will be able to tell if these functions will enhance control L Error L Error Error F F Loop Setpoint 5 Term T g Error Error with y Calculation S L squared b Deadband Process Variable Le PID Mode 1 Setting V 00 Loop Table V 23 XXXX Error Deadband Bit 15 14 13 12 11 10 9 8 76543210 Error Deadband select L Linear Squared Error select AE doo Aid Error Squared When selected the squared error function simply squares the error term but preserves the original algebraic sign which is used in the calculation This affects the Control Output by diminishing its response to smaller error va
240. ime It automatically places the results in the corresponding registers in the loop table The following timing diagram shows the events which occur in the closed loop auto tuning cycle The auto tune function examines the direction of the offset of the PV from the SP The auto tune function then takes control of the control output and induces a full span step change in the opposite direction Each time the sign of the error SP PV changes the output changes full span in the opposite direction This procedes through three full cycles Closed Loop Auto Tune Cycle Wave Limit Cycle Method SP gt gt TE Output Value l l l i NC Process Wave To PID Cycle gt lt gt a ee Se PID Cycle Auto Tune Cycle A y Auto Tune Start Auto Tune End Calculation of PID parameter Mmax Output Value upper limit setting Mmin Output Value lower limit setting This example is direct acting When set at reverse acting output is inverted DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only ES When the loop tuning observations are complete the loop controller computes To bump period and Xo amplitude of the PV Then it uses these values to compute Kpc sensitive limit and Tpc period limit From these values the loop controller auto tune function computes the PID gains and the sample rate according to the Ziegler Nichols equations shown below
241. ime sec y Step Change Am 10 Output Value Auto Tune Cycle PID Cycle gt a A PID Cycle Auto Tune Start Auto Turfe End When Auto Tune starts step change output Am 10 During Auto Tune the controller output reached the full scale positive limit Auto Tune stopped and the Auto Tune Error bit in the Alarm word bit turned on When PV change is under 2 output is changed at 20 When the loop tuning observations are complete the loop controller computes Rr maximum slope in sec and Lr dead time in sec The auto tune function computes the gains according to the Ziegler Nichols equations shown below PID tuning PI tuning P 1 2 Am LrRr P 0 9 Am LrRr 1 2 0 Lr l 3 33 Lr D 0 5 Lr D 0 Sample Rate 0 056 Lr Sample Rate 0 12 Lr AE doo did O N O1 L g e e La GC Am Output step change 10 0 1 20 0 2 We highly recommend using DirectSOFT32 for the auto tuning interface the duration of each auto tuning cycle will depend on the mass of our process A slowly changing PV will result in a longer auto tune cycle time When the auto tuning is complete the proportional integral and derivative gain values are automatically updated in loop table locations V 10 V 11 and V 12 respectively The sample time in V 07 is also updated automatically You can test the validity of the values the auto tuning procedure yields by measuring the closed loop
242. ing about an initial JMP stage ISG is that it is automatically active at powerup Afterwards it is like any other DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming RLL PLUS D E D DL D amp ep Add Safety Light Feature Modify the Block Diagram and State Diagram Next we will add a safety light feature to the door opener system Its best to get the main function working first as we have done then adding the secondary features The safety light is standard on many commercially available garage door openers It is shown to the right mounted on the motor housing The light turns on upon any door activity remaining on for approximately 3 minutes afterwards This part of the exercise will demonstrate the use of parallel states in our state diagram Instead of using the JMP instruction we will use the set and reset commands To control the light bulb we add an output to our controller block diagram shown to the right Y3 is the light control output In the diagram below we add an additional state called LIGHT Whenever the garage owner presses the door control switch and releases the RAISE or LOWER state is active and the LIGHT state is simultaneously active The line to the Light state is dashed because it is not the primary path m k Safety light E E E me Inputs Outputs Toggle 0 O Up limit 1 Down limit
243. ion V 02 for you However the ladder program must write the setpoint to that loop table location when generated from any other source unless the source HMI can write directly to the v memory location Obviously each of the three main loop parameters will have only one source or destination at any given time During the application development it s a good idea to draw loop schematic diagrams showing data sources etc to help avoid mistakes DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Auto Transfer The loop controller in the DL250 1 and DL260 CPUs have the ability to directly to Analog I O access referred to as auto transfer analog I O values or V memory registers apart from the ladder logic scan In particular these parameters are the process variable PV and the control output This feature is helpful if you must perform closed loop PID control while the CPU is in Program Mode or if you wish to use the pointer method for the analog I O or calculations in ladder logic to provide the PV values when in RUN mode The loop controller can read the analog PV value in the selected data format from the desired analog module and write the control output value to the desired output module This auto transfer feature when enabled accesses the analog values only once per PID calculation for each respective loop You may optionally configure each loop to access its analog I O PV and control output b
244. is 1413121098765432 10 mode change requests not commands A V certain conditions can prohibit a T particular mode change see next page Sns Rea The normal state of these mode request bits is 000 To request a mode change you must SET the corresponding bit to a 1 for one scan The PID loop controller automatically resets the bits back to 000 after it reads the mode change request Methods of requesting mode changes are e DirectSOFT32 s PID View this is the easiest method Click on one of the radio buttons and DirectSOFT sets the appropriate bit s HPP Use Word Status WD ST to monitor the contents of V 00 which will be a 4 digit BCD hex value You must calculate and enter a new value for V 00 that ORs the correct mode bit with its current value e Ladder program ladder logic can request any loop mode when the PLC is in Run Mode This will be necessary after application startup Use the program shown to the right to SET Go to Auto Mode the mode bit on do not use an out coil On xo B2000 1 a 0 1 transition of XO the rung sets the H SET Auto bit 1 The loop controller resets it al e Operator panel interface the operator s panel to ladder logic using standard methods then use the technique above to set the mode bit Since we can only request mode changes the PID loop controller decides when to permit mode changes and provides the loop mode status It reports the current mode
245. is crucial to know whether a particular loop is direct or reverse acting Unless you are controlling temperature there is no obvious answer In a flow control loop a valve positioning circuit can be configured and wired reverse acting as easily as direct acting One easy way to find out is to run the loop in Manual Mode where you must manually generate control output values Observe whether the PV goes up or down in response to a step increase in the control output To run a loop in Auto or Cascade Mode the control output must be correctly programmed refer to the previous section on Control Output Configuration Use normal output for direct acting loops and inverted output for reverse acting loops To compensate for a reverse acting loop the PID controller must know to invert the control output If you have a choice configure and wire the loop to be direct acting This will make it easier to view and interpret loop data during the loop tuning process DL205 User Manual 3rd Ed Rev A 08 03 P I D Loop Terms PID Loop Operation DL250 1 DL260 only You may recall the introduction of the position and velocity forms of the PID loop equations The equations basically show the three components of the PID calculation The following figure shows a schematic form of the PID calculation in which the control output is the sum of the proportional integral and derivative terms On each calculation of the loop each
246. l for each loop An address pointer in location V 34 in the loop table specifies the starting location of the ramp soak table In the example to the right the loop parameter tables for Loop 1 and 2 occupy contiguous 32 word blocks as shown Each has a pointer to its ramp soak table independently located elsewhere in user V memory Of course you may locate all the tables in one group as long as they do not overlap DL205 User Manual 3rd Ed Rev A 08 03 V2000 V2037 V2040 V2077 V3000 V3600 15 16 14 Ramp Soak Soak V Memory Space User Data LOOP 1 V2034 32 words N 3000 octal LOOP 2 la 32 words V2074 3600 octal 11 Ramp Soak 1 C 32 words Ramp Soak 2 g 32 words PID Loop Operation DL250 1 DL260 only The parameters in the ramp soak table must be user defined the most convenient way is to use DirectSOFT32 which features a special editor for this table Four parameters are required to define a ramp and soak segment pair as pictured below s Ramp End Value specifies the destination SP value for the end of the ramp Use the same data format for this number as you use for the SP It may be above or below the beginning SP value so the slope could be up or down we don t have to know the starting SP value for ramp 1 s Ramp Slope specifies the SP increase in counts units per second It is a BCD number from
247. l outputs from the drum The outputs are wired to devices on a machine for On Off control Drums usually have a finite number of positions within one rotation called steps Each step represents some process step At powerup the drum resets to a particular step The drum rotates from one step to the next based on a timer or on some external event During special conditions a machine operator can manually increment the drum step using a jog control on the drum s drive mechanism The contact closure of each wiper generates a unique on off pattern called a sequence designed for controlling a specific machine Because the drum is circular it automatically repeats the sequence once per rotation Applications vary greatly and a particular drum may rotate once per second or as slowly as once per week Electronic drums provide the benefits of mechanical drums and more For example they have a preset feature that is impossible for mechanical drums The preset function lets you move from the present step directly to any other step on command 3rd Ed Rev A 08 03 Drum Chart Representation Output Sequences Drum Instruction Programming For editing purposes the electronic drum is presented in chart form in DirectSOFT32 and in this manual Imagine slicing the surface of a hollow drum cylinder between two rows of pegs then pressing it flat Now you can view the drum as a chart as shown be
248. late these bits automatically when you use the auto tune feature within DirectSOFT32 Or you may have ladder logic access these bits directly for allowing control from another source such as a dedicated operator interface The individual control bits let you to start the auto tune procedure select PID or PI tuning and select closed loop or open loop tuning If you select Pl tuning the auto tune procedure leaves the derivative gain at 0 The Loop Mode and Alarm Status word V 06 reports the auto tune status as shown Bit 12 will be on 1 when during the auto tuning cycle automatically returning to off 0 when done Auto Tune Function m Start Auto Tune Auto Tune 0 to 1 transition Active O PID tuning Auto Tune Auto Tuning Teopen PI tuning Error Auto Tuning Controls O closed loop Status E 1 open loop PID Mode 2 Setting V 01 y Loop Mode and Alarm Status V 06 Pe Bit 15 14 13 12 11109876543210 Bit 15 14 13 12 11109876543210 gt g 25 Open Loop Auto Tuning During an open loop auto tuning cycle the loop 2 controller operates as shown in the diagram below Before starting this procedure AN place the loop in Manual mode and ensure the PV and control output values are in G lt the middle of their ranges away from the end points or 9 d PLC Syste
249. le Instructions Table Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute FILL V Data Reg 29 4us 1 0 us V Bit Reg a l G San 8 0us x ax E ws N K Constant 26 2US 8 0usx 1 0 us P Indir Data N P Indir Bit 55 1us 1 0 us 8 0us x N FIND V Data Reg N bits 66 8 us 1 0 us V Bit Reg N bits me A _ S 66 8 us 1 0 us K Constant N bits 64 0 us 1 0us FDGT V Data Reg N bits 66 1 us 1 0 us V Bit Reg N bits _ mes 66 1 us 1 0 us K Constant N bits 55 2 us 1 0 us FINDB V Data Reg N bits 210 8 us 1 0 us Ji V Bit Reg N bits _ 210 8us 1 0us DE P Indir Data 237 0 us 1 0 us Qo P Indir Bit 237 0us 1 0 us lt 9 zo 5x MOV Move V data reg to V data reg 450us 6 2us 586us 8 4us 60 2us 0 9us 60 2us 0 9 us 4O 17xN 8xN 9 5xN 9 5xN 3 Move V bit reg to V data reg 430us 6 2us 629us 8 4us D 244xN 114 7 xN Move V data reg to V bit reg 460us 6 2us 569us 8 4us 215xN 94 4 x N Move V bit reg to V bit reg 490us 6 2us 639us 8 4us N Hof words 448 x N 198 x N TTD V Data Reg LL 66 9 us 1 0 us V Bit Reg 66 9 us 1 0 us RFB V Data Reg 66 8 us 1 0 us V Bit Reg 66 8 us 1 0 us STT V Data Reg 67 8 us 1 0 us V Bit Reg 67 8 us 1 0 us K Constant 65 0 us 1 0 us RFT V Data R
250. lect The characteristics of Bumpless and II transfer types are listed in the chart below Note that their operation also depends on which PID algorithm you are using the position or velocity form of the PID equation Note that you must use Bumpless Transfer type when using the velocity form of the PID algorithm Transfer Type Transfer PID Algorithm Select Bit Manual to Auto Transfer Action Auto to Cascade Transfer Action Bumpless Transfer 0 Position Forces Bias Control Output Forces SP PV Forces Major Loop Output Minor Loop PV Velocity Forces SP PV Forces Major Loop Output Minor Loop PV Bumpless Transfer II 1 Position Forces Bias Control Output none Velocity none none DL205 User Manual 3rd Ed Rev A 08 03 8 27 PID Loop Operation DL250 1 DL260 only PID Loop Data Configuration Loop Parameter In choosing the Process Variable range and resolution a related choice to make is Data Formats the data format of the three main loop variables SP PV and Control Output the Integrator sum in V 04 also uses this data format The four data formats available are 12 or 15 bit right justified signed or unsigned MSB is sign bit in bipolar formats The four binary combinations of bits O and 1 of PID Mode 2 word V 01 choose the format The DirectSOFT32 PID Setup dialog sets these bits automatically when you select the data form
251. lication requires all outputs to be off at powerup there are two approaches e Make the preset step in the drum a reset step with all outputs off e Or use a drum with an output mask Initialize the mask to 0000 on the first scan using contact SPO and LD K000 and OUT Vxxx instructions where Vxxxx is the location of the mask register DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming 6 13 Cascaded Drums Occasionally the need arises for a drum Provide More Than with more than 16 steps The solution is to 16 Steps use two or more drums that are logically cascaded When the first drum finishes SOT lA the second one starts and so on if TL Remember that a drum instruction writes l I to the outputs on every scan even when ll its start input is off So two drums using JAI the same output points will be in conflict Ss The solution for this is to use separate control relays contacts CRs for each drum s outputs and logically OR them together to control the final outputs Fuuwre160o14 uononssu wnq SE Refer to the figure to the right The two Xo Drum 1 drums behave as one 32 step drum The Start a Guise procedure is xi CUB p Reset Info Mask e Use the drum cycle done bit of the Steps 2 Je A0 0 first drum for the start input of the CT4 o 9 9 da 9 next drum CTO in the example o o oo oo Use the last drum s cycle done bit for S K N
252. locations shown The goal of the loop tuning process covered later is to derive gain values that result in good overall loop performance NOTE The proportional gain is also simply called gain in PID loop terminology Loop Calculation kp P Setpoint gt Error Term l kj l gt gt Control Output Process Variable kd D V 10 Loop Table gt V 11 V 12 XX XX Proportional gain XX XX Integral gain XX XX Derivative gain DL205 User Manual 3rd Ed Rev A 08 03 AE doo Aid Jg C D O1 L g C o O G 8 36 PID Loop Operation DL250 1 DL260 only PID Loop Operation GO Q N a m _ T O Ye A S Using a Subset of PID Control The P and D gains are 4 digit BCD numbers with values from 0000 to 9999 kp P They contain an implied decimal point in the middle so the values are actually gt 00 00 to 99 99 Some gain values have o ki gt units Integral gain may be in units of de seconds or minutes by programming the bit shown Derivative gain is in seconds kd D V 10 XX XX Pgain V 11 XX XX gain O sec 1 min V 12 XX XX D gain sec PID Mode 2 Setting V 01 Bit 15 14 13 12 11 10 9 8 76543210 Units select
253. low Each row represents a step numbered 1 through 16 Each column represents an output numbered 0 through 15 to match word bit numbering The solid circles in the chart represent pegs On state in the mechanical drum and the open circles are empty peg sites Off state OUTPUTS STEP 15 14 13 12 11 109 8 7 6 5 4 3 210 1 000460460600 2 0 060600000060d06 3 O0 600208000000 4 9000 002000000000 5 OQoeoqeqeqeqeocd 6 040600680600 0000 7 9000000600 0000 8 9090200080 0000 0e 9 OGQOGQoQouoe eeqogqeaqod 10 OO O OR 88 O O Weeqgcogeqogqgo oqoqged 12 0808808 086066 0 12 008 0 O O CR 86 00 0 14 OO OO R 00 CR 60 00 15 qQogqo mso eo eo eocee Uee L Ha Haa Ha He Ha L Haa The mechanical drum sequencer derives its name from sequences of control changes on its electrical outputs The following figure shows the sequence of On Off controls generated by the drum pattern above Compare the two and you will find they are equivalent If you can see their equivalence you are on your way to understanding drum instruction operation Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Output O ay 1 1 0 t 2 0 1 3 Q 1 4 0 q 5 o 1 6
