Maple Systems EasyBuilder-5000 Operating Manual
COPY RIGHT NO TICE
This manual is a publication of Maple Systems, Inc., and is provided for use by its customers only. The contents of the
manual are copyrighted by Maple Systems, Inc.; reproduction in whole or in part, for use other than in support of Maple
Systems equipment, is prohibited without the specific written permission of Maple Systems.
The copyright of EasyBuilder-5000 and its related software belongs to Weintek Labs, Inc.
WAR RANTY
Maple Systems warrants each product to be free from electrical and mechanical defects in materials and workmanship for a
period of two years from the date of shipment. This warranty does not apply to defects in the Products caused by abuse,
misuse, accident, casualty, alteration, negligence, repair not authorized by Maple Systems, use on current or voltages other
than specified by Maple Systems, or application or installation not in accordance with published instruction manuals. This
warranty is in lieu of any other warranty either expressed or implied.
Maple Systems’ liability is limited to the repair or replacement of the Product only, and not costs of installation, removal, or
damage to user’s property or other liabilities. If Maple Systems is unable to repair or replace a nonconforming Product, it
may offer a refund of the amount paid to Maple Systems for such Product in full satisfaction of its warranty obligation.
Maximum liability of Maple Systems is the cost of the Product.
Information furnished by Maple Systems, Inc., is believed to be accurate and reliable. However, no responsibility is assumed
by Maple Systems for the use of this information nor for any infringements of patents or other rights of third parties which
may result from its use. No license is granted by implication, or otherwise, under any patent or patent rights of Maple
Systems, Inc. Maple Systems retains the right to revise or change its products and documentation at any time without notice.
IF SER VICE IS RE QUIRED
Contact Watlow Customer Service at (507) 454-5300 for instructions on how to return a product and how to obtain a Return
Materials Authorization (RMA) number.
Package the unit in its original packaging container or, if unavailable, any suitable rigid container. If a substitute container is
used, surround the unit with shock absorbing material; damage in shipment is not covered by the warranty. Include a letter
with the unit describing the difficulty and designating a contact person.
All returns will be tested to verify customer claims of noncompliance with the product warranty. Improper return packaging,
which makes verification impossible, will void the warranty. Products passing the tests will be returned “AS IS” to the
customer.
If noncompliance is verified and is not due to customer abuse or the other exceptions described with product warranty, Maple
Systems will, at its option, repair or replace the Product returned to it, freight prepaid , which fail to comply with the
foregoing warranty, provided Maple Systems is notified of such noncompliance within the two-year warranty period.
AP PLI CA TIONS AS SIS TANCE
This man ual is de signed to pro vide the nec es sary in for ma tion for trou ble-free in stal la tion and op er a tion of your new Op er a tor
In ter face Ter mi nal (OIT). How ever, if you need as sis tance, please call Watlow at (507) 494-5656 between 7 a.m. and 5 p.m.
Central Standard Time (CST). Ask for an Applications Engineer. Or you may e-mail your questions to
wintechsupport@watlow.com .
Ta ble of Con tents
EZware-5000 Sup port ...............1
OIT Mod els Sup ported ............1
PLCs Sup ported .................1
About Your Doc u men ta tion............1
Con ven tions ...................1
What You Need .................2
OIT Ba sics ........................2
What is a Sil ver Se ries OIT? ........4
List of Fea tures..................5
Chap ter 1 - In stal la tion of OITs ............7
Un pack ing the Unit ..............7
Man ag ing Elec tro static Dis charge ....7
CE Com pli ance .................7
NEMA Rat ing ...................7
En vi ron men tal Con sid er ations ......7
Safety Pre cau tions ...............8
Con trol Panel De sign Guide lines........8
Con trol Panel Ground ing ..........9
Con nect OIT Chas sis Ground to Con trol
Panel.........................9
Power Sup ply Se lec tion............11
Ca ble Rout ing and Noise Im mu nity...11
In stal la tion........................12
Con nect the OIT to Power .........12
Panel Prep a ra tion ...............14
Mount the OIT to the Panel.........14
Con fig u ra tion Wir ing ................15
Con nect the OIT to the PC for
Con fig u ra tion ..................15
