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Optimate OP-1212
User Manual
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AutomationDirect Optimate OP-1212 User Manual

OP-1212
Lamp/Pushbutton Panel
Manual Number OP-1212-M

WARNING

Thank you for purchasing automation equipment from Automationdirect.com™, doing business as, AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and any other relevant publications) before installing or operating the equipment.
At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards. We do not guarantee the products described in this publication are suitable for your particular application, nor do we assume any responsibility for your product design, installation, or operation.
Our products are not fault--tolerant and are not designed, manufactured or intended for use or resale as on--line control equipment in hazardous environments requiring fail--safe performance, such as in the operation of nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in which the failure of the product could lead directly to death, personal injury, or severe physical or environmental damage (”High Risk Activities”). AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities.
For additional warranty and safety information, see the Terms and Conditions section of our Desk Reference. If you have any questions concerning the installation or operation of this equipment, or if you need additional information, please call us at 770--844--4200.
This publication is based on information that was available at the time it was printed. We at AutomationDirect constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or publications at any time without notice and without any obligation. This publication may also discuss features that may not be available in certain revisions of the product.
Trademarks
This publication may contain references to products produced and/or offered by other companies. The product and company names may be trademarked and are the sole property of their respective owners. AutomationDirect disclaims any proprietary interest in the marks and names of others.
Copyright 2010, Automationdirect.com™ Incorporated
All Rights Reserved
No part of this manual shall be c opied, reproduced, or transmitted in any way without the prior, written consent of Automationdirect.com Incorporated. AutomationDirect retains the exclusive rights to all information included in this document.
AVERTISSEMENT
Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.comMC, en faisant des affaires comme, AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l’installer ou de l’utiliser.
Afin de réduire au minimum le risque d’éventuels problèmes de sécurité, vous devez respecter tous les codes locaux et nationaux applicables régissant l’installation et le fonctionnement de votre équipement. Ces codes diffèrent d’une région à l’autre et, habituellement, évoluent au fil du temps. Il vous incombe de déterminer les codes à respecter et de vous assurer que l’équipement, l’installation et le fonctionnement sont conformes aux exigences de la version la plus récente de ces codes.
Vous devez, à tout le moins, respecter toutes les sections applicables du Code national de prévention des incendies, du Code national de l’électricité et des codes de la National Electrical Manufacturer’s Association (NEMA). Des organismes de réglementation ou des services gouvernementaux locaux peuvent également vous aider à déterminer les codes ainsi que les normes à respecter pour assurer une installation et un fonctionnement sûrs.
L’omission de respecter la totalité des codes et des normes applicables peut entraîner des dommages à l’équipement ou causer de graves blessures au personnel. Nous ne garantissons pas que les produits décrits dans cette publication conviennent à votre application particulière et nous n’assumons aucune responsabilité à l’égard de la conception, de l’installation ou du fonctionnement de votre produit.
Nos produits ne sont pas insensibles aux défaillances et ne sont ni conçus ni fabriqués pour l’utilisation ou la revente en tant qu’équipement de commande en ligne dans des environnements dangereux nécessitant une sécurité absolue, par exemple, l’exploitation d’installations nucléaires, les systèmes de navigation aérienne ou de communication, le contrôle de la circulation aérienne, les équipements de survie ou les systèmes d’armes, pour lesquels la défaillance du produit peut provoquer la mort, des blessures corporelles ou de graves dommages matériels ou environnementaux (”activités à risque élevé”). La société AutomationDirect nie toute garantie expresse ou implicite d’aptitude à l’emploi en ce qui a trait aux activités à risque élevé.
Pour des renseignements additionnels touchant la garantie et la sécurité, veuillez consulter la section Modalités et conditions de notre documentation. Si vous avez des questions au sujet de l’installation ou du fonctionnement de cet équipement, ou encore si vous avez besoin de renseignements supplémentaires, n’hésitez pas à nous téléphoner au 770--844--4200.
Cette publication s’appuie sur l’information qui était disponible au moment de l’impression. À la société AutomationDirect, nous nous efforçons constamment d’améliorer nos produits et services. C’est pourquoi nous nous réservons le droit d’apporter des modifications aux produits ou aux publications en tout temps, sans préavis ni quelque obligation que ce soit. La présente publication peut aussi porter sur des caractéristiques susceptibles de ne pas être offertes dans certaines versions révisées du produit.
Marques de commerce
La présente publication peut contenir des références à des produits fabriqués ou offerts par d’autres entreprises. Les désignations des produits et des entreprises peuvent être des marques de commerce et appartiennent exclusivement à leurs propriétaires respectifs. AutomationDirect nie tout intérêt dans les autres marques et désignations.
Copyright 2010, Automationdirect.com Incorporated
Tous droits réservés
Nulle partie de ce manuel ne doit être copiée, reproduite ou transmise de quelque façon que ce soit sans le consentement préalable écrit de la société Automationdirect.com Incorporated. AutomationDirect conserve les droits exclusifs à l’égard de tous les renseignements contenus dans le présent document.
1
Manual Revisions
If you contact us in reference to this manual, be sure to include the revision number.
Title: OP--1212 Lamp/Pushbutton Panel Manual Number: OP--1212--M
Issue Date Effective Pages Description of Changes
Original 11/96 41 Original Issue
Rev. A 5/98
Rev. B 5/2010 All Updated manual to present date
10 15
Added cable OP--2CBL--1 Changes per MU--OP--001, 5/7/97
1