254. lues but maintaining its response to larger errors Some situations in which the error squared term might be useful e Noisy PV signal using a squared error term can reduce the effect of low frequency electrical noise on the PV which will make the control system jittery A squared error maintains the response to larger errors e Non linear process some processes such as chemical pH control require non linear controllers for best results Another application is surge tank control where the Control Output signal must be smooth Jg C D O1 L g C o O G Error Deadband When selected the error deadband function takes a range of small error values near zero and simply substitutes zero as the value of the error If the error is larger than the deadband range then the error value is used normally Loop parameter location V 23 must be programmed with a desired deadband amount Units are the same as the SP and PV units 0 to FFF in 12 bit mode and 0 to 7FFF in 15 bit mode The PID loop controller automatically applies the deadband symmetrically about the zero error point DL205 User Manual 3rd Ed Rev A 08 03 8 32 PID Loop Operation DL250 1 DL260 only PID Algorithms PID Loop Operation GO Q N a m _ T O Ye A S The Proportional Integral Derivative PID algorithm is widely used in process control The PID method of control adapts well to electronic soluti
255. m LD Process Variable AN La S Response A Step Function Open Loop Auto Tuning Control Setpoint Value Error Term Loop Output Manufacturing gt gt K Calculation Process Process Variable NOTE In theory the SP value does not matter in this case because the loop is not closed However the firmware requires that the SP value be more than 205 counts away from the PV value before starting the auto tune cycle 205 counts or more below the SP for forward acting loops or 205 counts or more above the SP for reverse acting loops When auto tuning the loop controller induces a step change on the output and simply observes the response of the PV From the PV response the auto tune function calculates the gains and the sample time It automatically places the results in the corresponding registers in the loop table DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only The following timing diagram shows the events which occur in the open loop auto tuning cycle The auto tune function takes control of the control output and induces a 10 of span step change If the PV change which the loop controller observes is less than 2 then the step change on the output is increased to 20 of span Open Loop Auto Tune Cycle Wave Step Response Method PV Tangent Rr Slope SPF a Process Wave D Base Line LrRr gt sec e T
256. material in process would be ruined The DL250 1 and DL260 loop controllers provide a programmable PV Rate of Change Alarm as shown below The rate of change is specified in PV units EE change per loop sample time This value is programmed into the loop table location NO V 21 To 0 So Loop Tabl PV slope OK PV slope excessive x Gop Tabie OO M V 21 XXXX PV Rate of Change Alarm Of 39 PV gt PID Mode and Alarm Status V 06 ra rate of change alarm NT Bit 15 14 13 1211109876543210 Sample time Sample time L PV Rate of Change Alarm As an example suppose the PV is temperature for our process and we want an alarm when the temperature changes faster than 15 degrees minute We must know PV counts per degree and the loop sample rate Then suppose the PV value in V 03 location represents 10 counts per degree and the loop sample rate is 2 seconds We will use the formula below to convert our engineering units to counts sample period 15 degrees 10 counts degree 150 Alarm Rate of Change X 5counts sample period 1 minute 30 loop samples min 30 From the calculation result we would program the value 5 in the loop table for the rate of change The PV Rate of Change Alarm can be independently enabled and disabled from the other PV alarms using bit 14 of the PID Mode 1 Setting V 00 word The alarm hysteresis feature disc
257. me In the figure below processes A and B converge when stages S2 and S4 transition to S5 at some point in time So S2 and S4 are Convergence Stages C D Convergence Stage Process A Se Convergence Stages CV Xx Viv iv 230 240 250 1 260 lt gt Le Process B While the converging principle is simple enough it brings a new complication As parallel processing completes the multiple processes almost never finish at the same time In other words how can we know whether Stage S2 or S4 will finish last This is an important point because we have to decide how to transition to Stage S5 The solution is to coordinate the transition CV condition out of convergence stages We s2 de accomplish this with a stage type ages designed for this purpose the Convergence Stage type CV In the CV example to the right convergence stages S4 S2 and S4 are required to be grouped x3 together as shown No logic is permitted r between CV stages The transition CvuMP condition X3 in this case must be located in the last convergence stage The SG transition condition only has power flow when all convergence stages in the group are active DL205 User Manual 3rd Ed 06 02 D E E U E E LD Suuue1Bo1y bes 7 20 RLLPLUS Stage Programming Convergence Jump Recall the last conve
258. mply following the transition condition with the Stage instruction for the next stage The power flow transition method does eliminate one Stage JMP instruction its only advantage However it is not as easy to make program changes as using the Stage JMP Therefore we advise using Stage JMP transitions for most programs DL205 User Manual 3rd Ed 06 02 7 19 RLLPLUS Stage Programming Parallel Processing Concepts Parallel Processes Previously in this chapter we discussed how a state may transition to either one state Converging Processes or another called an exclusive transition In other cases we may need to branch simultaneously to two or more parallel processes as shown below It is acceptable to use all JMP instructions as shown or we could use one JMP and a Set Stage bit instruction s at least one must be a JMP in order to leave S1 Remember that all instructions in a stage execute even when it transitions the JMP is not a GOTO Process A y Push On State xo S2 1 Come S4 JMP Note that if we want Stages S2 and S4 to energize exactly on the same scan both stages must be located below or above Stage S1 in the ladder program see the explanation at the bottom of page 7 7 Overall parallel branching is easy Now we consider the opposite case of parallel branching which is converging processes This simply means we stop doing multiple things and continue doing one thing at a ti
259. munications and I O wiring Mains filter Transient voltage Earth suppressor ground Mains disconnect switch UO common earthed Ferrite choke Panel or on I O wirin Ground Braid Single Point 9 gya Copper Lugs y Ground Lock Nut Le n Star Washers N Lock Nut Illustrations are not to scale Star Washers DL205 User Manual 3rd Ed Rev A 08 03 European Union Directives G5 Electrostatic We specify in all declarations of conformity that our products are installed inside an Discharge ESD industrial enclosure using metallic conduit for external wire runs therefore we test the products in a typical enclosure However we would like to point out that although our products operate normally in the presence of ESD this is only the case when mounted within an enclosed industrial control cabinet When the cabinet is open during installation or maintenance the equipment and or programs may be at risk of damage from ESD carried by personnel We therefore recommend that all personnel take necessary precautions to avoid the risk of transferring static electricity to components inside the control cabinet If necessary clear warnings and instructions should be provided on the cabinet exterior such as recommending the use of earth straps or similar devices or the powering off of equipment inside the enclosure ce D Sa ax lt ba n AC Mains Filters DL205 AC powered base power D suppli
260. n DL250 1 DL260 only Now that we have described the general ramp soak generator operation we list its PID Loop Operation GO Q N a m _ T O Ye A S Ramp Soak Table specific features e Each loop has its own ramp soak generator use is optional e You may specify up to eight ramp soak steps 16 segments s The ramp soak generator can run anytime the PLC is in Run mode Its operation is independent of the loop mode Manual or Auto s Ramp soak real time controls include Start Hold Resume and Jog e Ramp soak monitoring includes Profile Complete Soak Deviation SP minus PV and current ramp soak step number The following figure shows a SP profile consisting of ramp soak segment pairs The segments are individually numbered as steps from 1 to 16 The slope of each of the ramp may be either increasing or decreasing The ramp soak generator automatically knows whether to increase or decrease the SP based on the relative values of a ramp s end points These values come from the ramp soak table Step SP The parameters which define the ramp soak profile for a loop are in a ramp soak table Each loop may have its own ramp soak table but it is optional Recall the Loop Parameter table consists a 32 word block of memory for each loop and together they occupy one contiguous memory area However the ramp soak table for a loop is individually located because it is optiona
261. n a large antenna waiting to introduce noise into the system therefore you should tighten all connections in your system Loose ground wires are more susceptible to noise than the other wires in your system Review Chapter 2 Installation Wiring and Specifications if you have questions regarding how to ground your system e Electrical noise can enter the system through the power source for the CPU and I O Installing a isolation transformer for all AC sources can correct this problem DC sources should be well grounded good quality supplies Switching DC power supplies commonly generate more noise than linear supplies e Separate input wiring from output wiring Never run I O wiring close to high voltage wiring Sunooysa qno pue S9UBUaJUIE A DL205 User Manual 3rd Ed Rev A 08 03 9 18 Maintenance and Troubleshooting Machine Startup and Program Troubleshooting D lt o 00 cc On 52 re ea 52 SF D oO Syntax Check The DL205 CPUs provide several features to help you debug your program before and during machine startup This section discusses the following topics which can be very helpful e Program Syntax Check e Duplicate Reference Check e Test Modes e Special Instructions s Run Time Edits e Forcing I O Points Even though the Handheld Programmer and DirectSOFT32 provide error checking during program entry you may want to check a modified program Both programming devices offer a way to
262. n goes directly to the appropriate step number defined as the preset step Buiwwel6olg J 3 5 a a E E O O 5 Last step Outputs 7 C C9 7 78 78867 Are transition diti E Timer and or Event criteria conditions met Set Drum Complete bit m Complete Outputs 0 6 7 O C9 7 78 7 886 7 Reset Input Active Yes Reset CTO 0 Go to Preset Step Reset Drum Complete bit DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Drum Instruction Programming Overview of Drum Operation Drum Instruction Block Diagram The drum instruction utilizes various inputs and outputs in addition to the drum pattern itself Refer to the figure below Inputs DRUM INSTRUCTION Outputs Block Diagram Start Realtime Jog Inputs from ladder Reset Drum Preset Step Ode o o 0 Step S 2 2 S 2 Final Drum Counts Step a Step Pointer le o oe 7 Outputs Outputs Control O0 o o Timebase O 0 0 O ooo o x O O O Programming Events Selections Counter Pattern Output Mask Asterisked inputs are applicable only to particular drum instructions Counter Assignments m CTAO Counts in step V1000 XXXX m CTA1 Timer Value V1001 XXXX m CTA2 Preset Step v1002 XXXX CTA3
263. n is available on the PLC Clear PLC sub menu within DirectSOFT32 AUX 3 V memory Operations AUX 31 Clear V Memory e AUX 31 Clear V memory AUX 31 clears all the information from the V memory locations available for general use This AUX function is available on the PLC Clear PLC sub menu within DirectSOFT32 DL205 User Manual 3rd Ed Rev A 08 03 Auxiliary Functions ESA AUX 4 1 0 Configuration AUX 41 46 AUX 41 Show 1 0 Configuration AUX 42 UO Diagnostics AUX 44 Power up Configuration Check A D me AUX 45 Select Configuration A CE e TARR There are several AUX functions available that you can use to setup view or change the I O configuration e AUX 41 Show I O Configuration e AUX 42 I O Diagnostics e AUX 43 not used in DL205 e AUX 44 Power up Configuration Check e AUX 45 Select Configuration e AUX 46 Configure I O This AUX function allows you to display the current I O configuration With the Handheld Programmer you can scroll through each base and I O slot to view the complete configuration The configuration shows the type of module installed in each slot DirectSOFT32 provides the same information but it is much easier to view because you can view a complete base on one screen This is one of the most useful AUX functions available in the DL205 system This AUX function will show you the exact base and slot location o
264. n is zero in the accumulator SP64 Half borrow on when the 16 bit subtraction instruction results in a borrow SP65 Borrow on when the 32 bit subtraction instruction results in a borrow SP66 Half carry on when the 16 bit addition instruction results in a carry SP67 Carry when the 32 bit addition instruction results in a carry SP70 Sign on anytime the value in the accumulator is negative SP71 Invalid octal on when an Invalid octal number was entered This also occurs when number the V memory specified by a pointer P is not valid SP73 Overflow on if overflow occurs in the accumulator when a signed addition or subtraction results in an incorrect sign bit SP75 Data error on if a BCD number is expected and a non BCD number is encountered SP76 Load zero on when any instruction loads a value of zero into the accumulator SP100 XO is on X0 on when corresponding input is on SP540 Current target value on when the counter current value equals the value in V3630 SP541 Current target value on when the counter current value equals the value in V3632 SP542 Current target value on when the counter current value equals the value in V3634 SP543 Current target value on when the counter current value equals the value in V3636 SP544 Current target value on when the counter current value equals the value in V3640 SP545 Current target value on when the counter current value equals the value in V3642
265. n the 10 second timer range RTOB This instruction converts the real number back to binary This step prepares the number for conversion to BCD There is no real to BCD instruction BCD Convert the number in the accumulator to BCD format This satisfies the timer preset format requirement Output the result to V1400 In our example this is the I location of the timer preset for the second timer TO The second fast timer also counts in increments of 01 TMRF T1 seconds so its range is variable from 0 to a maximum V1400 of 1000 ticks or 10 seconds This timer s output T1 turns off the output coil YO when the preset is reached Ti TA KO Yo The N C T1 contact inverts the T1 timer output The control output is on at the beginning of the 10 second time Zz OUT interval YO turns off when T1 times out The STRNE contact prevents YO from energizing during the one scan when TO resets T1 YO is the actual control output END END coil marks the end of the main program DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Cascade Control Introduction Cascaded loops are an advanced control technique that is superior to individual loop control in certain situations As the name implies cascade means that one loop is connected to another loop In addition to Manual open loop and Auto closed loop Modes the DL250 1 and D
266. n the SP and PV values to a deviation threshold value A set of SP values called a profile which is generated in real time upon each loop calculation The profile consists of a series of ramp and soak segment pairs greatly simplifying the task of programming the PLC to generate such SP sequences Also called differentiator the rate term responds to the changes in the error term The location where a loop reads its setpoint when it is configured as the minor loop in a cascaded loop topology Also called integrator the reset term adds each sampled error to the previous maintaining a running total called the bias A condition created when the loop is unable to find equilibrium and the persistent error causes the integrator reset sum to grow excessively windup Reset windup causes an extra recovery delay when the original loop fault is remedied A loop in which the PV increases in response to a control output decrease In other words the process has a negative gain The time between PID calculations The CPU method of process control is called a sampling controller because it samples the SP and PV only periodically The desired value for the process variable The setpoint SP is the input command to the loop controller during closed loop operation The soak deviation is a measure of the difference between the SP and PV during a soak segment of the Ramp Soak profile when the Ramp Soak generator is active The behavior of t
267. nce and Troubleshooting UO Module Troubleshooting Things to Check If you suspect an I O error there are several things that could be causing the problem e A blown fuse e A loose terminal block e The 24 VDC supply has failed e The module has failed e The I O configuration check detects a change in the I O configuration UO Diagnostics If the modules are not providing any clues to the problem run AUX 42 from the handheld programmer or I O diagnostics in DirectSOFT32 Both options will provide the base number the slot number and the problem with the module Once the problem is corrected the indicators will reset An I O error will not cause the CPU to switch from the run to program mode however there are special relays SPs available in the CPU which will allow this error to be read in ladder logic The application program can then take the required action such as entering the program mode or initiating an orderly shutdown The following figure shows an example of the failure indicators el TE A C2 37 A O OSOS L COCO OO OO Program Control Information E252 NEW I O CFG V7752 0020 Desired module ID code V7753 0021 Current module ID code V7754 0002 Location of conflict V7755 0252 Fatal error code SP47 IO Configuration Error D lt o 00 cc On 52 Faj ES 52 SF Le