Chap ter 2 - OIT Lo cal Setup...............17
Fac tory Con fig u ra tion................17
Cal i brat ing the Touchscreen ........17
Get ting into Lo cal Setup ...........17
Chang ing the Sys tem Set tings .......18
View ing Sys tem In for ma tion ........22
Trans fer ring Pro jects and Data from
USB/CompactFlash ..............23
Chap ter 3 - Con nect the OIT to the PLC or
Con trol ler ............................25
COM Ports for the
HMI5080/HMI5104/HMI5121 ......26
COM Ports for the HMI5056 .......27
Con nect ing to COM1 and COM3 on
Port A ........................28
Con nect ing to COM1 and COM2 on
Port B ........................32
Con nect ing mul ti ple PLC/con trol lers
se ri ally us ing daisy chain ing ........33
Con nect ing one or more PLC/con trol lers
via Ethernet ....................33
Chap ter 4 - Cre at ing Your First Pro ject ......35
Be fore You Be gin ...................35
Con nect ing OIT to Com puter ..........35
Start ing EZware-5000 ...............35
Cre at ing a Sam ple Pro ject ............36
Set ting the Sys tem Pa ram e ters ......36
Cre at ing a Popup Win dow .........40
Cre at ing a Startup Win dow ........48
Fin ish ing Up ......................54
Chap ter 5 - Sim u la tor Mode ..............59
The Sim u la tion Screen ...............59
Chap ter 6 - Us ing EZware-5000 ...........61
Over view .........................60
The Pro ject Man ager ................60
Com mu ni ca tions & Pass word Set tings . 62
Ed i tor Set tings ..................63
Trans fer Set tings ................63
Sim u la tion Set tings...............63
View ing Data Log................65
Easy Printer ....................70
Con vert ing Data/Event Log.........70
Rec ipe Ex tended Mem. Editor .......71
Pass Through Mode ..............76
The EasyConverter Ap pli ca tion .........76
Man ag ing Pro jects ...............78
Ed it ing and Cre at ing Screen Ob jects..82
Ba sic Ed it ing Commands ..........86
Group ing Ojects ................90
Lay er ing Objects ................91
Nudg ing Objects ................93
Mak ing Ob jects Same Size .........97
Mak ing Ob jects Same Color........98
Gen eral Set tings ................101
Au to mat i cally Re boot OIT .............112
Save and Com pile the Pro ject ..........112
Chap ter 7 - Cre at ing Win dows ............116
Win dow Fun da men tals ...............117
Open ing a Win dow ..............117
Cre at ing a New Win dow ..........117
As sign ing Un der lay Win dows .......121
How to Dis play Un der lay Win dows ...122
Rules That Ap ply to Un der lay
Win dows ......................122
De let ing a Win dow ..............123
Us ing Base Win dows ................123
How to Dis play Base Win dows ......123
Us ing the Com mon Win dow ...........129
Chang ing the Ac tive Com mon
Win dow.......................132
Us ing the Fast Se lec tion Win dow........133
Us ing the Fast Se lec tion Key ........135
Chang ing screens us ing the Fast
Se lec tion win dow ................136
Sys tem Mes sage Win dow ..........138
Chap ter 8 - Cre at ing Graphic Ob jects .......140
Draw ing Ob jects ...................140
Us ing the Draw ing Tools ..........140
Us ing Text .....................144
ii Sil ver Se ries In stal la tion & Operation Man ual
Pre de fined Shapes and Pic tures.........146
Us ing a Pre de fined Shape ......146
Us ing a Pre de fined Pic ture ......148
Graphics Li brar ies ..................150
What are ‘states’? ............150
Us ing Shape Li brar ies .........150
Us ing Pic ture Li brar ies .........154
Us ing Group Li brar ies .........157
Us ing Sound Li brar ies .........160
Chap ter 9 - Cre at ing and Us ing Da ta bases and
Lan guages ............................164
Cre at ing and Us ing the Tag Li brary .....164
Im port ing and Ex port ing the Tag
Li brary.....................165
Us ing the Tag Li brary..........165
Cre at ing the La bel Li brary ............166
Set ting Dif fer ent Fonts for Dif fer ent Lan -
guages ....................168
Im port ing and Ex port ing the La bel
Li brary.....................169
Us ing the La bel Li brary...............169
Us ing Lan guages with the La bel
Li brary.....................170
Chap ter 10 - Rep re sent ing Data with Graphics
Ob jects...............................172
Gen eral Prop er ties of Objects ..........172
Us ing In dex Registers ................182
Us ing In ter nal Data Mem ory of OIT .....184
Rep re sent ing PLC Coil Reg is ters ........192
The Bit Lamp Ob ject ..........192
The Set Bit Ob ject ............196
The Tog gle Switch Ob ject .......197
Rep re sent ing PLC Data Reg is ters ........199
The Word Lamp Ob ject ........199
The Set Word Ob ject ..........202
The Slider Ob ject .............203