Table of Contents

Getting Started
The Purpose of this Manual 2.........................................................
Configuration Software 2.............................................................
Supplemental Manuals 2.............................................................
Technical Assistance 2..............................................................
How the OP-1212 Works 3...........................................................
Using the Pushbutton Panel...5 Easy Steps 4............................................
Step 1: Prepare Your Labels (Pages 5--6) 4.............................................
Step 2: Install the Panel (Pages 7--14) 4...............................................
Step 3: Use OP--WINEDIT Software 4.................................................
Step 4: Configure the Panel to Work with your PLC (Pages 15) 4..........................
Step 5: Write the Ladder Logic (Pages 19--31) 4........................................
Preparing the Labels
Applying Text to Each Label 5........................................................
Template for Creating Labels 6.......................................................
i
Installing the Panel
Panel Specifications: 7................................................................
Physical Specifications 7.............................................................
Environmental Specifications 7.......................................................
Operating Specifications 7...........................................................
Dimensions for Mounting 8...........................................................
Power and Cabling Requirements 9....................................................
What Are Your Application Needs? 9..................................................
Programming Cable 10...............................................................
PLC to Panel Cable 10...............................................................
Choosing the Proper Connecting Cables 12..............................................
Connecting a Power Supply 14..........................................................
Power Supply Connections 14.........................................................
Connecting the Panel to your Personal Computer 15......................................
Assigning an Address to the OP-1212 15................................................
How to Set the Address 15............................................................
The Termination Resistor 15...........................................................
Using the OP--9001 to Connect Multiple Panels 16........................................
Understanding the OP-1212 Panel
Overview 17.........................................................................
Memory Mapping 17..................................................................
Lamps 17...........................................................................
Flashing the Lamps 18................................................................
LEDs and Separation Mode 18........................................................
Flashing the LEDs 18.................................................................
Force Functions 18...................................................................
ii
Table of Contents
Applying Ladder Logic
General Concepts 19...................................................................
Memory Mapping 19..................................................................
Addressing Conventions 20...........................................................
Three Different Ways to Use the Panel 22...............................................
Method 1: Bit-of-Word DirectLOGIC and Allen-Bradley 22.................................
Method 2: Internal Relays (All Options Used) 22..........................................
Method 3: Remapping (Selected Options) 22............................................
Using bit--of--word with the OP--1212 23..................................................
Using Ladder Logic 23................................................................
Using All Functions with DirectLOGIC 24................................................
Using Ladder Logic 24................................................................
Using All Functions with the DL305 PLCs 25.............................................
Using Ladder Logic 25................................................................
Using Selected Functions with DirectLOGIC PLCs (not DL305 PLCs) 26....................
Using the Remapping Process 26......................................................
Using Ladder Logic with DirectLOGIC PLCs 27..........................................
Using Ladder Logic with the DL305 29..................................................
Using the OP-1212 with an Allen-Bradley PLC 31.........................................
Using Ladder Logic with Allen--Bradley PLC 31..........................................
Troubleshooting the OP-1212 Panel
Troubleshooting 32...................................................................
Panel Configuration 32...............................................................
Panel to PLC Communications 33......................................................
Panel Operation 33...................................................................
European Union Directives
Technical Support 35.................................................................
SELV Circuits 35.....................................................................
Environmental Specifications 35.......................................................
Preventative Maintenance and Cleaning 35..............................................
External Fuse Protection for Input Power 35.............................................
Appendix A: Worksheets Index
OP--1212 Pushbutton Panel
In This Manual....
— Getting Started — Preparing the Labels — Installing the Panel — Applying Ladder Logic
1
2