268. ndir Bit 71 5 us 10us 71 5 us 1 0 us DL205 User Manual 3rd Ed Rev A 08 03 C 22 Instruction Execution Times Math Instructions cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute INCB V Data Reg 88 us 10 4 us 35 us 84us 132us 10us 13 2us 1 0 us V Bit Reg 349 us 104us 211 us 8 4 us 13 2 us 1 0 us 13 2 us 1 0 us P Indir Data 126 us 8 4us 38 6us 0 9us 38 6 us 0 9 us P Indir Bit 307 us 8 4us 38 6us 0 9us 38 6 us 0 9 us DECB V Data Reg 82 us 10 4 us 33 us 8 4 us 13 2 us 1 0 us 13 2 us 1 0 us V Bit Reg 351 us 10 4us 210 us 8 4 us 13 2 us 1 0 us 13 2 us 1 0 us P Indir Data 123 us 8 4us 38 0us 09us 38 0us 0 9us P Indir Bit 304 us 8 4us 38 0us 09us 38 0us 0 9 us ADDB V Data Reg 24 9 us 1 0 us 24 9 us 1 0 us V Bit Reg 24 9 us 1 0 us 24 9 us 1 0 us K Constant 23 5 us 1 0 us 23 5 us 1 0 us P Indir Data NN 51 1 us 1 0us 51 1 us 1 0 us P Indir Bit 51 1 us 10us 51 1 us 1 0 us ADDBD V Data Reg 24 4 us 1 0 us V Bit Reg 24 4 us 1 0 us K Constant 20 7 us 1 0 us P Indir Data eN 50 7 us 1 0 us P Indir Bit 50 7 us 1 0 us SUBB V Data Reg 24 7 us 1 0 us 24 7 us 1 0 us
269. nes in Chapter 2 of this Installation Manual and to the DL205 Analog I O Module manual as needed The most commonly overlooked wiring details in installing PID loop controls are e It s easy to reverse the polarity of connection on sensor wiring s Pay attention to signal ground connections between loop components S Step 6 After wiring and installation we can choose the loop setup parameters The easiest Ro Loop Parameters method for programming the loop tables is using DirectSOFT32 s PID Setup dialog ae boxes Be sure to study the meaning of all loop parameters in this chapter before Le choosing values to enter oe lele NO Step 7 With the sensors and actuator wiring done and loop parameters entered we must os Check Open Loop manually and carefully check out the new control system use Manual Mode OS Performance e Verify the PV value from the sensor is correct lt gt e Ifitis safe to do so gradually increase the control output up above 0 and see if the PV responds and moves in the correct direction Step 8 If the open loop test shows the PV reading is good and the control output has the Loop Tuning proper effect on the process we can do the closed loop tuning procedure Automatic Mode In this most crucial step we tune the loop so the PV automatically follows the SP Refer to the section on Loop Tuning in this chapter Step 9 If the closed loop test shows PV will follow small changes in the SP we can consider
270. nfiguration errors before you place the CPU into RUN mode Uncorrected errors can cause unpredictable machine operation that can result in a risk of personal injury or damage to equipment gt E S DO O lt 8 da D gt X 2 gt Le ao DL205 User Manual 3rd Ed Rev A 08 03 A6 Auxiliary Functions AUX 46 You will probably never need to use this feature but the DL250 1 and DL260 CPU O Configuration allows you to use AUX 46 to manually assign I O addresses for any or all I O slots on the local or expansion bases It is generally much easier to do the I O configuration operations from within DirectSOFT32 The software package provides a really nice screen that is available from the PLC Configure I O sub menu This feature is useful if you have a standard configuration you must sometimes change slightly to accommodate special requests For example you may require two adjacent input modules to have addresses starting at X10 and X200 respectively In automatic configuration the addresses were assigned on 8 point boundaries Manual configuration assumes that all modules are at least 16 points so you can only assign addresses that are a multiple of 20 octal For example X30 and Y50 would not be valid starting addresses for a module X20 and Y40 are valid examples of starting addresses in a manual configuration This does not mean you can only use 16 or 32 point modules with manual configuration You can use 8 point modul
271. nfigure I O x x Y Y CPU and HPP AUX 5 CPU Configuration AUX 8 Password Operations 51 Modify Program Name Y Y Y Y 81 Modify Password YY Y ir 52 Display Change Calen x Y Y Y 82 Unlock CPU II Y dar 83 Lock CPU PAPA A a 53 Display Scan Time Viv Y Y 54 Initialize Scratchpad Viviv Y Y supported 55 Set Watchdog Timer Viv Y Y x not supported 56 Set CPU Network Ad X Y Y not applicable dress 57 Set Retentive Ranges Viv Y Y 58 Test Operations Viv Y Y 59 Bit Override X v Y 5B Counter Interface Con Viv Y Y fig 5C Display Error History X v Y Y DL205 User Manual 3rd Ed Rev A 08 03 Auxiliary Functions Accessing AUX DirectSOFT32 provides various menu options during both online and offline Functions via programming Some of the AUX functions are only available during online gt DirectSOFT32 programming some only during offline programming and some during both online S and offline programming The following diagram shows an example of the PLC oS operations menu available within DirectSOFT32 lt E a co RE 2 x lt gt O m OK Online MN nr wage i r a FR a fee ot Menu Options Be Accessing AUX You can also access the AUX functions by using a Handheld Programmer Plus Functions via the remember some of the AUX functions are only available from the Handheld Handheld Sometimes the AUX name or description cannot fit on
272. ng the output of the major loop Once the cascaded control is programmed and debugged we only need to deal with the original setpoint and process variable at the system level The cascaded loops behave as one loop but with improved performance over the previous single loop LORS doo Aid g C D O1 L g C o O G El solution External External Disturbances Disturbances 7 E Output B Setpoint oop Setpoint Loop A Output A Process A Process B Calculation Calculation secondary primary Minor Major Loop Loop PV Process A One of the benefits to cascade control can be seen by examining its response to external disturbances Remember the minor loop is faster acting than the major loop Therefore if a disturbance affects process A in the minor loop the Loop A PID calculation can correct the resulting error before the major loop sees the effect PV Process B DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only Cascaded Loops in In the use of the term cascaded loops we must make an important distinction Only the DL250 1 the minor loop will actually be in the Cascade Mode In normal operation the major DL260 CPUs loop must be in Auto Mode If you have more than two loops cascaded together the outer most major loop must be in Auto Mode during normal operation and all inner loops in Cascade Mode N
273. nitoring Operator Interface gana Te Recipe In a typical application the separate stage sequences above operate as follows e Powerup Initialization This stage contains ladder rung tasks performed once at powerup Its last rung resets the stage so this stage is only active for one scan or only as many scans that are required e Main Process This stage sequence controls the heart of the process or machine One pass through the sequence represents one part cycle of the machine or one batch in the process s E Stop and Alarm Monitoring This stage is always active because it is watching for errors that could indicate an alarm condition or require an emergency stop It is common for this stage to reset stages in the main process or elsewhere in order to initialize them after an error condition e Operator Interface This is another task that must always be active and ready to respond to an operator It allows an operator interface to change modes etc independently of the current main process step D E E U E E LD Suuue1Bo1y 26e1s Although we have separate processes Operator Interface there can be coordination among them For example in an error condition the Contr Status Stage may want to automatically switch the operator interface to the status mode to show error information as shown Set to the right The monitor stage could set Monitor S2_ status the stage bit for Status and Rese
274. ns 7 7 Stage Jump Set and Reset Instructions 7 7 Stage Program Example Toggle On Off Lamp Controller 7 8 A ASIA Process zone Adsense os ot es celos ra ae AERO Ak BREE BON 7 8 Four Steps to Writing a Stage Program 7 9 Stage Program Example A Garage Door Opener 7 10 Garage Door Opener Example 20 0 cece eee eee cette eee eens 7 10 Draw ihe Block Diagram es des sees MR Re cs Reis EAN 7 10 Draw the State Diagonal watts owe eh Sa wee See Ae od te 7 11 Add Safety Light Feature 42004 sario ace are Fer s ai Fate be bran 7 12 Modify the Block Diagram and State Diagram 7 12 Using a Timer Inside a Stage 7 13 Add Emergency Stop Feature nananana neern 7 14 EXGlUsiveTIRAMSIMIONS o a O oe E eR eat TRT tee ie Fetes aes 7 14 Stage Program Design Considerations 7 15 Stage Program Organization hates fede ed At ec edt nao PM nied 7 15 How Instructions Work Inside Stages 7 16 Using a Stage as a Supervisory Process 7 17 Stage Counter asss a 0 ut oe ee oe Oe H Re A et une on 7 17 Unconditional OUPS uta dd ne
275. ocess requires What Stage Bits Do You may recall that a stage is a section of ladder program which is either active or inactive at a given moment All stage bits SO Sxxx reside in the PLCs image register as individual status bits Each stage bit is either a boolean 0 or 1 at any time Program execution always reads ladder rungs from top to bottom and from left to right The drawing below shows the effect of stage bit status The ladder rungs below CH E the stage instruction continuing until the next stage instruction or the end of program NE belong to stage 0 Its equivalent operation is shown on the right When SO is true the 25 two rungs have power flow GH a S e If Stage bit SO 0 its ladder rungs are not scanned executed de e If Stage bit SO 1 its ladder rungs are scanned executed CH amp Actual Program Appearance Functionally Equivalent Ladder SG SO a Cc L Cc includes all rungs in stage Stage Instruction The inline stage boxes on the left power Characteristics rail divide the ladder program rungs into stages Some stage rules are SG e Execution Only logic in active stages are executed on any scan C e Transitions Stage transition C instructions take effect on the next occurrence of the stages involved SG s Octal numbering Stages are S1 numbered in octal like I O points C et
276. ollowing example shows how to perform the duplicate reference check with a Handheld Programmer Use AUX 21 to perform syntax check an e om ee AUX 21 CHECK PRO 1 SYN 2 DUP REF Select duplicate reference check ent You may not get the busy BUSY display if the program is not very long One of two displays will appear Error Display example 00024 E471 DUP COIL REF shows location in question Syntax OK display NO DUP REFS If you get an error press CLR and the Handheld will display the instruction where the error occurred Correct the problem and continue running the Duplicate Reference check until no duplicate references are found sas NOTE You can use the same coil in more than one location especially in programs using the Stage instructions and or the OROUT instructions The Duplicate Reference check will find these outputs even though they may be used in an 20UBUAJUIEIN acceptable fashion E a re Cc 2 D 12 gt O le O DL205 User Manual 3rd Ed Rev A 08 03 EZ Maintenance and Troubleshooting D amp o Q 00 cc On 52 re 3 52 gt D Kd TEST PGM and TEST RUN Modes Test Mode allows the CPU to start in TEST PGM mode enter TEST RUN mode run a fixed number of scans and return to TEST PGM mode You can select from 1 to 65 525 s
277. oltage for 230V nominal supplies 150VAC working voltage for 115V supplies and high energy capacity eg 140 joules Transient suppressors must be protected by fuses and the capacity of the transient suppressor must be greater than the blow characteristics of the fuses or circuit breakers to avoid a fire risk A recommended AC supply input arrangement for Koyo PLCs is to use twin 3 amp TT fused terminals with fuse blown indication such as DINnectors DN F10L terminals or twin circuit breakers wired to a Schaffner FN2010 filter or equivalent with high energy transient suppressor soldered directly across the output terminals of the filter PLC system inputs should also be protected from voltage impulses by deriving their power from the same fused filtered and surge suppressed supply DL205 User Manual 3rd Ed Rev A 08 03 OS x 2 So co qj 2 gt LU European Union Directives Internal Enclosure A heavy duty star earth terminal block should be provided in every cubicle for the Grounding connection of all earth ground straps protective earth ground connections mains filter earth ground wires and mechanical assembly earth ground connections This should be installed to comply with safety and EMC requirements local standards and the requirements found in IEC 1000 5 2 The Machinery Directive also requires that the common terminals of PLC input modules and common supply side of loads driven from PLC output modules should b
278. om programmer YO in image register YO at output module DL205 User Manual 3rd Ed Rev A 08 03 9 28 Maintenance and Troubleshooting D lt o 00 cc On 52 Fa ES 52 SF D Kd Regular Forcing with Direct Access The following diagrams show a brief example of how you could use the DL205 xO YO Handheld Programmer to force an I O OUT point Remember if you are using the Bit Override feature the CPU will retain the co forced value until you disable the Bit Override or until you remove the force The image register will not be updated with the status from the input module Also the solution from the application program will not be used to update the output image register The example assumes you have already placed the CPU into Run Mode From a clear display use the following keystrokes 16P STATUS STAT ENT BIT REF X Use the PREV or NEXT keys to select the Y data type Once the Y appears press 0 to start at YO A Y 10 X 0 NEXT 0 ENT Use arrow keys to select point then use Y2 is now on ON and OFF to change the status 10 ON E SHFT NS K
279. on gt GO ro N a m T O Ye A S a PID Loop Operation DL250 1 DL260 only Glossary of PID Loop Terminology Automatic Mode Bias Freeze Bias Term Bumpless Transfer Cascaded Loops Cascade Mode Continuous Control Direct Acting Loop Error Error Deadband Error Squared Feedforward Control Output Derivative Gain Integral Gain Major Loop Manual Mode Minor Loop On Off Control PID Loop Position Algorithm Process Process Variable PV An operational mode of a loop in which it makes PID calculations and updates the loop s control output A method of preserving the bias value operating point for a control output by inhibiting the integrator when the output goes out of range The benefit is a faster loop recovery In the position form of the PID equation it is the sum of the integrator and the initial control output value A method of changing the operation mode of a loop while avoiding the usual sudden change in control output level This consequence is avoided by artificially making the SP and PV equal or the bias term and control output equal at the moment of mode change A cascaded loop receives its setpoint from the output of another loop Cascaded loops have a major minor relationship and work together to ultimately control one PV An operational mode of a loop in which it receives its SP from another loop s output Control of a process done by delivering
280. on Execution Times Accumulator Data Instructions Accumulator Stack Load DL230 DL240 DL250 1 DL260 and Output Data Instructions Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute LD V Data Reg 68 us 8 4 us 68 us 8 4 us 11 8 us 1 0 us 11 8 us 1 0 us V Bit Reg 149 us 8 4 us 143 us 8 4 us 11 8 us 1 0 us 11 8 us 1 0 us K Constant 62 us 8 4 us 159 us 8 4 us 9 0 us 1 0 us 9 0 us 1 0 us P Indir Data 169 us 8 4 us 238 us 8 4 us 33 9 us 0 9 us 33 9 us 0 9 us P Indir Bit 256 us 8 4 us 62 us 84us 339us 09us 339us 0 9us LDA O Octal constant for bi 58us 84us 56us 84us 10 4us 10us 10 4us 10us LDD V Data Reg 72 us 8 4 us 67 us 8 4 us 12 2 us 1 0 us 12 2 us 1 0 us V Bit Reg 266 us 8 4 us 228 us 8 4 us 12 2 us 1 0 us 12 2 us 1 0 us K Constant 64 us 8 4 us 69 us 8 4 us 9 0 us 1 0 us 9 0 us 1 0 us P Indir Data 172 us 8 4 us 158 us 8 4 us 37 8 us 0 9 us 37 8 us 0 9 us P Indir Bit 373 us 8 4 us 323 us 84us 37 8us 0 9us 37 8us 0 9 us 5 LDF 1st 2nd 2 X Y C S K Constant 86us 8 4us 20 5us 0 9s 20 5us 0 9us DE T CT SP 5us x N 0 9us x 0 9us x DT N N 29 LDR V Data Reg 29 5us 1 0us 295us 1 0us 0 V Bit Reg S ra _ 29 5 us 1 0 us 29 5 us 1 0 us 30 K Constant 25 5 us 1 0 us 25 5 us 1 0 us 3 P Indir Data 54 9 us 1 0 us 54 9 us 1 0 us D P Indir Bit 54 9us 1 0us 54 9us 1 0us se LDSX K
281. on from one X Viv iv to another Note the use of stage blocks does not require each stage in a program to aa 240 Sat 200 reside inside a block shown below by the stages outside blocks Block 0 Block 1 Block 2 Stages outside blocks ee ones STO A program with 20 or more stages may be considered large enough to use block grouping however their use is not mandatory When used the number of stage blocks should probably be two or higher because the use of one block provides a negligible advantage A block of stages is separated from other ladder logic with special beginning and ending instructions In the figure to the BLK y right m BLK instruction at ve top marks Co HISERIEMENON the start of the stage block At the bottom the Block End BEND marks the end of SG the block The stages in between these SO boundary markers SO and S1 in this case and their associated rungs make up the All other rungs in stage block Note the block instruction has a reference S1 value field set to CO in the example The block instruction borrows or uses a All other rungs in stage control relay contact number so that other Block End parts of the program can control the block Instruction Any control relay number such as CO BEND used in a BLK instruction is not available for use as a control relay SM1d T14 a a a D D e Q S 3 2 gt a
282. ons whether implemented in analog or digital CPU components The DL250 1 and DL260 CPUs implement the PID equations digitally by solving the basic equations in software I O modules serve only to convert electronic signals into digital form or vise versa The CPUs features two types of PID controls position and velocity These terms usually refer to motion control situations but here we use them in a different sense s PID Position Algorithm The control output is calculated so it responds to the displacement position of the PV from the SP error term e PID Velocity Algorithm The control output is calculated to represent the rate of change velocity for the PV to become equal to the SP The vast majority of applications will use the position form of the PID equation If you are not sure of which algorithm to use try the Position Algorithm first Use DirectSOFT32 s PID View Setup dialog box to select the desired algorithm Or use bit 5 of PID Mode 1 Setting V 00 word as shown below to select the desired algorithm Position Algorithm Loop Calculation l Position Algorithm Setpoint Error Control Output y gt Velocity Algorithm Process Variable PID Mode 1 Setting V 00 Bit 15 14 13 12 11109876543210 Position Velocity select E NOTE The selection of a PID al