The MultiState Switch Ob ject.....205
The Nu meric Dis play Ob ject.....209
The Nu meric In put Ob ject ......211
The ASCII Dis play Ob ject .......216
The ASCII In put Ob ject.........217
The Mov ing Shape Ob ject ......218
The An i ma tion Ob ject .........222
The XY Plot Ob ject ............224
Chap ter 11 - Us ing and Cre at ing Keypads ...240
How to Cre ate a Key pad .............240
Dis play ing and Us ing a Key pad ........241
Chap ter 12 - Bar Graphs, Me ters and Trends . 246
Cre at ing Bar Graphs ................246
Cre at ing Me ter Dis plays ..............248
Cre at ing Trend Dis plays & Data Sam pling
Ob jects ..........................251
His tory Data Dis play Part .......258
Chap ter 13 - Cap tur ing Alarms and Events ...264
Us ing Alarms ......................264
Mon i tor ing Alarms with the Alarm/Event
Log .............................263
Dis play ing Alarms/Alarm Dis play Ob ject ..266
Dis play ing Alarms us ing the Alarm Bar
Ob ject.....................267
Us ing Events ................269
Mon i tor ing Events With the Event Log
Ob ject.....................269
Dis play ing Events Us ing the Event
Dis play Ob ject ...............269
Chap ter 14 - Data and Rec ipe Trans fer Ob jects 272
Us ing the Data Trans fer Ob ject.........271
Us ing the Rec ipe Trans fer (Data Trans fer, Trig -
ger Based) Ob ject ..................272
Cre at ing a Rec ipe ............273
Backup Part .................274
Chap ter 15 - Mac ros ....................277
Us ing Mac ros .....................277
Macro Sam ple and
Im ple men ta tion .............277
Vari ables, Dec la ra tions and Mem ory
Us age ...........................278
Mem ory Us age: .............278
Vari able Dec la ra tions..........279
Vari able Ini tial iza tion ..........279
Ar ray ini tial iza tion ............280
Re served Words ..............281
Op er a tor...................281
Or der of Pre ce dence ..........282
Main Func tions and Sub-
func tions ...................282
Lo cal and Global Vari ables .....282
Cre at ing Vari able Ar rays .......283
Us ing Mac ros Within Rec i pes ....283
State ments, Con di tions &
Ex pres sions .................284
Func tion Calls and Pass ing Pa ram e ters
246
Read ing & Writ ing Ex ter nal Reg is ters in
a Macro ...................286
Pre cau tions, Tips & Tricks when Us ing
Mac ros ....................288
Com piler Er rors & Er ror Codes .........288
Chap ter 16 - Mis cel la neous Objects.........291
Misc. Objects ......................291
Sched uler Object ............293
Time Set Tab ................293
Pro hibit Tab .................295
Me dia Player ................296
In dex ................................303
1010-1007, Rev 06
Sil ver Se ries In stal la tion & Op er a tion Man ual
iii
1010-1007W, Rev 06
Introduction 1
Introduction - Welcome
Welcome to the Maple Systems’ Silver Series Operator Interface Terminals (OITs) from Watlow. Using graphic OITs has
never been easier. This powerful family of graphics operator interface terminals connect to Watlow controllers and other
devices such as programmable logic controllers (PLCs) to provide the human-machine interface in industrial applications.
The Silver Series has several features not found in other graphic OITs. This manual explains the operation of the Silver
Series OITs and how to implement the many available features using the EZware-5000 Configuration Software.
Watlow and Maple Systems have worked together to bring you this product. Please contact Watlow for support, and be sure
to utilize any resources referenced in this manual on the Watlow website (www.watlow.com) and the Maple Systems
Website (www.maplesystems.com).
EZware-5000 Sup port
OIT Mod els Sup ported
For the latest list of Silver Series Models supported by Watlow, please visit the Watlow website at www.watlow.com.
PLCs Supported
For the latest list of PLCs and controllers supported by the Silver Series OITs, please visit our website.
About Your Doc u men ta tion
Maple Systems provides many resources to allow you to get the most out of your Silver Series OIT.
· Silver Series Operation Manual (shipped with EZware-5000 as a PDF file) - describes installation, general operation
and features of the Silver Series using EZware-5000 configuration software..
· Watlow Silver Operator Interface Terminal Manual Addendum - contains specific instructions and examples on
communicating with and creating interfaces for Watlow controllers.
· Controller Information Sheets - important information specific to each supported protocol.
· EZware-5000 On-line Help - covers the operation of EZware-5000. Always available by clicking HelpTopics from
the Help menu in EasyBuilder, or press F1 from any dialog.