Getting Started

Getting Started
The Purpose of this Manual
Configuration Software
This manual shows you how to install, operate and maintain the OP-1212 Lamp Pushbutton Panel. It includes wiring diagrams and power requirements, as well as the information you need for selecting the proper connecting cables.
All OptiMate panels are configured using the OptiMate OP--WINEDIT configuration software. OP--WINEDIT software is compatible with computers running Windows 95/98/2000/NT/XP. OP--WINEDIT is ordered as a separate item from the OptiMate panel from AutomationDirect. The software is loaded onto your personal computer and simple follow the setup instructions in the supplied user manual and the built--in HELP screens. The software allows setup of y our complete application, including the type of PLC being used. Note that OP--WINEDIT is also used to configure the OP--9001, Communications Master panel. The software can be used with Allen--Bradley PLCs.
Supplemental Manuals
Technical Assistance
There are several other manuals you will find helpful or necessary:
D Respective PLC User Manual for the PLC(s) you are using with the OptiMate
panel.
D OP--9001--M Communications Master User Manual provides details of how to
use the OP-9001 for connecting multiple OP-Panels to a single CPU.
D DirectSOFTt User Manual--Shows you how to use the DirectSOFT
Windows software to write your ladder logic for DirectLOGICt PLCs.
If you are not successful with implementing the information in this manual, you may call AutomationDirect technical support at (800) 633-0405, Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern Standard Time. The technical support team will work with you to answer your application questions. If you have a comment or question about our products, services, or manuals which we provide, please fill out and return the suggestions card included with this manual.
Getting Started
33
How the OP-1212 Works
AutomationDirect
The purpose of the panel is to provide you with both pushbuttons (12) and lamps (12) so that you can have status and control functions that will work with your PLC. An additional benefit of this panel is found in the LEDs that are in the upper left hand corner of each pushbutton. These LEDs can operate as indicators to reflect the status of the individual pushbutton, or they can operate independent of the pushbutton status. The LEDS can turn ON or OFF and even flash for added attention.
To link the pushbuttons, LEDs, and lamps to your PLC, the OP-1212 uses a technique called “memory mapping”. This technique ties the pushbuttons, LEDs, and lamps to specific reserved areas of memory in the PLC. You can use any available memory as long as it is consecutive.
The base register address is entered during configuration using the OPWinEdit software. Each of the functions for the pushbuttons, LEDs, and lamps are controlled by the status of their assigned bits within the memory words that you have reserved. You interface these words of memory through your ladder logic.
Prior to connecting the OP-1212 to your PLC, load the OP--WINEDIT configuration software onto your personal computer, and begin to define how you want to use the functions that have been designed into the panel. Among other decisions, you are prompted to fill in a base register address. In the example we have shown here, we have used V40600 as the start of the mapped memory addresses.
Allen-Bradley
The same OP--WINEDIT configuration software used for the AutomationDirect product is also used for the Allen-Bradley product. As you move through the screens, one of the key items you complete is the base register address for storing data relative to the pushbuttons. In the example, we have used N7:0 as the start of the mapped memory addresses. This means the PLC file number is 7 and the base address is 0.
4
Getting Started

Using the Pushbutton Panel...5 Easy Steps

Step 1: Prepare Your Labels (Pages 5--6)
Step 2: Install the Panel (Pages 7--14)
Step 3: Use OP--WINEDIT Software
First, you need to prepare the labels for each of the pushbuttons and lamps. The labels insert into plastic sleeves behind the main cover. To access the sleeve, you merely snap loose the front bezel.
Preparing for installation, you will want to check the individual specifications. These include dimensions, power requirements, cabling requirements, and NEMA ratings. We include information you will need for mounting; i.e. cutout dimensions, cabling requirements, components needed, etc.
You will need the OP--WINEDIT configuration software in order to configure the panel and PLC. OP--WINEDIT is ordered as a separate item from the OptiMate panel from AutomationDirect. The software is used for both DirectLOGIC and Allen--Bradley PLCs.
Cables
External Power
Step 4: Configure the Panel to Work with your PLC (Pages 15)
Step 5: Write the Ladder Logic (Pages 19--31)
After setting a DIP switch on the rear of the panel and attaching the programming cable, you are ready to configure your panel. The simple and easy-to-follow screens make configuration a painless process.
The amount of ladder logic programming knowledge you need is very basic. In most cases, you are already familiar with the elements of logic that are required. We’ll give you examples in the final section of this manual, and you will see right away just how easy it is.
C100
C101
Y10
OUT
Y11
OUT
DIP Switch