283. ontact as long as N YO you place any unconditional outputs first OUT at the top of a stage section of ladder xo Yi The first rung of Stage 1 does this oun WARNING Unconditional outputs placed SG elsewhere in a stage do not necessarily S2 remain on when the stage is active In Stage 2 to the right YO is shown as an ke E unconditional output but its powerflow OUT comes from the rung above So YO status YO will be the same as Y1 is not correct OUT Our discussion of state transitions has shown how the Stage JMP instruction makes the current stage inactive and the next stage named in the JMP active As an alternative way to enter this in DirectSOFT32 you may use the power flow method for stage transitions The main requirement is the current stage be located directly above the next jump to stage in the ladder program This arrangement is shown in the diagram below by stages SO and S1 respectively E SG SG SO SO X0 S1 All other rungs in stage N XO Equivalent SG gt Power flow S1 transition SG S1 Recall the Stage JMP instruction may occur anywhere in the current stage and the result is the same However power flow transitions shown above must occur as the last rung in a stage All other rungs in the stage will precede it The power flow transition method is also achievable on the handheld programmer by si
284. ontrol It makes the following assumptions which you can alter to fit your application e The loop table starts at V2000 so the control output is at V2005 s The data format of the control output is 12 bit unipolar 0 FFF or 0 4 095 e The on off control output is YO The control program must match the resolution of the output to the resolution of the time interval The time interval for one full cycle of the on off waveform is 10 seconds speed of your process when you choose this control method Use continuous control 8 NOTE Some processes change too fast for time proportioning control Consider the for processes that change too fast for time proportioning control S S a TO A fast timer 0 01 sec timebase establishes the primary O TMRF TO time interval The constant K1000 sets the preset at 10 O VA K1000 seconds 1 000 ticks The N C enabling contact TO on makes the timer self resetting TO is on for one scan OZ each 10 seconds when it resets itself and T1 ss TO LD At the end of the 10 second period TO turns on and Ol V2005 loads the control output value binary from the loop table 2 l V 05 location V2005 The BTOR instruction changes the number in the BTOR a a accumulator to a real number Dividing the control output by 4 095 converts the DIVR 0 4095 range to 0 1000 which matchs the R4 095 number of ticks i
285. oop operates normally and generates new control output values It calculates the PID equation and writes the result in location V 05 every In Cascade Mode the loop operates like in Automatic Mode with one important change The data source for the SP changes from its normal location at V 02 using the control output value from another loop the purpose of cascading loops is covered later in this chapter So in Auto or Manual modes the loop calculation uses the data at V 02 In Cascade Mode the loop calculation reads the control output from another loop s parameter table c2 sample period of that loop The equivalent schematic diagram is shown below 26 S Input from Operator Manual oN Control Output V 05 O2 gt ae Loop 9 J Calculation Auto ok a Another loop Cascaded loop Loop Control Output V 05 Cascade Calculation ne Setpoint gt Loop Control Output Normal SP V 02 e H 2 CARE Auto Manual Process Variable Realizing the way PID calculations change data sources according to the Manual Auto Cascade modes naturally some restrictions on mode changes exist As pictured below a loop change from one mode to another but cannot go from Manual Mode to Cascade This mode change is prohibited because a loop would be changing two data sources at the same time and could cause a loss of control a aom DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250
286. op Operation GO Q N a m _ T O Ye A S Main Features DL250 1 and DL260 PID Loop Features The DL250 1 and DL260 CPUs process loop control offers a sophisticated set of features to address many application needs The main features are e DL260 up to 16 loops individual programmable sample rates e DL250 1 up to 4 loops individual programmable sample rates e Manual Automatic Cascaded loop capability available e Two types of bumpless transfer available e Full featured alarms s Ramp soak generator with up to 16 segments e Auto Tuning The DL250 1 and DL260 CPUs have process control loop capability in addition to ladder program execution You can select and configure up to four loops All sensor and actuator wiring connects to standard DL205 1 0 modules as shown below All process variables gain values alarm levels etc associated with each loop reside in a Loop Variable Table in the CPU The CPU reads process variable PV inputs during each scan Then it makes PID loop calculations during a dedicated time slice on each PLC scan updating the control output value The control loops use the Proportional Integral Derivative PID algorithm to generate the control output command This chapter describes how the loops operate and what you must do to configure and tune the loops Analog or Digital Output Manufacturing Process DL250 1 DL260 PID Loop Calculations
287. op Test Whether you use manual or auto tuning it is very important to verify basic characteristics of a newly installed process before attempting to tune it With the loop in Manual Mode verify the following items for each new loop e Setpoint verify the source which is to generate the setpoint can do so You can put the PLC in Run Mode but leave the loop in Manual Mode Then monitor the loop table location V 02 to see the SP value s The ramp soak generator if you are using it should be tested now e Process Variable verify the PV value is an accurate measurement and the PV data arriving in the loop table location V 03 is correct If the PV signal is very noisy filter the input either through hardware RC low pass filter or using a digital S W filter e Control Output if it is safe to do so manually change the output a small amount perhaps 10 and observe its affect on the process variable Verify the process is direct acting or reverse acting and check the setting for the control output inverted or non inverted Make sure the control output upper and lower limits are not equal to each other e Sample Rate while operating open loop this is a good time to find the ideal sample rate procedure give earlier in this chapter However if you are going to use auto tuning note the auto tuning procedure will automatically calculate the sample rate in addition to the PID gains g C D O1 L g C o O G
288. or LDLBL instruction was used without the MISSING LBL appropriate label Refer to the programming manual for details on these instructions SP52 will be on and the error code will be stored in V7755 E403 A subroutine in the program does not end with the RET instruction SP52 will MISSING RET be on and the error code will be stored in V7755 DL240 ONLY E404 A NEXT instruction does not have the corresponding FOR instruction SP52 MISSING FOR will be on and the error code will be stored in V7755 DL240 DL250 1 DL260 m gt 35 ojo 03 Oa Qx Du DL205 User Manual 3rd Ed Rev A 08 03 Es DL205 Error Codes DL205 Error Code Description E405 A FOR instruction does not have the corresponding NEXT instruction SP52 MISSING NEXT will be on and the error code will be stored in V7755 DL240 250 1 260 E406 An interrupt routine in the program does not end with the IRT instruction MISSING IRT SP52 will be on and the error code will be stored in V7755 E412 There is greater than 64 SBR LBL or DLBL instructions in the program This SBR LBL gt 64 error is also returned if there is greater than 128 GTS or GOTO instructions DL240 250 1 260 used in the program SP52 will be on and the error code will be stored in V7755 mg XD Ke cO Ou 20 ii E413 There is greater than 64 FOR NEXT loops in the application program SP52 FOR NEXT gt 64 will be on and the error code will be sto
289. ord protection while not locking the communication port to an operator interface The multi level password can be invoked by creating a password with an upper case A followed by seven numeric characters e g A1234567 AUX 82 can be used to unlock a CPU that has been password protected DirectSOFT32 will automatically ask you to enter the password if you attempt to communicate with a CPU that contains a password AUX 83 can be used to lock a CPU that contains a password Once the CPU is locked you will have to enter a password to gain access Remember this is not necessary with DirectSOFT32 since the CPU is automatically locked whenever you exit the software package DL205 User Manual 3rd Ed Rev A 08 03 DL205 Error Codes In This Appendix Error Code Table ET DL205 Error Codes DL205 Error Code Description ng XD Ke cO Ou 20 ii E003 If the program scan time exceeds the time allotted to the watchdog timer this SOFTWARE error will occur SP51 will be on and the error code will be stored in V7755 To TIME OUT correct this problem add RSTWT instructions in FOR NEXT loops and subroutines or use AUX 55 to extend the time allotted to the watchdog timer E041 The CPU battery is low and should be replaced SP43 will be on and the error CPU BATTERY LOW code will be stored in V7757 E099 If the compiled program length exceeds the amount of available CPU RAM PROGRAM this error
290. ossible data sources for the SP value SP Location The PID loop controller has the built in ability to select between two sources according to the current loop mode Refer to the figure below A loop reads its setpoint from table location V 02 in Auto or Manual modes If you plan to use Cascade Mode for the loop at any time then you must program its loop parameter table with a remote setpoint pointer The Remote SP pointer resides in location V 32 in the loop table For loops that will be cascaded made a minor loop you will need to program this location with the address of the major loop s Control Output address Find the starting location of the major loop s parameter table and add offset 05 to it Loop Table V 32 XXXX Remote SP Pointer Another loop major loop Cascaded loop minor loo Loop Control Output V 05 Cascade N Calculation pa Setpoint 5 Loop Control Output Normal SP V 02 y ae gi Calculation Auto Manual Process Variable A DirectSOFT32 Loop Setup dialog box will allow you to enter the Remote SP pointer if you know the address Otherwise you can enter it with a HPP or program it through ladder logic using the LDA instruction Process Variable The process variable input to each loop is the value the loop is ultimately trying to PV Configuration control to make it equal to the setpoint and follow setpoint changes as quickly as possible Most sensors for process vari
291. ow shows you how NOTE When writing the bias term one must be careful to design ladder logic to write the value only once at the moment when the new bias operating point is to occur If ladder logic writes the bias value on every scan the loop s integrator is effectively disabled How do we know when to write to the bias term and what value to write Suppose we have an oven temperature control loop and we have already tuned the loop for optimal performance Refer to the figure below We notice that when the operator opens the oven door the temperature sags a bit while the loop bias adjusts to the heat loss Then when the door closes the temperature rises above the SP until the loop adjusts again Feedforward control can help diminish this effect Oven door Closed Open Closed PV sags PV g PV excess Bias First we record the amount of bias change the loop controller generates when the door opens or closes Then we write a ladder program to monitor the position of an oven door limit switch When the door opens our ladder program reads the current bias value from V 04 adds the desired change amount and writes it back to V 04 When the door closes we duplicate the procedure but subtracting desired change amount instead The following figure shows the results Oven door Sed Open Closed PV Feed forward Feed forward N v4 Bias
292. p transitions and three types also offer events The figure below shows how timer only transitions work gt Step 1 Outputs 0006806000066000 Increment count timer Has counts per step expired Step2 Outputs O0 0060000000000000 Use next transition criteria The drum stays in each step for a specific duration user programmable The timebase of the timer is programmable from 0 01 seconds to 99 99 seconds This establishes the resolution or the duration of each tick of the clock Each step uses the same timebase but has its own unique counts per step which you program The drum spends a specific amount of time in each step given by the formula Time in step 0 01 seconds X Timebase x Counts per step DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming 6 5 For example if you program a 5 second time base and 12 counts for Step 1 the drum will spend 60 seconds in Step 1 The maximum time for any step is given by the formula Max Time per step 0 01 seconds X 9999 X 9999 999 800 seconds 277 7 hours 11 6 days Fuuwe160o14 J 3 5 a a E E O O 5 sasa NOTE When first choosing the timebase resolution a good rule of thumb is to make it about 1 10 the duration of the shortest step in your drum You will be able to optimize the duration of that step in 10 increments Other steps with longer durations allow optimizing
293. pdate In this way both and J pointers cycle from 1 to the highest loop number used except at different rates Their combined activity keeps all loops properly updated Loop Sample Times lt 2 seconds Loop Sample Times gt 2 seconds Begin PID loop task a U Er S O 1e G TO D seb ER O Loop Time up AUO 09Z10 1 0SZ21a Sample rate lt 2 sec Loop PID Calculation Loop J Time up Set 1 1 Loop J PID Calculation gt total number selected loops J gt total number of loops Set J J 1 Set J 0 No Yes Set 1 0 End PID loop task DL205 User Manual 3rd Ed Rev A 08 03 8 18 PID Loop Operation DL250 1 DL260 only Ten Steps to Successful Process Control PID Loop Operation gt GO o N a m _ T O Ye A S Step 1 Know the Recipe Step 2 Plan Loop Control Strategy Step 3 Size and Scale Loop Components Step 4 Select I O Modules Modern electronic controllers such as the DL250 1 and DL260 CPUs provide sophisticated process control features Automated control systems can be very difficult to debug because a given symptom can have many possible causes We recommend a careful step by step approach to bringing new control loops online The most important knowledge is how to make your product This knowledge is the fo
294. plement and tune a loop without feedforward and adding it only if better loop performance is still needed The term feed forward refers to the control technique involved shown in the diagram below The incoming setpoint value is fed forward around the PID equation and summed with the output Feedforward path ki Setpoint gt Loop 5 Control Output Calculation Process Variable In the previous section on the bias term we said that the bias term value establishes a working region or operating point for the control output When the error fluctuates around its zero point the output fluctuates around the bias value Now when there is a change in setpoint an error is generated and the output must change to a new operating point This also happens if a disturbance introduces a new offset in the loop The loop does not really know its way to the new operating point the integrator bias must increment decrement until the error disappears and then the bias has found the new operating point Suppose that we are able to know a sudden setpoint change is about to occur common in some applications We can avoid much of the resulting error in the first place if we can quickly change the output to the new operating point If we know from previous testing what the operating point bias value will be after the setpoint change we can artificially change the output directly which
295. qual SHFL Shift accumulator left And ess tnan NON D amp o 00 cc KR 52 Faj ES5 52 SF Le oO DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting 9 25 Use the program logic shown to describe how this process works In the example xO x1 Yo change XO to C10 Note the example as sumes you have already placed the CPU in Run Mode Go Use the MODE key to select Run Time Edits MODE CHANGE MODE NEXT NEXT ENT RUN TIME EDIT Press ENT to confirm the Run Time Edits Note the RUN LED on the DL205 MODE CHANGE ENT Handheld starts flashing to indicate RUNTIME EDITS Run Time Edits are enabled Find the instruction you want to change X0 X A SHFT FD REF SHEL SET 0 FIND 00000 STR X0 Press the arrow key to move to the X Then enter the new contact C10 SHFT ENT 7 E gt B A x RUNTIME EDIT STR C10 Press ENT to confirm the change ent Note once you press ENT the next address is displayed OR CO 20UBUAJUIEIA E a pas G D n 3 ma 5 O DL205 User Manual 3rd Ed Rev A 08 03 EZS Maintenance and Troubleshooting Forcing I O Points There are many times especially during machine startup and troubleshooting D lt o Q 0
296. r Data 229us 109 0 us 30 2 us 30 2 us 30 2 us 30 2 us P Indir Bit 322 us 113 0 us 30 2 us 30 2 us 30 2 us 30 2 us P Indir Data V Data Reg 29 9us 29 9 us 29 9us 29 9 us V Bit Reg 29 9us 29 9us 29 9us 29 9 us K Constant 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0 us 51 0us 51 0 us 51 0 us P Indir Bit V Data Reg 29 9us 29 9us 29 9us 29 9 us V Bit Reg 299us 29 9us 299us 29 9 us K Constant 27 4us 27 4us 27 4 us 27 4 us P Indir Data 51 0 us 51 0 us 51 0 us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0us ANDNE 1st 2nd V Data Reg V Data Reg 75 us 12 0 us 44 us 13 9 us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 120us 133us 13 9us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 55 us 12 0 us 44 us 13 9 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 139 us 109 0 us 30 2 us 30 2 us 30 2us 30 2 us P Indir Bit 233us 113 0 us 30 2 us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 158us 12 0us 134us 13 9us 7 6 us 7 6 us 7 6 us 7 6 us V Bit Reg 239 us 120us 223us 13 9us 7 6 us 7 6 us 7 6 us 7 6 us K Constant 137 us 12 0us 133 us 13 9us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 229 us 109 0 us 30