For more information about these and other training sources, visit the Maple Systems website.
Con ven tions
When using EZware-5000, there are usually several ways to perform a task. For example, if you want to copy a graphics
object, you can:
· Click the Copy command on the Edit menu.
· Click the Copy button on the Standard toolbar.
· Press the CTRL + C keys on your com puter.
1010-1007W, Rev 06
2 Sil ver Se ries In stal la tion & Operation Man ual
In most cases, we will describe each method when the task is first discussed. The menu method is then used whenever the
task is used in later procedures. Other conventions used in this manual are listed in the following table.
Convention Meaning
Bold
Italic
ALL CAPITALS Directory names, file names, key names, and acronyms
KEY1+KEY2
click Refers to clicking the primary mouse button (usually the left mouse button) once.
Double-click Refers to quickly clicking the primary mouse button (usually the left mouse button) twice.
Right-click
Characters that you must type exactly as they appear. For example, if you are directed to type a:\setup,
you should type all the bold characters exactly as they are printed.
Placeholders for information you must provide. For example, if you are directed to type filename, you
should type the actual name for a file instead of the word shown in italic type. Italics are also used to
indicate a glossary term.
A plus sign (+) between key names means to press and hold down the first key while you press the second
key.
Refers to clicking the secondary mouse button (usually the right mouse button) once. Right-clicking
usually opens shortcut menus.
The following table identifies symbols and margin icons.
Icon Meaning
4 Identifies a procedure.
4 Indicates a reference to additional information.
Indicates an important note.
What You Need
The following items are needed to configure and operate your OIT.
Configuration Software EZware -5000
Configuration Cable
Personal Computer
Power Cable 6030-0009 2-conductor 18 AWG, shielded, no connectors
24VDC Power Supply User Provided
PLC User Provided
Controller Information Sheet
Communication Cable
(HMI to PLC)
1
Al lows you to con nect OIT directly to PC Ethernet port or to USB port to download/upload projects into the OIT.
2
Computer requirements include a Pentium 1.7 GHz or higher processor, 512 MB RAM, 200 MB available Hard Disk
1
2
7431-0104 ( Ethernet Crossover cable for HMI5056T, HMI5080T, HMI5104T/XH, HMI5121T/X, HMI5150X
models)
7431-0115 (USB download cable for HMI5043N, HMI 5056N, HMI5070NH/TH and HMI5100N/T models)
User Provided
Maple Systems provides Controller Information Sheets which contain important information specific to each
PLC. Please locate the sheet that corresponds to your PLC on our website.
Refer to our web site (www. maple-systems.com) for a list of available cables.
Space, SVGA or higher resolution monitor, Keyboard and Mouse, available Ethernet port or USB port (for downloading
project), at least one RS232 port for online simulation, Windows XP, 2000 or Vista.
OIT Ba sics
Operator Interface Terminals (OITs) provide much more versatility than traditional mechanical control panels. An OIT
allows a plant floor operator to monitor current conditions of a control system and, if necessary, to initiate a change in the
operation of the system. OITs connect to programmable logic controllers (PLCs) typically through the PLC’s serial
communications port. The OIT can be programmed to monitor and/or change current values stored in the data memory of the
PLC.
OITs can have either text-based or graphics-based displays. A text-based OIT can display printable text characters but no
graphics. Some text-based OITs can display text characters in various sizes. A graphics-based OIT can display printable text
characters of varying fonts and sizes and graphics shapes such as icons, bitmaps, or pictures. Using pictures instead of words
or characters often greatly simplifies the operation of the OIT, making the OIT much more intuitive to use.
1010-1007W, Rev 06
Introduction 3
Some OITs use touchscreen displays while others use a membrane-style keypad. Membrane-style keyboards are best used in
applications in which the keypad is likely to become dirty. Touchscreen displays are placed over the OIT screen thus
providing much more flexibility than typical membrane-style keypads. Because of this, switches can be created on a
touchscreen that appear only when needed.
The Maple Systems Silver Series OITs are graphics-based touchscreen OITs. Before we get any further into the operation of
these OITs, it is necessary to define some terms that will be used throughout this manual.
Projects
The OIT has two basic segments of internal memory. The code memory contains the information required by the OIT that
controls how it operates such as the features supported and how it communicates to a PLC. The OIT programmer does not
have the ability to change code memory. The project memory pertains to all of the window screens created and any other
features that the OIT programmer can create using the EZware-5000 configuration software. Therefore, the term project is
used to designate the file that is sent to the OIT from the EZware-5000 software.