Preparing the Labels

5
Preparing the Labels
Applying Text to Each Label
Insert legend between window frame and cabinet
Preparing the labels for the OP--1212 panel requires you to slide a legend transparency into two pockets in the panel overlay. Use the following procedure:
1. Remove the bezel from the module by unsnapping the four tangs that hold the
bezel to the module frame.
2. Create a legend transparency. There are several ways of doing this. A template is
provided on the next page that gives you the available dimensions. The nicest legends result from using a computer graphics program and a laser printer to create the transparency.
Finished Legend
Window Frame
Bezel
3. Slide the finished legend into the pocket space between the window frame and
LED bars.
4. Re--attach the bezel by snapping the bezel onto the case.
6
Preparing the Labels

Template for Creating Labels

3.00
Dimensions in Inches
0.15
0.60
0.60
3.00
0.15
0.07
0.35
0.40
0.70
3.60
0.20
0.10
0.10

Installing the Panel

In this section you will be given all of the information you need to install the panel. Before actually installing the OP-1212 panel, it may be helpful to examine the specifications and make sure that the requirements of your application are met.
Panel Specifications:
7
Installing the Panel
Physical Specifications
Environmental Specifications
Operating Specifications
Weight 18 ounces...............................
Panel Fasteners Four 6x32 threaded studs.......................
NEMA Rating NEMA 4..........................
Operating Temperature 0° to 50° C.................
Storage Temperature --20° to 80° C...................
Operating Humidity 5 to 95% (non-condensing).....................
Air Composition No corrosive gases permitted........................
Power Budget Requirement 7 VA @ 8 -- 30 VDC.............
570 mA @ 12 VDC (all Lamps and LEDs ON)
285 mA @ 24 VDC (all Lamps and LEDs ON)
Power Connector Removable Terminal Block......................
2 position
Absolute Maximum Voltage 32 VDC..............
Diagnostics Power On, CPU...........................
Communication Link RS232 or RS422....................
4800, 9600 and 19200* baud
15 pin female D type connector
*Only 4800 and 9600 baud will work
with Allen-Bradley PLCs.
8
Installing the Panel

Dimensions for Mounting

Cutout Area
Example panel mounting
8.85
8.40
0.23
0.75
2.00
3.50
0.5
3.50
0.16 DIA
Dimensions in Inches
1.75

Power and Cabling Requirements

9
Installing the Panel
What Are Your Application Needs?
1. Point-to-Point
A single cable connection from the PLC to the panel gives you access to the PLC’s data registers and ladder logic.
Your communication cable requirements depends on your particular application. There are two types of configuration possibilities: point-to-point (a single operator interface connected to a PLC) and multi-drop (multiple operator interfaces connected to a PLC).
D Point-to-Point -- If you only need one operator interface connected to one
PLC, then choose the appropriate cables from the chart on page 11.
D Multi-drop -- By using an OptiMate OP--9001 Communications Master,
multiple Optimate units can be connected to a single PLC. Up to 31 individual units can be connected in a daisy-chain fashion to the OP--9001. Communications are via RS422 between the OP--9001 and the operator interfaces. When using a quality shielded cable, a total distance of up to 4000 feet between the OP--9001 and the last operator interface unit in the chain can be achieved. If the distance is 30 feet or less, a ribbon cable with easy-to-install crimp-on ribbon connectors can be used.
2. Multi-drop
Multiple OP-panels can be interfaced to a single PLC. This requires the use of the OP-9001 Communications Master. With the Communication Master, up to 31 panels can be interfaced to a single CPU port. Each can be programmed for entirely different functions. Panels can be distributed up to 4000 feet* from the OP-9001.
OP-9001
Power Source
*NOTE: Please read and follow the cabling requirements in the OP-9001 User Manual (OP-9001-M) when using multiple panels. Failure to follow the guidelines of the User Manual may affect the integrity of the RS422 link, resulting in communication errors.
DL405 CPU Base
Power Supply OP-panels
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