297. ram or in an interrupt routine SP52 will be on and the error code will ADDRESS be stored in V7755 DL240 250 1 260 DL205 User Manual 3rd Ed Rev A 08 03 DL205 Error Codes B 5 DL205 Error Code Description E436 An INT must be programmed after the end statement not in the main body of INVALID INT the program SP52 will be on and the error code will be stored in V7755 ADDRESS E438 An IRT must be programmed after the end statement not in the main body of INVALID IRT the program SP52 will be on and the error code will be stored in V7755 ADDRESS E440 Either the DLBL instruction has been programmed in the main program area INVALID DATA not after the END statement or the DLBL instruction is on a rung containing ADDRESS input contact s E441 An ACON or NCON must be programmed after the end statement not in the ACON NCON main body of the program SP52 will be on and the error code will be stored DL240 250 1 260 in V7755 E451 MLS instructions must be numbered in ascending order from top to bottom BAD MLS MLR E452 An X data type is being used as a coil output X AS COIL E453 A timer or counter contact is being used where the associated timer or MISSING T C counter does not exist E454 One of the contacts is missing from a TMRA instruction BAD TMRA E455 One of the contacts is missing from a CNT or UDC instruction BAD CNT E456 One of the contacts is
298. ration 32 14 Soak Duration 13 6 Soak PV Deviation 33 14 Soak PV Deviation 14 7 Ramp End SP Value 34 15 Ramp End SP Value 15 7 Ramp Slope 35 15 Ramp Slope 16 8 Soak Duration 36 16 Soak Duration 17 8 Soak PV Deviation 37 16 Soak PV Deviation DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation gt GO o N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only Ramp Soak Table Flags Ramp Soak Generator Enable Ramp Soak Controls Many applications do not require all 16 R S steps Use all zeros in the table for unused steps The R S generator ends the profile when it finds ramp slope 0 The individual bit definitions of the Ramp Soak Table Flag Addr 33 word is listed in the following table Bit Ramp Soak Flag Bit Description Read Write Bit 0 Bit 1 0 Start Ramp Soak Profile write 0 1 Start Hold Ramp Soak Profile write 0 1 Hold 2 Resume Ramp soak Profile write 0 gt 1 Resume 3 Jog Ramp Soak Profile write 0 gt 1 Jog 4 Ramp Soak Profile Complete read Complete 5 PV Input Ramp Soak Deviation read Off On 6 Ramp Soak Profile in Hold read Off On 7 Reserved read Off On 8 15 Current Step in R S Profile read decode as byte hex The main enable control to permit ramp soak generation of the SP value is accomplished with bit 11 in the PID Mode 1 Setting V 00 word
299. rective attempts to ensure that devices equipment and systems have the ability to function satisfactorily in their electromagnetic environment without introducing intolerable electromagnetic disturbance to anything in that environment s Machinery Safety Directive this Directive covers the safety aspects of the equipment installation etc There are several areas involved including testing standards covering both electrical noise immunity and noise generation e Low Voltage Directive this Directive is safety related and covers electrical equipment that has voltage ranges of 50 1000VAC and or 75 1500VDC e Battery Directive this Directive covers the production recycling and disposal of batteries Certain standards within each Directive already require mandatory compliance such as the EMC Directive which has gained the most attention and the Low Voltage Directive Ultimately we are all responsible for our various pieces of the puzzle As manufacturers we must test our products and document any test results and or installation procedures that are necessary to comply with the Directives As a machine builder you are responsible for installing the products in a manner which will ensure compliance is maintained You are also responsible for testing any combinations of products that may or may not comply with the Directives when used together DL205 User Manual 3rd Ed Rev A 08 03 European Union Directives G3
300. red in V7755 DL240 250 1 260 E421 Two or more SG or ISG labels exist in the application program with the same DUPLICATE STAGE number A unique number must be allowed for each Stage and Initial Stage REFERENCE SP52 will be on and the error code will be stored in V7755 E422 Two or more SBR or LBL instructions exist in the application program with the DUPLICATE same number A unique number must be allowed for each Subroutine and SBR LBL Label SP52 will be on and the error code will be stored in V7755 REFERENCE E423 Nested loops programming one FOR NEXT loop inside of another is not NESTED LOOPS DL240 250 1 260 allowed in the DL240 250 1 260 series SP52 will be on and the error code will be stored in V7755 E431 An ISG or SG must not be programmed after the end statement such as in a INVALID ISG SG subroutine SP52 will be on and the error code will be stored in V7755 ADDRESS E432 A LBL that corresponds to a GOTO instruction must not be programmed after INVALID JUMP the end statement such as in a subroutine SP52 will be on and the error GOTO ADDRESS code will be stored in V7755 DL240 250 1 260 E433 A SBR must be programmed after the end statement not in the main body of INVALID SBR the program or in an interrupt routine SP52 will be on and the error code will ADDRESS be stored in V7755 DL240 250 1 260 E435 A RT must be programmed after the end statement not in the main body of INVALID RT the prog
301. required for these applications The terms ramp and soak have special sp meanings in the process control industry and refer to desired setpoint SP values in temperature control applications In the figure to the right the setpoint increases during the ramp segment It remains steady at one value during the soak segment Time gt Complex SP profiles can be generated by specifying a series of ramp soak segments The ramp segments are specified in SP units per second time The soak time is also programmable in minutes It is instructive to view the ramp soak generator as a dedicated function to generate SP values as shown below It has two categories of inputs which determine the SP values generated The ramp soak table must be programmed in advance containing the values that will define the ramp soak profile The loop reads from the table during each PID calculation as necessary The ramp soak controls are bits in a special loop table word that control the real time start stop functionality of the ramp soak generator The ladder program can monitor the status of the ramp soak profile current ramp segment number Ramp soak table Y Ramp soak Setpoint gt Loop Control Output Ramp soak controls Generator Calculation Process Variable DL205 User Manual 3rd Ed Rev A 08 03 AE doo did Jg C D O1 L g C o O G 8 60 PID Loop Operatio
302. rge mass of air in the balloon effectively averages the effect of the burner converting the bursts of heat into a continuous effect slowly changing balloon temperature and ultimately the altitude which is the process variable Time Proportioning Control AE doo Aid Jg le D O1 L g le o O G gt Time proportioning control approximates continuous control by virtue of its duty cycle the ratio of ON time to OFF time The following figure shows an example of how duty cycle approximates a continuous level when it is averaged by a large process mass L period Desired Effect On off On Control Off If we were to plot the on off times of the burner in the hot air balloon we would probably see a very similar relationship to its effect on balloon temperature and altitude DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only On Off Control The following ladder segment provides a time proportioned on off control output It Program Example converts the continuous output in V2005 to on off control using the ouptut coil YO Loop V2005 Time YO Process P gt eee on alculation Proportionin V continuous on off SP PV The example program uses two timers to generate on off c
303. rgence stage only CV CVJMP has power flow when all CV stages in the S2 Convergence van Aw AE group are active To complement the Jump corivergence stage we need a new jump 230 240 250 1 260 instruction The Convergence Jump CV CVJMP shown to the right will transition S4 to Stage S5 when X3 is active as one va might expect but it also automatically de P resets all convergence stages in the CVJMP group This makes the CVJMP jump a very powerful instruction Note that this se o instruction may only be used with convergence stages 35 ne Convergence The following summarizes the requirements in the use of convergence stages ae Stage Guidelines including some tips for their effective application E S e Aconvergence stage is to be used as the last stage of a process which is running in parallel to another process or processes A transition to the convergence stage means that a particular process is through and represents a waiting point until all other parallel processes also finish e The maximum number of convergence stages which make up one group is 17 In other words a maximum of 17 stages can converge into one stage e Convergence stages of the same group must be placed together in the program connected on the power rail without any other logic in between e Within a convergence group the stages may occur in any order top to bottom It does not matter which stage is last in the group because all convergence stages h
304. rocess e Assign I O point numbers X and Y to physical inputs and outputs D E E U E E LD Suuue1Bo1y bes 3 Draw the State Transition Diagram The state transition diagram describes the central function of the block diagram reading inputs and generating outputs e Identify and name the states of the process e Identify the event s required for each transition between states e Ensure the process has a way to re start itself or is cyclical e Choose the powerup state for your process e Write the output equations 4 Write the Stage Program Translate the state transition diagram into a stage program e Make each state a stage Remember to number stages in octal Up to 384 total stages are available in the DL230and DL240 CPU Up to 1024 total stages are available in the DL250 1 and DL260 CPUs e Put transition logic inside the stage which originates each transition the stage each arrow points away from e Use an initial stage ISG for any states that must be active at powerup e Place the outputs or actions in the appropriate stages You will notice that Steps 1 through 3 prepare us to write the stage program in Step 4 However the program virtually writes itself because of the preparation beforehand Soon you will be able to start with a word description of an application and create a stage program in one easy session DL205 User Manual 3rd Ed 06 02 RLLPLUS Stage Programming RLL PLUS D E
305. rograms become difficult to modify later because they do not intuitively resemble the application problem they are solving It s easy to see that these inefficiencies consume a lot of additional time and time is money Stage programming overcomes these obstacles We believe a few moments of studying the stage concept is one of the greatest investments in programming speed and efficiency a PLC programmer can make So we encourage you to study stage programming and add it to your toolbox of programming techniques This chapter is designed as a self paced tutorial on stage programming For best results e Start at the beginning and do not skip over any sections e Study each stage programing concept by working through each example The examples build progressively on each other e Read the Stage Questions and Answers at the end of the chapter for a quick review DL205 User Manual 3rd Ed 06 02 7 3 RLLPLUS Stage Programming Learning to Draw State Transition Diagrams Introduction to Process States The Need for State Diagrams A 2 State Process Those familiar with ladder program execution know the CPU must scan the Inputs Ladder Outputs ladder program repeatedly over and over Program gt Its three basic steps are 1 Read the inputs 2 Execute the ladder program PLC Scan 3 Write the outputs 1 Read Execute Write _ The benefit is that a chang
306. rrent minimum and maximum scan times The minimum and maximum times are the ones that have occurred since the last Program Mode to Run Mode transition You can also perform this operation from within DirectSOFT32 by using the PLC Diagnostics sub menu gt amp lt gt OO O lt 8 da Jx 2 gt Le ao DL205 User Manual 3rd Ed Rev A 08 03 A Auxiliary Functions U ZS xe iP 2S E G E AUX 54 Initialize Scratchpad AUX 55 Set Watchdog Timer AUX 56 CPU Network Address The DL205 CPUs maintain system parameters in a memory area often referred to as the scratchpad In some cases you may make changes to the system setup that will be stored in system memory For example if you specify a range of Control Relays CRs as retentive these changes are stored NOTE You may never have to use this feature unless you have made changes that affect system memory Usually you ll only need to initialize the system memory if you are changing programs and the old program required a special system setup You can usually change from program to program without ever initializing system memory AUX 54 resets the system memory to the default values You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu The DL205 CPUs have a watchdog timer that is used to monitor the scan time The default value set from the factory i
307. rring to the figure below location V 07 contains a BCD number from 00 05 to 99 99 with an implied decimal point This represents 50 mS to 99 99 seconds This number may be programmed using DirectSOFT32 s PID Setup screen or any other method of writing to V memory It must be programmed before the loop will operate properly Setpoint gt Error Term Loop Control Output gt Calculation Process Variable f Sample Rate V 07 Le a ample Rate XIX XIX BCD 00 05 to 99 99 sec DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation GO ro N a m _ T O Ye A S PID Loop Operation DL250 1 DL260 only PID Loop Effect Since PID loop calculations are a task within the CPU scan activities the use of PID on CPU Scan Time loops will increase the average scan time The amount of scan time increase is proportional to the number of loops used and the sample rate of each loop The execution time for a single loop calculation depends on the number of options selected such as alarms error squared etc The chart to the right gives the range of times you can expect PID Calculation Time Minimum 150 uS Typical 250 uS Maximum 350 uS To calculate scan time increase we also must know or estimate the scan time of the ladder without loops because a fast scan time will increase by a smaller percentage t
308. s 29 6 us 29 6 us 29 6 us 2 P Indir Bit 29 6us 29 6us 29 6us 29 6 us E ANDB _ V Data Reg 2 8 us 2 8 us 2 8 us 2 8 us E V Bit Reg ez 2 8 us 2 8 us 2 8 us 2 8 us O 5 P Indir Data 29 6 us 29 6 us 29 6 us 29 6 us P Indir Bit 29 6us 29 6us 29 6us 29 6 us S ANDNB V Data Reg 2 7 us 2 7 us 2 7 us 2 7 us a V Bit Reg 27us 27us 27us 2 7us Lo P Indir Data 29 6 us 29 6 us 29 6 us 29 6 us 2 P Indir Bit 29 6 us 29 6 us 29 6 us 29 6 us MN OUTB v Data Reg 3 1us 34us 3 1us 34us V Bit Reg 3 1 us 3 4 us 3 1 us 3 4 us P Indir Data 30 3 us 30 7 us 30 3 us 30 7 us P Indir Bit 30 3us 30 7us 30 3us 30 7 us SETB V Data Reg 13 4us 3 4 us 13 4us 3 4 us V Bit Reg 13 4 us 3 4 us 13 4 us 3 4 us P Indir Data 41 1 us 29 1 us 41 1 us 29 1 us P Indir Bit 41 1 us 29 1 us 41 1 us 29 1 us RSTB V Data Reg 13 5 us 1 4 us 13 5 us 1 4 us V Bit Reg 13 5 us 1 4 us 13 5 us 1 4 us P Indir Data 41 3 us 29 1 us 41 3 us 29 1 us P Indir Bit 41 3 us 29 1 us 41 3 us 29 1 us DL205 User Manual 3rd Ed Rev A 08 03 Immediate Instructions Instruction Execution Times Immediate DL230 DL240 DL250 1 DL260 Instructions Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute LDI V
309. s As stages these program sections are active only when they are actually needed by the process Most processes can be organized into a sequence of stages connected by event based transitions Q Isn t a stage really like a software subroutine A No it is very different A subroutine is called by a main program when needed and executes only once before returning to the point from which it was called A stage however is part of the main program It represents a state of the process so an active stage executes on every scan of the CPU until it becomes inactive SM 1d T14 a D Q D D e Q S 3 2 3 a Q What are Stage Bits A A stage bit is a single bit in the CPU s image register representing the active inactive status of the stage in real time For example the bit for Stage 0 is referenced as SO If SO O then the ladder rungs in Stage O are bypassed not executed on each CPU scan If SO 1 then the ladder rungs in Stage 0 are executed on each CPU scan Stage bits when used as contacts allow one part of your program to monitor another part by detecting stage active inactive status Q How does a stage become active A There are three ways e If the Stage is an initial stage ISG it is automatically active at powerup e Another stage can execute a Stage JMP instruction naming this stage which makes it active upon its next occurrence in the program e Aprogram rung can execute a Set Stage Bit instru
310. s 1 and 2 1 Input Output Data Format select write 12 bit 15 bit See Notes 1 and 2 2 Analog Input PV filter write off on 3 SP Input limit enable write disable enable 4 Integral Gain Reset units select write seconds minutes 5 Select Autotune PID algorithm write closed loop open loop 6 Autotune selection write PID Pl only rate 0 7 Autotune start read write autotune force start done 8 PID Scan Clock internal use read Bat 9 Input Output Data Format 16 bit select write not select cz See Notes 1 and 2 16 bit 16 bit O 10 Select separate data format for input and write same separate ate output See Notes 2 and 3 format formats an On 11 Control Output Range write unipolar bipolar a Unipolar Bipolar select Ol See Notes 2 and 3 JO a 12 Output Data Format select write 12 bit 15 bit La See Notes 2 and 3 E 13 Output data format 16 bit select write not select See Notes 2 and 3 16 bit 16 bit 14 15 Reserved for future use Note 1 If the value in bit 9 is 0 then the values in bits O and 1 are read If the value in bit 9 is 1 then the values in bits 0 and 1 are not read and bit 9 defines the data format the range is automatically unipolar Note 2 If the value in bit 10 is 0 then the values in bits 0 1 and 9 define the input and output ranges and data formats the values in bits 11 12 and 13 are not read If the value in bit 10 is 1