Objects
An object is any action that the OIT performs while it is communicating to the PLC. In order to get the operator interface
terminal to ‘do anything’, you must program the OIT with objects. Objects perform actions such as display text or graphics,
write a value to a PLC register, or display an alarm. Objects most often are graphics shapes that are to be displayed on the
OIT screen. For example, a Text Object is used to display text on the OIT. But objects are also used to configure the OIT to
perform some action. For example, a PLC Control Object tells the OIT to continuously monitor a PLC register that is used
by the PLC to request a new window. Some objects can display a graphics shape on the OIT screen and
perform some
action. For example, a Toggle Switch Object creates a graphic object on the OIT that when pressed, activates a bit in the
PLC.
Graphics Object
A graphics object is any text, icon, or picture that can be displayed on the OIT. Graphics objects are further defined by how
they are composed or created. A Text Object is a graphics object that displays text on the OIT screen. A Bitmap Object is a
graphics object that displays a bitmap on the OIT screen. Bitmaps are files stored in the OIT to display pictures. A Shape
Object is a graphics object that displays a shape on the OIT screen. Shapes are also files stored in the OIT to display
pictures. Shapes differ from bitmaps in that shapes are stored using a vector-based file format whereas bitmaps use a
pixel-based file format. Each format has its advantages and disadvantages. We will not go into any more detail about bitmap
objects and shape objects until later in this manual. For now, think of them as objects used to display pictures on the OIT
screen. Finally, a Group Object is the most complex type of graphics object. It is a combination of other objects. Briefly, a
group object consists of one or more objects that are ‘grouped’ together and stored as one object. A good example is a
keypad, which is really a combination of several keys each designed to perform a specific task. When grouped together, a
keypad can be stored as a group object for use in other projects or windows.
Windows
A window is a screen that can be displayed on the OIT. Windows can be full-sized to completely cover the OIT display or
partially sized. Any partially sized window is usually referred to as a popup window. Windows can appear on the OIT
display by a request from the PLC or by a press from the touchscreen. Windows can be configured to any size. Once a
window is displayed, it can be moved around the OIT display, removed from the display, or minimized to an icon. Windows
can even overlap each other. Each window can display graphics objects and there is no limit to the number of graphics
objects that can be placed on each window. The Silver Series is capable of storing up to 1999 windows , but the actual limit
is determined by the total amount of memory used for the application. A more in-depth discussion of windows is covered in
later chapters. For now, think of windows as screens that can be displayed on the OIT.
1010-1007W, Rev 06
4 Sil ver Se ries In stal la tion & Op er a tion Man ual
What is a Silver Series OIT?
The Silver Series OITs by Maple Systems are graphics operator interfaces designed to connect to PLCs in an industrial
environment. The displays are covered with analog resistive touchscreens designed for harsh industrial environments. The
touchscreens use the latest in touchscreen technology enabling the OIT programmer to create switches that are very fine in
resolution. Unlike many other touchscreen OITs on the market, the Silver Series OITs are not limited to a fixed number of
cells in which switches can be created. The OIT programmer can create as many switches of varying sizes and shapes as he
wishes, limited only by the total amount of memory available for the project.
Three LED indicators are provided on the face of the Silver Series OITs to provide instant feedback to the OIT operator of
the current operating condition of the OIT.
LED Indicator Purpose
PWR LED (yellow) indicates if power is applied to the OIT
CPU LED (green) indicates if the OIT is operating correctly
COM LED (red) indicates communications activity on PLC port
The Silver Series OITs have three serial ports, which provide a connection to a PLC using RS-232 or
RS-485 communications and an Ethernet connection for PLC communication and project upload and download. The serial
ports also provide the ability to use the EZware-5000 configuration software in Simulation Mode enabling the OIT
programmer to test his project on the PC instead of downloading the project to the OIT.
The Silver Series is powered using +24VDC. Finally, a reset switch is provided on the back of the OIT to reinitialize the
OIT if an operational failure occurs. The Silver Series is designed for industrial environments and carries a NEMA 4X
(indoor only) rating as well as CE compliance for noise immunity and emissions.
List of Fea tures
The next chapter will guide you through the creation of your first project. Before you proceed, you may wish to read this
brief list of some of the features offered in the Silver Series OIT.
Icon Name Description
Bit Lamp
Word Lamp Creates a graphics object to reflect the current state of a multi-state PLC data register.
Set Bit
Set Word
Toggle Switch
Slider Object
Multi-State
Switch
Creates a graphics object to reflect the current status of a PLC bit.
Creates a touchscreen graphics object that represents a two-state switch. When pressed it
sets/resets a PLC bit.