311. s 200 ms If the scan time exceeds the watchdog time limit the CPU automatically leaves RUN mode and enters PGM mode The Handheld displays the following message E003 S W TIMEOUT when the scan overrun occurs Use AUX 55 to increase or decrease the watchdog timer value You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu Since the DL240 DL250 1 and DL260 CPUs have an additional communication port you can use the Handheld to set the network address for the port and the port communication parameters The default settings are s Station address 1 s HEX mode e Odd parity You can use this port with either the Handheld Programmer DirectSOFT32 or as a DirectNET communication port The DirectNET Manual provides additional information about communication settings required for network operation NOTE You will only need to use this procedure if you have the bottom port connected to a network Otherwise the default settings will work fine Use AUX 56 to set the network address and communication parameters You can also perform this operation from within DirectSOFT32 by using the PLC Setup sub menu DL205 User Manual 3rd Ed Rev A 08 03 AUX 57 Set Retentive Auxiliary Functions The DL205 CPUs provide certain ranges of retentive memory by default The default ranges are suitable for many applications but you can change them if your
312. s a V memory data register Don t think that you cannot load a bit pattern into these types of registers you can It s just that their primary use is as a data register The following locations are considered as data registers Data Registers DL230 DL240 DL250 1 DL260 Timer Current Values VO V77 VO V177 VO V377 VO V377 Counter Current Values V1000 V1077 V1000 V1177 V1000 V1177 V1000 V1377 User Data Words V2000 V2377 V4000 V4177 V2000 V3777 V4000 V4377 V1400 V7377 V10000 V17777 V400 V777 V1400 V7377 V10000 V35777 V Memory Bit Registers You may recall that some of the discrete points such as X Y C etc are automatically mapped into V memory The following locations that contain this data are considered bit registers Bit Registers DL230 DL240 DL250 1 DL260 Input Points X V40400 V 40407 V40400 V 40407 V40400 V 40437 V40400 V 40477 Output Points Y V40500 V40507 V40500 V40507 V40500 V40537 V40500 V 40577 Control Relays C V40600 V40617 V40600 V40617 V40600 V40677 V40600 V 40777 Timer Status Bits V41100 V41103 V41100 V41107 V41100 V41117 V41100 V 41177 Counter Status Bits V41040 V41143 V41040 V41147 V41040 V41147 V
313. s per step Unused steps can be left blank this is the default entry The discrete output points may be individually assigned as X Y or C types or may be left unused The output pattern may be edited graphically with DirectSOFT32 Whenever the Start input is energized the drum s timer is enabled It stops when the last step is complete or when the Reset input is energized The drum enters the preset step chosen upon a CPU program to run mode transition and whenever the Reset input is energized Drum Parameters Field Data Types Ranges Counter Number aaa 0 177 DL250 1 0 377 DL260 Preset Step bb K 1 16 Timer base cece K 0 99 99 seconds Counts per step dddd K 0 9999 Discrete Outputs Fffff X Y C GX GY see page 3 52 or page 3 53 DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming Drum instructions use four counters in the CPU The ladder program can read the counter values for the drum s status The ladder program may write a new preset E LJ step number to CTA n 2 or a new current step number to CTA n 3 at any time Ue However the other counters are for monitoring purposes only eS o gt 32 Counter Ranges of n Ranges of n Function Counter Bit Function 35 Number DL250 1 DL260 B S CTA n 0 174 0 374 Counts in step CTn Drum Complete CTA n 1 2 175 2 375 Timer value CT n 1 not used CTA n 2 3 176 3 376 Preset
314. se cycle occurs That takes us to the LOWER state turning on output Y2 to command the motor to lower the door We transition back to the DOWN state when the o down limit switch X2 energizes y _ Sx XO X1 I Powerup ses DOWN State a Y ra X0 S1 3 D MP 5 Q ac Push UP State XO S2 x0 4 GP Output equations Y1 RAISE Y2 LOWER SG 82 RAISE State The equivalent stage program is shown to the right For now we will assume the door is SP1 Y1 down at powerup so the desired powerup OUT state is DOWN We make S0 an initial stage xt s3 ISG Stage SO remains active until the door Comp control pushbutton activates Then we S transition JMP to Push UP stage S1 S UP State A push release cycle of the pushbutton takes us through stage S1 to the RAISE stage S2 XO S4 We use the always on contact SP1 to IMP energize the motor s raise command Y1 When the door reaches the fully raised SG position the up limit switch X1 activates This S4 Push DOWN State takes us to the UP Stage S3 where we wait S E 0 S5 until another door control command occurs Y ME In the UP Stage S3 a push release cycle of l s the pushbutton will take us to the LOWER Se Stage S5 where we activate Y2 to command 35 LOWER State the motor to lower the door This continues until the door reaches the down limit switch SP1 Y2 X2 When X2 closes we transition from Stage OUT S5 to the DOWN stage SO where we began xo SO NOTE The only special th
315. sk of personal injury or damage to equipment There are some important operations sequence changes during Run Time Edits 1 If there is a syntax error in the new instruction the CPU will not enter the Run Mode 2 If you delete an output coil reference and the output was on at the time the output will remain on until it is forced off with a programming device 3 Input point changes are not acknowledged during Run Time Edits So if you re using a high speed operation and a critical input comes on the CPU may not see the change wee sh uand Not all instructions can be edited during a Run Time Edit session The following list shows the instructions that can be edited Timer OR ORN Or greater than or equal TMRF Fast timer or a than t tant TMRA Accumulating timer CE E A sa ant ADDD Add data double constant Courier SUBD Subtract data double constant Up Down counter SCENT a Multiply constant ESSE ESE Divide constant STR STRN Store Store not AND ANDN a al CMPD Compare accumulator constant do ANAND ANDD And accumulator constant OR ORN Or Or not AD Or accumulator constan STRE STRNE Store equal Store not equal XORD Exclusive or accumulator constant ANDE ANDNE And equal And not equal LDF O Load discrete points to accumulator ORE ORNE Orequal Or not equal Output accumulator to discrete points STR STRN Store greater than or equal AND ANDN And greater than or e
316. steps 16 segments per loop with indication of ramp soak step number PV curves Select standard linear or square root extract for flow meter input Set Point Limits Specify minimum and maximum setpoint values Process Variable Limits Specify minimum and maximum Process Variable values Proportional Gain Specify gains of 0 01 to 99 99 Integrator Reset Specify reset time of 0 1 to 999 8 in units of seconds or minutes Derivative Rate Specify the derivative time from 0 01 to 99 99 seconds Rate Limits Specify derivative gain limiting from 1 to 20 Bumpless Transfer Automatically initialized bias and setpoint when control switches from manual to automatic Bumpless Transfer II Automatically set the bias equal to the control output when control switches from manual to automatic Step Bias Provides proportional bias adjustment for large setpoint changes Anti windup For position form of PID this inhibits integrator action when the control output reaches 0 or 100 speeds up loop recovery when output recovers from saturation Error Deadband Specify a tolerance plus and minus for the error term SP PV so that no change in control output value is made Alarm Feature Specifications Deadband Specify 0 1 to 5 alarm deadband on all alarms PV Alarm Points Select PV alarm settings for Low low Low High and High high conditions
317. ster so the output remains in its current state DL205 User Manual 3rd Ed Rev A 08 03 Drum Instruction Programming 6 11 Drum Control Techniques S Ye Drum Now we are ready to put together the XO Start 82 Control Inputs concepts on the previous pages and a Outputs Sa demonstrate general control of the drum Jog Setup 3c instruction box The drawing to the right X Reset Into Mask az shows a simplified generic drum 5 instruction Inputs from ladder logic Steps 2 J2 J2 9 control the Start Jog and Reset Inputs 09040609 The first counter bit of the drum CTO for EITC example indicates the drum cycle is CE eE R done O e o LO 6 The timing diagram below shows an arbitrary timer drum input sequence and how the drum responds As the CPU enters run mode it initializes the step number to the preset step number typically this is Step 1 When the Start input goes high the drum begins running looking for an event and or running the count timer depending on the drum type and setup After the drum enters Step 2 Reset turns On while Start is still On Since Reset has priority over Start the drum goes to the preset step Step 1 Note the drum is held in the preset step during Reset and that step does not run respond to events or run the timer until Reset turns off After the drum has entered step 3 the Start input goes off momentarily halting the drum s timer until Start turns on
318. struction Execution Times In This Appendix Introduction Boolean Instructions Comparative Boolean Bit of Word Boolean Instructions Immediate Instructions Timer Counter Shift Register Instructions Accumulator Data Instructions Logical Instructions Math Instructions Differential Instructions Bit Instructions Number Conversion Instructions Table Instructions CPU Control Instructions Program Control Instructions Interrupt Instructions Network Instructions Message Instructions HLL PLUS Instructions Message Instructions DRUM Instructions Clock Calander Instructions MODBUS Instructions ASCII Instructions C 2 Ls E Oc x D 5 ED B XI U Instruction Execution Times Introduction V Memory Data Registers This appendix contains several tables that provide the instruction execution times for the DL205 CPUs One thing you will notice is that many of the execution times depend on the type of data being used with the instruction For example you ll notice that some of the instructions that use V memory locations are further defined by the following items e Data Registers e Bit Registers Some V memory locations are considered data registers For example the V memory locations that store the timer or counter current values or just regular user V memory would be considered a
319. t 15 will be OFF when a E auto transfer from Base Base Not Channel Base Slot is selected Number Slot Used Number Number CPU Base Number Base Channel Number Slot Number DL250 1 Local CPU base 0 0 7 1 8 Local expansion base 1 2 DL260 Local base 0 Local expansion base 1 4 PV Auto Transfer Addr 36 from V memory Option Bit 15 will be ON when auto transfer from V memory is selected Control Output Auto Transfer Addr 37 The definitions for PV Auto Transfer word Addr 36 are listed in the table below for the Transfer from V memory option The ladder logic pointer method can be used with this option to get the analog module s channel values into V memory Refer to the DL205 Analog I O Modules D2 ANLG M for pointer method information MSB LSB 154 0 V Memory Address Hex format Memory Type DL250 1 Range DL260 Range V memory Vv V1400 V7377 V400 V677 V1400 V7377 V10000 V35777 V10000 V17777 The nibble definitions for the Control Output Auto Transfer word Addr 37 are listed in the table below When the Control Output Auto Transfer function is used for any channel on an analog output module the ladder logic pointer method cannot be used for this module Refer to the DL205 Analog I O Modules D2 ANLG M for pointer method information
320. t Mask Word Start MDRMD CTaaa Ff Ef Ep Fff Ff FI Et Control 6 Step Preset Kbb F E F F Uw Fffff Ffff FR Inputs 0 01 sec Count K ccce 15 Ggggg 0 Reset Step Counts Event Eeee O O O OOOO OO OO OF CO OO O Eeeee O O O OOOO OO OO OF CO OO O Es OMS Q Step Number Eee ROMO LOMO OMS Q Eeee O O O OOOO OF O OO OF O OO O Counts per Step Eeee O O O OOOO OO OO OF CO OO G Esc Cl OMS keel ROMO ROMO OO Q Event per step Eeee O O O OOOO OO OO OF CO OO O 10 Kdddd Eeeee O O O O 0 OO OF O OO OF O oooO Output Pattern 11 Kdddd Eeeee CO O O SO CTO GO Do OO Y O Off On 12 Kkkkl Essas OC 13 Kdddd Eeeee O OO OO O O oo oo oo oo o 14 Kdddd Eeeee O OO O O OO OO OO OO OC O O ie Kkiki ES HOMO O Oro OO OO OQO OO i6 iKddddiEceec ECHO COMO ROM e T ECHO T HOMO The Masked Event Drum with Discrete Outputs features sixteen steps and sixteen outputs Drum outputs are logically ANDed bit by bit with an output mask word for each step The Ggggg field specifies the beginning location of the 16 mask words Step transitions occur on timed and or event basis The jog input also advances the step on each off to on transition Time is specified in counts per step and events are specified as discret
321. t the stages Control and Recipe Fahey and arm Monitoring DL205 User Manual 3rd Ed 06 02 7 16 RLL PLUS D E D DL D amp ep RLLPLUS Stage Programming How Instructions Work Inside Stages DL205 User Manual We can think of states or stages as simply dividing up our ladder program as depicted in the figure below Each stage contains only the ladder rungs which are needed for the corresponding state of the process The logic for transitioning out of a stage is contained within that stage It s easy to choose which ladder rungs are active at powerup by using an initial stage type ISG Stage 0 Most instructions work like they do in standard RLL You can think of a stage like a miniature RLL program which is either active or inactive Output Coils As expected output coils in active stages will turn on or off outputs according to power flow into the coil However note the following e Outputs work as usual provided each output reference such as Y3 is used in only one stage e Output coils automatically turn off when leaving a stage However Set and Reset instructions are not undone when leaving a stage An output can be referenced from more than one stage as long as only one of the stages is active at a time e Ifan output coil is controlled by more than one stage simultaneously the active stage nearest
322. t the system Lo power before inspecting the physical wiring 1 First disconnect the system power and check all incoming wiring for loose connections 2 If you are using a separate termination panel check those connections to make sure the wiring is connected to the proper location 3 If the connections are acceptable reconnect the system power and measure the voltage at the base terminal strip to insure it is within specification If the voltage is not correct shut down the system and correct the problem 4 If all wiring is connected correctly and the incoming power is within the specifications required the base power supply should be returned for repair Faulty CPU There is not a good check to test for a faulty CPU other than substituting a known good one to see if this corrects the problem If you have experienced major power surges it is possible the CPU and power supply have been damaged If you suspect this is the cause of the power supply damage a line conditioner which removes damaging voltage spikes should be used in the future fad o 35 oO c3 To D 3 nD D O Q Cp J O DL205 User Manual 3rd Ed Rev A 08 03 9 12 Maintenance and Troubleshooting D amp o 00 cc On 52 Faj ES5 52 gt Le oO Device or Module causing the Power Supply to Shutdown Power Budget Exceeded It is possible a faulty module or external device using the system 5
323. ta Reg 29 9 us 29 9 us 29 9 us 29 9 us V Bit Reg 29 9 us 29 9 us 29 9 us 29 9 us K Constant 27 7us 27 7us 27 7 us 27 7 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0 us STRNE 1st 2nd V Data Reg V Data Reg 77 us 13 8 us 46 us 16 2us 7 6us 7 6 us 7 6 us 7 6 us V Bit Reg 158us 13 8us 136us 16 2us 7 6us 7 6 us 7 6 us 7 6 us K Constant 57 us 13 8 us 46 us 16 2 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 141 us 111 0us 30 2us 30 2us 30 2us 30 2 us P Indir Bit 235us 115 0 us 30 2us 30 2us 30 2us 30 2 us V Bit Reg V Data Reg 158us 13 8us 135us 16 2us 7 6us 7 6 us 7 6 us 7 6 us V Bit Reg 240us 138us 225us 16 2us 7 6us 7 6 us 7 6 us 7 6 us K Constant 139 us 138us 135us 16 2 us 4 8 us 4 8 us 4 8 us 4 8 us P Indir Data 231us 111 0us 30 2us 30 2us 30 2us 30 2 us P Indir Bit 324us 115 0us 30 2 us 30 2us 30 2us 30 2 us P Indir Data V Data Reg 30 3 us 30 3us 30 3us 30 3 us V Bit Reg LL 30 3 us 30 3us 30 3us 30 3 us K Constant 274us 27 4us 27 4us 27 4 us P Indir Data 51 0us 51 0us 51 0us 51 0 us P Indir Bit 51 0us 51 0us 51 0us 51 0us P Indir Bit V Data Reg 30 3 us 30 3 us 30 3 us 30 3 us V Bit R
324. tain environments The user may need to provide shielding or other measures to eliminate the interference DL205 User Manual 3rd Ed Rev A 08 03
325. ted by the handheld programmer while the CPU MODE SWITCH mode switch was in a position other than the TERM position DL240 250 1 260 E526 The handheld programmer is in the OFFLINE mode To change to the OFF LINE ONLINE mode use the MODE the key E527 The handheld programmer is in the ON LINE mode To change to the OFF ON LINE LINE mode use the MODE the key E528 The operation attempted is not allowed during a Run Time Edit CPU MODE E540 The CPU has been password locked To unlock the CPU use AUX82 with the CPU LOCKED password E541 The password used to unlock the CPU with AUX82 was incorrect WRONG PASSWORD E542 The CPU powered up with an invalid password and reset the password to PASSWORD RESET 00000000 A password may be re entered using AUX81 E601 Attempted to enter an instruction which required more memory than is MEMORY FULL available in the CPU E602 A search function was performed and the instruction was not found INSTRUCTION MISSING E604 A search function was performed and the reference was not found REFERENCE MISSING E610 The application program has referenced an I O module as the incorrect type BAD I O TYPE of module E620 An attempt to transfer more data between the CPU and handheld OUT OF MEMORY programmer than the receiving device can hold E621 An attempt to write to a non blank EEPROM was made Erase the EEPROM EEPROM NOT and then retry the write BLANK E622 A data transfer was attempted with no EEPROM
326. tep which is step 4 shown in CTA13 If we have programmed step 4 to have 3000 counts the step is over half completed CTA11 is the count timer shown in units of 0 01 seconds So each least significant digit change represents 0 01 seconds The value of 200 means you have been in the current count 1528 for 2 seconds 0 01 x 100 Finally CTA12 holds the preset step value which was programmed into the drum instruction When the drum s Reset input is active it presets to step 1 in this case The value of CTA12 and CTA13 can be written to in ladder logic Counter bit CT10 turns on when the drum cycle is complete and turns off when the drum is reset DL205 User Manual 3rd Ed Rev A 08 03 6 7 Drum Instruction Programming Last Step The last step in a drum sequence may be any step number since partial drums are Completion valid Refer to the following figure When the transition conditions of the last step are satisfied the drum sets the counter bit corresponding to the counter named in the drum instruction box such as CTO Then it moves to a final drum complete state The drum outputs remain in the pattern defined for the last step including any output mask logic Having finished a drum cycle the Start and Jog inputs have no effect at this point The drum leaves the drum complete state when the Reset input becomes active or on a program to run mode transition It resets the drum complete bit such as CTO and the
327. term receives the same error signal value Setpoint gt Error Term Loop Calculation P I i ar gt Control Output _ Process Variable The role of the P I and D terms in the control task are as follows s Proportional the proportional term simply responds proportionally to the current size of the error This loop controller calculates a proportional term value for each PID calculation When the error is zero the proportional term is also zero e Integral the integrator or reset term integrates Sums the error values Starting from the first PID calculation after entering Auto Mode the integrator keeps a running total of the error values For the position form of the PID equation when the loop reaches equilibrium and there is no error the running total represents the constant output required to hold the current position of the PV e Derivative the derivative or rate term responds to change in the current error value from the error used in the previous PID calculation Its job is to anticipate the probable growth of the error and generate a contribution to the output in advance The P I and D terms work together as a team To do that effectively they will need some additional instructions from us The figure below shows the P I and D terms contain programmable gain values kp ki and kd respectively The values reside in the loop table in the
328. th ends of the shield for analog circuits provides the perfect electrical environment for the twisted pair cable as the loop consists of signal and return in a perfectly balanced circuit arrangement with connection to the common of the input circuitry made at the module terminals RS232 cables are handled in the same way RS422 twin twisted pair and RS485 single twisted pair cables also require a OV link which has often been provided in the past by the cable shield It is now recommended that you use triple twisted pair cabling for RS422 links and twin twisted pair cable for RS485 links This is because the extra pair can be used as the OV inter system link With loop DC power supplies earth grounded in both systems earth loops are created in this manner via the inter system Ov link The installation guides encourage earth loops which are maintained at a low impedance by using heavy equi potential bond wires To account for non European installations using single end earth grounds and sites with far from ideal earth ground characteristics we recommend the addition of 100 ohm resistors at each 0V link connection in network and communications cables Last Slave Slave n Master TXD OV RXD TXD OV RXD RXD OV TXD Fee FT rl 1002 1002 J E E 1002 Termination Termination When you run cables between PLC items within an en
329. the PV is stable and in the middle of a safe range 2 Try to choose a time when the process will have negligible external disturbances Then induce a sudden 10 step change in the control value 3 Record the rise or fall time of the PV time between 10 to 90 points 4 Divide the recorded rise or fall time by 10 This is the initial sample rate you can use to begin tuning your loop Suu 10 of full output range 90 10 a Rise Time Sample A RER Rate In the figure above suppose the measured rise time response of the PV was 25 seconds The suggested sample rate from this measurement will be 2 5 seconds For illustration the sample rate time line shows ten samples within the rise time period These show the frequency of PID calculations as the PV changes values Of course the sample rate and PID calculations are continuous during operation NOTE An excessively fast sample rate will diminish the available resolution in the PV Rate of Change Alarm because the alarm rate value is specified in terms of PV AE doo did g C D O1 L ms g Fe o O G El change per sample period For example a 50 mS sample rate means the smallest PV rate of change we can detect is 20 PV counts least significant bit counts per second or 1200 LSB counts per minute Programming the The Loop Parameter table for each loop has data locations for the sample rate Sample Rate Refe
330. the bottom of the program determines the final output status during each scan So use the OROUT instruction instead when you want multiple stages to have a logical OR control of an output One Shot or PD coils Use care if you must use a Positive Differential coil in a stage Remember the input to the coil must make a 0 1 transition If the coil is already energized on the first scan when the stage becomes active the PD coil will not work This is because the 0 1 transition did not occur PD coil alternative If there is a task which you want to do only once on 1 scan it can be placed in a stage which transitions to the next stage on the same scan Counter When using a counter inside a stage the stage must be active for one scan before the input to the counter makes a 0 1 transition Otherwise there is no real transition and the counter will not count The ordinary Counter instruction does have a restriction inside stages it may not be reset from other stages using the RST instruction for the counter bit However the special Stage Counter provides a solution see next paragraph Stage Counter The Stage Counter has the benefit that its count may be globally reset from other stages by using the RST instruction It has a count input but no reset input This is the only difference from a standard counter instruction Drum Realize the drum sequencer is its own process and is a different programming method than stage programming
331. these AUX Functions are designed specifically for the Handheld Programmer setup so they will not be needed or available with the DirectSOFT32 package Even though this Appendix provides many examples of how the AUX functions operate you should supplement this information with the documentation for your choice of programming device Note the Handheld Programmer may have additional AUX functions that are not supported with the DL205 CPUs AUX Function and Descrip 230 240 250 1 260 AUX Function and Description 230 240 250 1 260 HPP ten AUX 6 Handheld Programmer Configuration rom MEL 61 Show Revision Numbers ll Y 21 Check Program Viv Y Y 62 Beeper On Off x 1x Xx x Y el dai IA 4 65 Run Self Diagnostics x xX x x Y 23 Clear Ladder Range Viv Y Y AUX 7 EEPROM Operations 24 Clear All Ladders Viv Y Y 71 Copy CPU memory to x 1x K Xx Y AUX 3 V Memory Operations HPP EEPROM 31 Clear V Memory Viv Y Y 72 Write HPP EEPROM to x xX x x Y AUX 4 I O Configuration GPU 41 Show I O Configuration Viv Y Y is a ale a ies x x S er HS AE le 74 Blank Check HPP EE x fe x EAE 44 Power up I O Configura Y Y Y Y PROM tion Check 75 Erase HPP EEPROM xix x x vx 45 Select Configuration Viv Y Y 76 Show EEPROM Type e x x x Y 46 Co
332. tinuously Loop Configuration and Monitoring TT ee a Y Manufacturing Process Loop Calculation S CT rt Be gz ge o 1324 524 524 Ic T rm CT OT Control Output Process Variable The personal computer shown is used to run DirectSOFT32 the PLC programming software for DirectLOGIC programmable controllers The software features a forms based editor to configure loop parameters It also features a PID loop trending screen which will be helpful during the loop tuning process Details on how to use that software are in the DirectSOFT32 Manual DL205 User Manual 3rd Ed Rev A 08 03 EE doo Aid O N O1 L g Fe o gt La GC gt ES PID Loop Operation DL250 1 DL260 only Loop Setup Parameters PID Loop Operation GO Q N a m _ T O Ye A S Loop Table and Number of Loops The DL250 1 and DL260 CPUs gets its PID loop processing instructions only from tables in V memory A PID instruction type in RLL does not exist for the DirectLogic PLCs Instead the CPU reads setup parameters from reserved V memory locations Shown in the table below you must program a value in V7640 to point to the main loop table Then you will need to program V7641 with the number of loops you want the CPU to calculate V7642 contains error flags w
333. to either turn off or to hold its last output state on the transition to TEST PGM mode You can use AUX 58 on the Handheld Programmer to select the action for each individual output This feature is also available via a menu option within DirectSOFT32 The following diagram shows the differences between RUN and TEST RUN modes RUN Mode to PGM Mode xo X2 Yo Ga X1 X3 X4 Outputs are y L OFF Status on final scan X10 xo X2 bal A la x1 X3 X4 END v 1 7 en 17 uE X10 Y1 2 3 CD TEST RUN to TEST PGM oe XO X2 YO es CG O 38 X1 X3 X4 Hold YO ON El Y X10 y1 Let Y1 turn d OFF En Before you decide that Test Mode is the perfect choice remember the DL205 CPUs also allow you to edit the program during Run Mode The primary difference between the Test Modes and the Run Time Edit feature is you do not have to configure each individual I O point to hold the output status When you use Run Time Edits the CPU automatically maintains all outputs in their current states while the program is being updated DL205 User Manual 3rd Ed Rev A 08 03 Maintenance and Troubleshooting Special There are several instructions that can be used to help you debug your program Instructions during machine startup operations e END e PAUSE e STOP END Instruction If you need a way to quickly disable part of the program insert an
334. truction Execution Times Tode UNC a Le cscs 2 soci ss A cs V Memory Data Registers nn ti ER HRE RETER Ra ae ee oe Wee V Memory Bit Registers cortas ame gate ases e mulet nn de ef CR aeRO AS How to Read the Tables 4 eee e e e e erednrennn etes mnt Lees Boolean La ES A Te 10 SR Uae eS fe RTT Comparative Boolean 2 o NS A me manne oe Bit of Word Boolean Instructions o oococococcnncn Immediate Instructions 2 58 x s e ren ai me die der ie nie laps ait Timer Counter Shift Register Instructions Table of Contents Accumulator Data Instructions 0 x x x eens C 17 Logical Instructions 11 ss s e c c x x x x x x x x e e K K A desde C 19 Math Instructions 258 cc recreate ee beak a C 21 Differential Instructions ccs x x s c x x A a sais OR eee Gares ns ie sde C 24 Bit UASURUCTIONS 00 A bn C 25 Number Conversion Instructions 0 x x x x x e e eee eee eee eee eee C 26 Table INSTUCIONS ii da ate C 27 CPU Control Instructions io a A ee ee as C 29 Program Control Instructions void rs e ee woven eevee se C 29 Interrupt Instr ctions 047 00 sai A in TAI ee R RRR N ee E C 30 Network Instructions s s x x x e K x x x e K K x pian las C 30 Intelligent VO Instructions s x x x x e e e e e x x x x K K K K eee eee eee eee eee eens C 30 Message Instructions ins x x x s x K K K K Pasta saree ae Saar nee ea C 31 REEPLEUS INSTTUCHONS c 9 e 9 RT R RT A eed ed C 31 DRUM INS
335. ts the keystrokes for entering the drum example on the G LD previous page NOTE Drum editing requires Handheld Programmer firmware SE version 1 8 or later SE 177 cu Cn Handheld Programmer Keystrokes O Si Start on gt A g ENT NOTE You may use the NXT and PREV keys A to skip past entries for unused outputs or steps B Jog str gt 1 at C Reset sm gt gt ENT E D R U M A Drum Inst SHFT 3 on isa orst gt 0 ENT Preset Step DEF K0001 NEXT Handheld Programmer Keystrokes cont d Time Base DEF K0000 G Z E a NExT 7 1 Cc H 1 F DEF 0000 SHFT 2 7 NEXT DEF K0000 5 NEXT DEF 0000 SHET 3 B i a o NEXT DEF K0000 c p A o NEXT DEF 0000 SHFT ug P 4 NEXT DEF Koo IE NEXT DEF 0000 SHFT Xis E 4 NEXT DEF K0000 E 4 F 3 NEXT DEF 0000 SHFT es E 5 NEXT DEF K0000 G i l A o NEXT Y G J C D DEF 0000 SHFT his 6 NEXT DEF K0000 9 2 3 PS DEF 0000 SHET 3 E 4 NEXT DEF K0000 G i c 3 A o NEXT DEF 0000 Shen S NEXT Counts Der Koo a ee E NEXT Outputs Step Y A B c A A DEF
336. tting 1 Description Read Write Bit 0 Bit 1 O Manual Mode Loop Operation request write 0 1 request 1 Automatic Mode Loop Operation re write 0 1 quest request 2 Cascade Mode Loop Operation request write 0 1 request 3 Bumpless Transfer select write Mode Mode II 4 Direct or Reverse Acting Loop select write Direct Reverse 5 Position Velocity Algorithm select write Position Velocity 6 PV Linear Square Root Extract select write Linear Sq root 7 Error Term Linear Squared select write Linear Squared 8 Error Deadband enable write Disable Enable 9 Derivative Gain Limit select write Off On 10 Bias Integrator Freeze select write Off On 11 Ramp Soak Operation select write Off On Ox 12 PV Alarm Monitor select write Off On DO 13 PV Deviation alarm select write Off On aR 14 PV rate of change alarm select write Off On FO 15 Loop mode is independent from CPU write Loop with Loop oe mode when set CPU mode independent OF of CPU mode Zz DL205 User Manual 3rd Ed Rev A 08 03 PID Loop Operation DL250 1 DL260 only PID Mode Setting 2 The bit definitions for PID Mode Setting 2 word Addr 01 are listed in the following Bit Descriptions table More information about the use of this word is available later in this chapter Addr 01 Bit PID Mode Setting 2 Description Read Write Bit 0 Bit 1 0 Input PV and Control Output Range write unipolar bipolar Unipolar Bipolar select See Note
337. ty Modules H2 CTRIO 2 3 oz 65g D2 CTRINT 2 3 oz 65g H2 ECOM 1 6 oz 45g H2 ECOM F 5 5 oz 156g H2 ERM 1 6 oz 45g H2 ERM F 5 5 oz 156g D2 DCM 3 8 oz 109g D2 EM 2 3 oz 65g D2 CM 1 8 oz 50g F2 08SIM 2 1 oz 60g D2 08CDR 3 5 oz 100g DL205 User Manual 3rd Ed Rev A 08 03 PLC Memory In This Appendix DL205 PLC Memory FA PLC Memory DL205 PLC Memory When designing a PLC application it is important for the PLC user to understand the different types of memory in the PLC Two types of memory are used by the DL205 CPU RAM and EEPROM This memory can be configured by the PLC user as either retentive or non retentive Retentive memory is memory that is configured by the user to maintain values through a power cycle or a PROGRAM to RUN transition Non retentive memory is memory that is configured by the PLC user to clear data after a power cycle ora PROGRAM to RUN transition The retentive ranges can be configured with the handheld programmer using AUX 57 or DirectSOFT32 PLC Setup The contents of RAM memory can be written to and read from for an infinite number of times but RAM requires a power source to maintain the contents of memory The contents of RAM are maintained by the internal power supply 5VDC only while the PLC is powered by an external source normally 120VAC When power to the PLC is turned off the contents of RAM can be maintained b
338. uction INSTRUCTION E494 The BLK instruction is not followed by a BEND instruction MISSING BEND INSTRUCTION E499 Invalid PRINT instruct usage Quotations and or spaces were not entered or PRINT entered incorrectly INSTRUCTION E501 An invalid keystroke or series of keystrokes was entered into the handheld BAD ENTRY programmer E502 An invalid or out of range address was entered into the handheld BAD ADDRESS programmer E503 An invalid instruction was entered into the handheld programmer BAD COMMAND E504 An invalid value or reference number was entered with an instruction BAD REF VAL E505 An invalid instruction was entered into the handheld programmer INVALID INSTRUCTION E506 An invalid operation was attempted by the handheld programmer INVALID OPERATION E520 An operation which is invalid in the RUN mode was attempted by the BAD OP RUN handheld programmer E521 An operation which is invalid in the TEST RUN mode was attempted by the BAD OP TRUN handheld programmer E523 An operation which is invalid in the TEST PROGRAM mode was attempted BAD OP TPGM by the handheld programmer E524 An operation which is invalid in the PROGRAM mode was attempted by the BAD OP PGM handheld programmer DL205 User Manual 3rd Ed Rev A 08 03 B 8 DL205 Error Codes ng XD Ke se Ou 20 ii DL205 Error Code Description E525 An operation was attemp
339. uction Stage bits are 0 or 1 determining the inactive active status of the corresponding stages A stage JMP has the following results When the JMP is executed the remainder of the current stage s rungs are executed even if they reside past under the JMP instruction On the following scan that stage is not executed because it is inactive e The Stage named in the Stage JMP instruction will be executed upon its next occurrence If located past under the current stage it will be executed on the same scan If located before above the current stage it will be executed on the following scan Q How can know when to use stage JMP versus a Set Stage Bit or Reset Stage Bit A These instructions are used according to the state diagram topology you have derived e Use a Stage JMP instruction for a state transition moving from one state to another e Use a Set Stage Bit instruction when the current state is spawning a new parallel state or stage sequence or when a supervisory state is starting a state sequence under its command e Use a Reset Stage Bit instruction when the current state is the last state in a sequence and its task is complete or when a supervisory state is ending a state sequence under its command Q What is an initial stage and when do use it A An initial stage ISG is automatically active at powerup Afterwards it works like any other stage You can have multiple initial stages if required Us
340. uction by changing the transition condition to the DOWN state to X2 AND NOT X93 This ensures the obstruction event has the priority The modifications we must make to the LOWER Stage S5 logic are shown to the right The first rung remains unchanged The second and third rungs implement the transitions we need Note the opposite relay contact usage for X3 which ensures the stage will execute only one of the JMP instructions DL205 User Manual 3rd Ed 06 02 e LOWER State SP1 Y2 OUT x2 x3 to DOWN SO 1 UMP X3 to Push UP s Camp 7 15 RLLPLUS Stage Programming Stage Program Design Considerations Stage Program The examples so far in this chapter used one self contained state diagram to Organization represent the main process However we can have multiple processes implemented in stages all in the same ladder program New stage programmers sometimes try to turn a stage on and off each scan based on the false assumption that only one stage can be on at a time For ladder rungs that you want to execute each scan put them in a stage that is always on The following figure shows a typical application During operation the primary manufacturing activity Main Process Powerup Initialization E Stop and Alarm Monitoring and Operator Interface are all running At powerup four initial stages shown begin operation Main Process Goad 186 D Ge Powerup Initialization E Stop and Alarm Mo