Creates a touchscreen graphics object that represents a multi-state switch. When pressed it can
place a constant value in a PLC register or jog the value.
Creates a touchscreen graphics object that represents a two-state switch changing state
(picture) based upon a PLC bit. When pressed, it can control another PLC bit.
Creates a touchscreen graphics object that changes the state according to the position of a
slider switch.
Creates a multi-state touchscreen graphics object that changes state (picture) according to the
value in a PLC data register. When pressed, it sends a value(s) to another PLC register.
1010-1007W, Rev 06
Function Key Creates a touchscreen graphics object or runs a macro.
Numeric Input
Displays a number stored in a PLC register. The number can be changed using a numeric
keypad.
Introduction 5
Numeric Data
ASCII Input
ASCII Data Displays ASCII characters stored in a PLC register.
Moving Shapes
Animation
Indirect Window
Direct Window Displays a Window based on a bit in a PLC register.
Alarm Displays Creates alarms to display alarms sent from the Alarm/Event Log Object.
Alarm Bar Displays alarms detected by the Alarm/Event Log Object on a single horizontal scrolling line.
Displays a number stored in a PLC register.
Displays ASCII characters stored in a PLC register. Characters can be changed using an
alphanumeric keypad.
Creates a multi-state graphics object, which changes state (picture) and position on the screen
according to a value in a PLC register.
Creates a multi-state graphics object, which changes state (picture) on the screen according to a
value in a PLC register. The positions on the screen are predefined.
Configures the OIT to monitor PLC data registers to display for a specific window popup by a
PLC word address
Data Transfer
(triggered)
Data Transferred
(time-based)
Event Displays Displays messages detected in the Alarm/Event Log and can acknowledge the message(s).
Data Sampling
(Data Logging)
Alarm/Event Log Contains the data for detecting alarm conditions.
Trend Displays
Bar Graph
Displays
Meter Displays Creates a scale meter.
Recipe Transfer Transfers data to the specified PLC registers.
System
Message
Transfers data to the specified PLC registers based on a touch or PLC bit status.
Transfers data to the specified PLC registers on a timed basis.
Stores data for trending and archiving.
Creates a trend graph. Samples data in a single or multiple 16-bit PLC register and plots the
data on a time graph.
Creates a bar graph with alarm monitoring.
Customizes the content of system-generated messages.
PLC Control Configures the OIT to monitor PLC data registers to display full window screens.
History Data
Display
Displays historical data in a tabular format.
1010-1007W, Rev 06
6 Sil ver Se ries In stal la tion & Operation Man ual
Backup Copies recipe, event or historical data to one of the USB memory devices.
Data Block
Display
XP Plot Creates an XY Plot.
Media Player Displays a video file.
Option List Creates a drop-down list blox
Scheduler Peforms an action based upon a time schedule.
Displays the data in a series of registers as a line graph.
1010-1007W, Rev 06
In stal la tion of OITs 7
Chapter 1 - Installation of OITs
Be fore You Be gin
Please read the following for proper handling of your new OIT.
Un packing the Unit
Carefully unpack the OIT. Please read any instructions or cautions that appear on the shipping container. Check all
material in the container against the enclosed packing list. Maple Systems, Inc. will not accept responsibility for
shortages against the packing list unless notified within 30 days. The equipment and its accessories were inspected
and tested by Maple Systems before shipment; all of the equipment should be in good working order. Examine the
equipment carefully; if any shipping damage is evident, notify the carrier immediately. You are responsible for
claim negotiations with the carrier. Save the shipping container and packing material in case the equipment needs to
be stored, returned to Maple Systems, or transported for any reason.
Man aging Elec tro static Dis charge
It is best NOT to remove the rear enclosure of the OIT. When the rear part of the enclosure is removed, the circuitry
inside is exposed to possible damage by electrostatic discharge during handling. Minimize the possibility of
electrostatic discharge by:
• Discharging personal static by grounding yourself prior to handling the OIT
• Handling the OIT at a static-free grounded workstation
• Connecting the frame ground (FG) connector of the OIT to a clean earth ground
• Placing the OIT in an anti-static bag during transport
CE Com pli ance
The Silver Series OITs have been tested to conform to European CE requirements per Council Directive
89/336/EEC. The European Union created these requirements to ensure conformity among products traded in those
countries. Specifically, the Silver Series OITs meet or exceed the noise emissions and immunity requirements as set
forth in the EN50081 (Emissions) and EN50082 (Immunity) standards. These products are designed to withstand
electrical noise in harsh ind ustrial environments. They also conform to requirements that limit electrical emissions.
However, this does not guarantee that the products will be totally immune from possible malfunction in cases where
severe electrical noise occurs. Therefore, we strongly recommend that you follow the guidelines outlined in this
chapter for proper wire routing and grounding to insure the proper operation of the Silver Series OIT.
NEMA Rat ing
The Silver Series OITs are rated for NEMA 4X/12 (indoor only) or IP65 installations. This means that when the
OIT is properly mounted to a panel or other enclosure, the front enclosure of the OIT will provide protection to the
inside of the panel from splashing water, wind blown dust, rain, or hose-directed water. The OIT must be installed
according to the instructions in this chapter to be properly sealed.
En vi ron men tal Con sid er ations
The Silver Series is designed to operate in temperatures from 0-45° C. It is intended for indoor installations and not
designed for outdoor applications. Avoid installing the Silver Series in environments with severe mechanical
vibration or shocks. Do not install the OIT in enclosures with rapid temperature variations or high humidity. Either
will cause condensation of water inside the device and eventual damage to the OIT.
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I / O control lines
PLC/Host
Ground wires
(rear side)
OIT is
grounded to
control panel
Ground
strap
Power
line
filter
Quiet ground
(isolated)
Quiet ground
Line
Filter
OIT
Power
Supply
Shielded power cable
Shielded
communication
cable
Control panel is
tied to a reliable
earth ground
Silver Series
OIT
24V
GND
COM1 [RS-485 2/4W]
PLC [RS-232]
COM3 [RS-485]
COM3 [RS-232]
COM1 [RS-232]
COM2 [RS-232]
Safety Pre cau tions
Please observe the following precautions when installing the Silver Series OIT. Failure to comply with these
restrictions could result in loss of life, serious personal injury, or equipment damage.
Warning: Do not operate the OIT in areas subject to explosion due to flammable gases,
vapors, or dusts.
Warning: Do not connect the OIT to an AC power source. You will cause permanent damage
to the OIT.
Warning: Do not attempt to use a DC power supply that does not meet OIT power
requirements. You may cause malfunction or permanent damage to the OIT.
Warning: Do not power the OIT with a DC power supply used for inductive loads or for input
circuitry to the programmable logic controller. Severe voltage spikes caused by these devices may
damage the OIT.
Con trol Panel De sign Guide lines
Pay careful attention to the placement of system components and associated cable routing. These items can
significantly enhance the performance and integrity of your control application.
Con trol Panel Ex am ple
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In stal la tion of OITs 9
Frame ground (marked FG)
Stud or screw
Area on panel free of paint
Control panel
(connected to earth ground)
Con trol Panel Grounding
The control panel should be connected to a good, high-integrity earth ground both for safety considerations and
shielding purposes. Maple Systems cannot overemphasize the importance of good grounding. If you fail to use
good grounding procedures during installation, sporadic malfunction of the OIT may occur:
· Connect the OIT’s chassis ground terminal to a reliable earth ground with a low-resistance path.
· Route all earth ground wires that lead from the OIT, the PLC, the power supply, and the line filter to a
central earth ground point such as a barrier strip. This will ensure that no ground current from one device
influences the operation of the other devices.
· Connect the OIT chassis ground terminal to the control panel door using a heavy-gauge short braided cable
or ground wire to minimize resistance.
· Connect the power cable’s shield wire to the OIT’s chassis ground terminal.
· Connect the control panel to earth ground using a copper grounding rod close to the OIT and control panel.
Hinged doors on control panels do not provide a long-term electrical connection to the rest of the enclosure.
Corrosion develops over time and prevents good electrical contract. For this reason, a separate wire braid should be
installed from the hinged control panel to the rest of the enclosure.
For a more in-depth overview of ground wiring techniques, refer to technical note #1027, “OIT Ground Wiring and
Electrical Noise Reduction,” which you can find on our web site.
Con nect OIT Chas sis Ground to Con trol Panel
To reduce the possibility of electrical interference, con nect the chassis ground terminal of the OIT to a clean earth
ground. If the control panel is metal, make sure it is properly grounded. Then connect a short heavy-gauge wire
(#18 AWG) from the chassis ground terminal of the OIT to a mounting bolt on the control panel door. The
mounting bolt must have good electrical contact to the control panel; scrape away any paint that may be covering
the panel to provide a good connection.
If the control panel is made of a non-conductive material, it is essential that you connect the chassis ground terminal
of the OIT to a clean earth ground point located close to the panel.