341. ule in slot 4 of the local base is busy Slot 4 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP131 Com error on when the communication module in slot 4 of the local base has Slot 4 encountered a communication error SP132 Module busy on when the communication module in slot 5 of the local base is busy Slot 5 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP133 Com error on when the communication module in slot 5 of the local base has Slot 5 encountered a communication error SP134 Module busy on when the communication module in slot 6 of the local base is busy Slot 6 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP135 Com error on when the communication module in slot 6 of the local base has Slot 6 encountered a communication error SP136 Module busy on when the communication module in slot 7 of the local base is busy Slot 7 transmitting or receiving You must use this relay with the RX or WX instructions to prevent attempting to execute a RX or WX while the module is busy SP137 Com error on when the communication module in slot 7 of the local base has Slot 7 encountered a communication error DL205 User M
342. undation for designing an effective control system A good process recipe will do the following e Identify all relevant Process Variables such as temperature pressure or flow rates etc which need precise control e Plot the desired Setpoint values for each process variables for the duration of one process cycle This simply means choosing the method the machine will use to maintain control over the Process Variable s to follow their Setpoints This involves many issues and trade offs such as energy efficiency equipment costs ability to service the machine during production and more You must also determine how to generate the Setpoint value during the process and whether a machine operator can change the SP Assuming the control strategy is sound it is still crucial to properly size the actuators and properly scale the sensors e Choose an actuator heater pump etc which matches the size of the load An oversized actuator will have an overwhelming effect on your process after a SP change However an undersized actuator will allow the PV to lag or drift away from the SP after a SP change or process disturbance e Choose a PV sensor which matches the range of interest and control for our process Decide the resolution of control you need for the PV such as within 2 deg C and make sure the sensor input value provides the loop with at least 5 times that resolution at LSB level However an over sensitive sensor can
343. unter current value equals the value in V3746 SP610 Current target value on when the counter current value equals the value in V3750 SP611 Current target value on when the counter current value equals the value in V3752 SP612 Current target value on when the counter current value equals the value in V3754 SP613 Current target value on when the counter current value equals the value in V3756 SP614 Current target value on when the counter current value equals the value in V3760 SP615 Current target value on when the counter current value equals the value in V3762 SP616 Current target value on when the counter current value equals the value in V3764 SP617 Current target value on when the counter current value equals the value in V3766 DL205 User Manual 3rd Ed Rev A 08 03 DL205 Product Weights In This Appendix Product Weight Table 7 ta uo X D 5 eS 29S Q5 Io pun am DL205 Product Weights Product Weight Table CPUs Weight DC Output Modules D2 230 2 8 oz 80g D2 04TD1 2 8 oz 80 D
344. ur ladder program to verify it is not writing to the SP location V 02 in the loop table A quick way to do this is to temporarily place an end coil at the beginning of your program then go to PLC Run Mode Q The SP and PV values I enter with DirectSOFT32 work okay but these values do not work properly when the ladder program writes the data A The PID View in DirectSOFT lets you enter SP PV and Bias values in decimal and displays them in decimal for your convenience For example when the data format is 12 bit unipolar the values range from 0 to 4095 However the loop table actually requires these in hex so DirectSOFT32 converts them for you The values in the table range from 0 to FFF for 12 bit unipolar format Q The loop seems unstable and impossible to tune no matter what gains use A Check the following for possible causes Bibliography The loop sample time is set too long Refer to the section near the front of this chapter on selecting the loop update time The gains are too high Start out by reducing the derivative gain to zero Then reduce the integral gain and the proportional gain if necessary There is too much transfer lag in your process This means the PV reacts sluggishly to control output changes There may be too much distance between actuator and PV sensor or the actuator may be weak in its ability to transfer energy into the process There may be a process disturbance that is over powering t
345. urs All rungs in the stage still finish executing during the current scan even if there are other rungs in the stage below the jump instruction e The reset will be in effect on the following scan so the stage that executed the jump instruction previously will be inactive and bypassed e The stage bit of the stage named in the Jump instruction will be set immediately so the stage will be executed on its next occurrence In the left program shown below stage S1 executes during the same scan as the JMP S1 occurs in SO In the example on the right Stage S1 executes on the next scan after the JMP S1 executes because stage S1 is located above stage SO SG SG Executes on next SO S1 scan after Jmp Q d i OUT SG Executes on same SG S1 scan as Jmp SO S1 YO ae ae gt OUT Note Assume we start with Stage 0 active and stage 1 inactive for both examples DL205 User Manual 3rd Ed 06 02 7 8 RLL PLUS D E D DL D amp ep RLLPLUS Stage Programming Stage Program Example Toggle On Off Lamp Controller A 4 State Process Powerup In the process shown to the right we use an ordinary momentary pushbutton to control a light bulb The ladder program will latch the switch input so that we will push and release to turn on the light push and release again to turn it off sometimes called toggle function Sure
346. us 0 9 us 2 a V Bit Reg 483 us 10 6us 385 us 84us 266 1us O 9us 266 1us 0 9 us 32 K Constant 487 us 8 4 us 334 us 84us 286 9us 0 9us 286 9 us 0 9 us 5 P Indir Data 401 us 8 4us 290 0us 0 9us 290 0us 0 9 us 4O P Indir Bit 461 us 84us 290 0us 0 9us 290 0us 0 9 us 3 D MULD V Data Reg 839 1 us 0 9 us 839 1 us 0 9 us V Bit Reg _ _ 839 1 us 0 9us 839 1 us 0 9 us P Indir Data _ ER 863 1 us 0 9us 863 1 us 0 9 us P Indir Bit 863 1 us 0 9us 863 1 us 0 9 us DIV V Data Reg 909 us 10 6 us 601 us 84us 3639us 0 9us 363 9us 0 9 us V Bit Reg 1108 us 10 6 us 675 us 84us 363 9us 0 9us 363 9us 0 9 us K Constant 699 us 8 4 us 573 us 84us 384 4us 0 9us 384 4us 0 9 us P Indir Data 691 us 8 4us 419 8us 0 9us 419 8 us 0 9 us P Indir Bit 771 us 84us 419 8us 0 9us 419 8us 0 9 us DIVD V Data Reg 398 3 us 0 9us 398 3us 0 9 us V Bit Reg en 398 3 us 0 9us 398 3us 0 9 us P Indir Data E _ 390 9 us 0 9us 390 9 us 0 9 us P Indir Bit 390 9 us 0 9us 390 9us 0 9 us INC V Data Reg 48 5 us 1 0 us 48 5 us 1 0 us V Bit Reg S 48 5 us 1 0 us 48 5 us 1 0 us P Indir Data c En _ 74 7 us 1 0us 74 7 us 1 0 us P Indir Bit 74 7 us 10us 74 7 us 1 0 us DEC V Data Reg 47 5 us 1 0 us 47 5 us 1 0 us V Bit Reg 47 5 us 1 0 us 47 5 us 1 0 us P Indir Data 71 5 us 1 0us 71 5 us 1 0 us P I
347. us 2 7 us 252 0 us 2 7 us P Indir Data 271 3us 3 4us 271 3us 3 4 us P Indir Bit 271 3us 3 4us 271 3us 3 4 us Intelligent 1 0 Instructions Network Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute RD V Data Reg TBD TBD TBD TBD 385 7 us 1 2us 385 7 us 1 2 us V Bit Reg 385 7 us 1 2us 385 7us 1 2 us WT V Data Reg TBD TBD TBD TBD 385 6 us 1 2us 385 6us 1 2 us V Bit Reg 385 6 us 1 2us 385 6us 1 2 us DL205 User Manual 3rd Ed Rev A 08 03 Message Instructions C 31 Instruction Execution Times Message Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute FAULT V Data Reg 171 us 8 4 us 23176 8 4 us 84 9 us 1 1 us 84 9 us 1 1 us V Bit Reg 253 us 8 4 us us 8 4 us 84 9 us 1 1 us 84 9 us 1 1 us K Constant 2798 us 8 4 us 23206 8 4 us 80 8 us 1 2 us 80 8 us 1 2 us us 29108 us DLBL K Ous Ous Ous Ous Ous Ous Ous Ous NCON K O us O us O us O us O us O us O us O us ACON K Ous Ous Ous Ous Ous Ous O us O us PRINT Text Data 36 3 us 1ius 363us 1 1us RLLPLUS Instructions RLL PLUS Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execut
348. us 3 7us 3 7us 3 7us MLR K 0 7 18us 13 us 12 7us 12 7us 3 5 us 3 5 us 3 5 us 3 5 us N 1 to 7 24xN 2 4xN 2 3 xN 2 3 XN DL205 User Manual 3rd Ed Rev A 08 03 C 30 Ls Er Oc x 55 ED B XI U Instruction Execution Times Interrupt Instructions Interrupt Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute ENI None 9 us 5 us 10 5 us 8 4 us 5 0 us 1 0 us 5 0 us 1 0 us DISI None 8 us 5us 11 us 8 4 us 5 7 us 0 9 us 5 7 us 0 9 us INT 0 0 7 O us O us O us O us O us O us O us O us IRT None 1 6 us O us 8 us O us 1 3 us O us 1 3 us O us IRTC None 0 5 us O us Network Instructions Network Instructions DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute RX X Y C T CT SP S TBD TBD 2513us 1 1us 2513us 1 1us V Data Reg 2513us 1 1us 251 3us 1 1 us V Bit Reg 251 3us 1 1us 251 3us 1 1 us P Indir Data 270 3us 19us 270 3us 1 9 us P Indir Bit 270 3us 19us 270 3us 1 9us WX X Y C T CT SP S TBD TBD 252 0 us 2 7 us 252 0us 2 7 us V Data Reg 252 0 us 2 7 us 252 0us 2 7 us V Bit Reg 252 0
349. us SUBS None 97 5 us 1 0 us MULS None 342 5 us 1 0us DIVS None 467 3 us 1 0 us ADDBS None 24 3 us 1 0 us SUBBS None 23 7 us 1 0 us MULBS None 11 7 us 1 0 us DIVBS None 29 7 us 1 0 us DL205 User Manual 3rd Ed Rev A 08 03 C 24 Instruction Execution Times Math Instructions cont DL230 DL240 DL250 1 DL260 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not tion Execute Execute Execute Execute SQRTR None 87 9 us 1 0 us SINR None NN 2268 us 10us COSR None 213 1us 10us TANR None 285 5 us 1 0 us ASINR None E 489 8 us 1 0 us ACOSR None NN ES 508 3 us 1 0 us ATANR None 317 1 us 1 0 us ao d Differential Instructions 25 x O s z A E 3 Differential Instructions DL230 DL240 DL250 1 DL260 D 2 Instruc Legal Data Types Execute Not Execute Not Execute Not Execute Not qu tion Execute Execute Execute Execute w PD X Y C 13 5us 13 5us 15 9us 146us 14 4us 14 4us 14 4us 144us STRPD X Y C S T CT 5 4 us 5 4 us 5 4 us 5 4 us STRND X Y C S T CT
350. ussed next does not affect the Rate of Change Alarm DL205 User Manual 3rd Ed Rev A 08 03 8 58 PID Loop Operation DL250 1 DL260 only PID Loop Operation gt GO o N a m _ T O Ye A S PV Alarm Hysteresis The PV Absolute Value Alarm and PV Deviation Alarm are programmed using threshold values When the absolute value or deviation exceeds the threshold the alarm status becomes true Real world PV signals have some noise on them which can cause some fluctuation in the PV value in the CPU As the PV value crosses an alarm threshold its fluctuations cause the alarm to be intermittent and annoy process operators The solution is to use the PV Alarm Hysteresis feature The PV Alarm Hysteresis amount is programmable from 1 to 200 hex When using the PV Deviation Alarm the programmed hysteresis amount must be less than the programmed deviation amount The figure below shows how the hysteresis is applied when the PV value goes past a threshold and descends back through it Alarm threshold PV Alarm t Hysteresis T Loop Table V 22 XXXX PV Alarm Hysteresis Alarm Programing Error The hysteresis amount is applied after the threshold is crossed and toward the safe zone In this way the alarm activates immediately above the programmed threshold value It delays turning off until the PV value has returned through the threshold by the hysteresis
351. v A 08 03 Auxiliary Functions ES AUX 5C The DL240 DL250 1 and DL260 CPU will automatically log any system error codes Display Error and custom messages created with the FAULT instructions The CPU logs the error History code date and time the error occurred There are two separate tables that store this information e Error Code Table the system logs up to 32 errors in the table When an error occurs the errors already on the table are pushed down and the most recent error is loaded into the top slot If the table is full when an error occurs the oldest error is pushed out erased of the table e Message Table the system logs up to 16 messages in this table When a message is triggered the messages already stored in the table are pushed down and the most recent message is loaded into the top slot If the table is full when an error occurs the oldest message is pushed out erased of the table The following diagram shows an example of an error table for messages gt S gt oO lt 3 da Jx 2 gt Le ao Date Time Message 1993 05 26 08 41 51 11 Conveyor 2 stopped 1993 04 30 17 01 11 56 Conveyor 1 stopped 1993 04 30 17 01 11 12 Limit SW1 failed 1993 04 28 03 25 14 31 Saw Jam Detect You can use AUX Function 5C to show the error codes or messages You can also view the errors and messages from within DirectSOFT32 by using the PLC Diagnostics sub menu DL
352. vious no change CTA n 3 Current Step Initialize Preset Step Use Previous no change Applications with relatively fast drum cycle times typically will need to be reset on powerup using the non retentive option Applications with relatively long drum cycle times may need to resume at the previous point where operations stopped using the retentive case The default option is the retentive case This means that if you initialize scratchpad V memory the memory will be retentive g Ue fo 82 o 32 3c eel WO O 5 DL205 User Manual 3rd Ed Rev A 08 03 D E E D e a Drum Instruction Output Mask Operation Drum Instruction Programming Sometimes we need more flexibility in controlling outputs than standard drum output patterns provide The output mask feature lets you disable drum pattern control of selected outputs on selected steps allowing those outputs to be controlled by other ladder logic Two of the four drum instructions have the output mask feature s MDRMD Masked Event Drum with Discrete Outputs s MDRMW Masked Event Drum with Word Output The output mask is simply a bit by bit enable disable control for the drum writing to the image register of the sixteen outputs Refer to the figure below The image register contains the official current status of all I O points At the end of each PLC scan the CPU uses the image register status to write to the actual output
353. we could buy a mechanical switch with the alternate on off action built in However this example is educational and also fun Next we draw the state transition diagram A typical first approach is to use XO for both transitions like the example shown to the right However this is incorrect please keep reading Inputs Powerup Outputs Ladder Program X Ta Output equation YO ON Note that this example differs from the motor example because now we have only one pushbutton When we press the pushbutton both transition conditions are met We would transition around the state diagram at top speed If implemented in Stage this solution would flash the light on or off each scan obviously undesirable The solution is to make the the push and the release of the pushbutton separate events Refer to the new state transition diagram below At powerup we enter the OFF state When switch XO is pressed we enter the Press ON state When it is released we enter the ON state Note that XO with the bar above it denotes XO NOT Output equation YO ON When in the ON state another push and release cycle similarly takes us back to the OFF state Now we have two unique states OFF and ON used when the pushbutton is released which is what was required to solve the control problem The equivalent stage program is shown to the right The desired powerup state is OFF so we make SO an initial stage ISG In th
354. y an optional battery See page 3 11 The contents of RAM will be lost when external power is lost without battery backup The contents of EEPROM memory can be read from for an infinite number of times but there is a limit to the number of times it can be written to typical specification is 100 000 writes EEPROM does not require a power source to maintain the memory contents It will retain the contents of memory indefinately PLC user V memory is stored in both volatile RAM and non volatile EEPROM memory See the memory map pertaining to the Data Word range for your particular CPU page 3 50 to 3 53 Data values that must be retained for long periods of time when the PLC is powered off should be stored in EEPROM based V memory Data values that are continually changing or which can be initialized with program logic should be stored in RAM based V memory Memeory LL 2 Lo eb Q Ze PL DL205 User Manual 3rd Ed Rev A 08 03 European Union Directives CE In This Appendix European Union EU Directives Basic EMC Installation Guidelines OS x 2 So co m 2 gt LU European Union Directives European Union EU Directives Member Countries Applicable Directives Compliance NOTE The information contained in this section is intended as a guideline and is based on our interpretation of the various standards and requirements Since the actual standards
355. y placing proper values in the associated loop table registers The following figure shows the loop table parameters at V 36 and V 37 and their role in direct access to the analog values Example using the PV Auto Transfer from I O module Base Slot Channel option Setpoint V 02 5 Error Loop Control Output V 05 a Calculation Process Variable V 03 Loop Table V2036 OX XX Base Slot Channel number for PV V2037 OX XX Base Slot Channel number for Output XX OX E Channel number 1 to 8 Slot number O to 7 Base number 0 to 4 DL260 0 to 2 DL250 1 EE doo Aid Jg le D O1 L g le o O G gt You may program these loop table parameters directly or use the PID Setup feature in DirectSOFT32 for easy configuring For example a value of 0102 in register V2036 directs the loop controller to read the PV data from slot number 1 and the second channel Note that slot 1 is the second slot to the right of the CPU because slot O is adjacent to the CPU A value of 0000 in either register tells the loop controller notto access the corresponding analog value directly In that case ladder logic must transfer the value between the loop table and the physical I O module If the PV or control output values require some math manipulation by ladder logic then it will not be possible to use the auto transfer to from l O function of the loop controller In this

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