Typ i cal Chas sis Con nec tion
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Power Sup ply Se lec tion
The power supply used to power the OIT should provide an output of +24 VDC 5% measured at the OIT power
terminal block. A 24VDC regulated power supply dedicated to the OIT is required. Consult the datasheet of your
particular OIT for current requirements.
The power cable for the OIT should be 18AWG, 2-conductor wire with a shield drain wire and protective shield
(foil or braid). The shield drain wire must be connected to earth ground at both ends of the cable. Please refer to the
“Connect the OIT to Power” section for more information.
A power line filter installed at the AC input to the OIT power supply is highly recommended as a safeguard against
conducted RF noise, which is often present on factory power lines. The wires connecting the output of the power
line filter to the power supply should be kept as short as possible to minimize any additional noise pickup. The case
of the power line filter should be connected to a quiet earth ground. The power line filter should have a current
rating of at least 3 Amps with common mode and differential mode attenuation.
Do not use the power supply used to provide power to the OIT to power switching relays, solenoids, or other active
devices.
Power Line Fil ter Connection
Ca ble Routing and Noise Im mu nity
Follow these guidelines when routing cable to the OIT:
· Always route the OIT communication cable and the power cable away from any AC voltage or rapidly
switching DC control lines.
· Never bundle the OIT cables together with 120VAC power wires or with relay wiring.
· Try to keep at least 8 inches (20 cm) of separation between the OIT cables and other power wiring. If
voltages greater than 120VAC are used in the system, greater separation is required.
· If the OIT cables must come near AC wiring, make sure they cross at 90 degrees.
· Run AC power wires in a separate grounded conduit to reduce electrical noise interference.
· Keep the cable lengths for the OIT as short as possible. Do not coil excess cable and place it next to AC
powered equipment.
· Cover any equipment used in the enclosure that operates at high frequency or high current levels with a
grounded metal shield.
In stal la tion
It is necessary to follow all installation procedures described in this chapter for electrical noise immunity and CE
compliance.
Your Maple Systems OIT is designed to connect easily to your PLC. External rear connectors provide quick
connections for power, communications and programming wiring.
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In stal la tion of OITs 11
OIT
(rear side)
24Vdc
power supply
Control
panel
Shield wire (bare)
Black wire (-)
Red wire (+)
24V
120Vac
Black
Shield drain
Red
FG
DC Output -V (Gnd)
DC Output +V (+24V)
(+)
GND
(-)
FG
There are two connectors for serial communications on the rear of the OIT. Both of these are D-subminiature 9-pin
connectors.
Use the supplied separate 3-position terminal block to provide power to the OIT.
Con nect the OIT to Power
The power cable for the OIT should be 18AWG, 2-conductor wire with a shield drain wire and protective shield
foil. You may buy cable P/N 6030-0009 by the foot from Maple Systems to make these.
Always run the DC ground wire directly back to the signal return of the power supply. Do not use the chassis
ground wire as your signal return.
4To connect the OIT to power:
1. Connect the power cable to the OIT
a. Strip the power cable shield to expose 2” of the black and red wires.
b. Strip about ¼” of insulation from the black and red wires.
c. Thread the black and red wires through the ferrite core. The shield wire must be outside.
d. Connect the red wire to the DC positive (+) input of the OIT power terminal.
e. Connect the black wire to the DC negative (-) input of the OIT power terminal.
f. Connect the power cable shield wire to the OIT power terminal’s chassis ground input.
2. Route the power cable to the OIT power supply. The power cable should not be any longer
than necessary.
3. Install the power supply wires as follows (with colors shown for Maple Systems cable P/N
6030-0009):
OIT Power Inputs
Color Power Supply OIT
Red +Output/+24 Vdc +24V
Black -Output/+24 Vdc return GND
Shield Case ground FG
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12 Sil ver Se ries In stal la tion & Op er a tion Man ual
The power connector on the Silver Series is a terminal block with wire clamps. Lugs
are not required.
Typ i cal Power Wir ing
Panel Prep a ra tion
A metal panel or mounting surface with a minimum thickness of 15 gauge (0.059 inch/3.3mm) if cold-rolled steel or
hardened steel, or 10 gauge (0.101 inch/2.6mm) if aluminum alloy (6061-T6 preferred) is required. Thinner panels
or surfaces may bow between the mounting clamps and not form a seal with the gasket.
The area of the panel or mounting surface where the gasket comes into contact must be flat and free of scratches,
pits, and other features that prevent the gasket from sealing properly. If the panel or mounting surface is not
uniform, thick, flat, stiff, or smooth enough, then a sealant such as silicone may be required.
WARNING: The OIT requires a stiff, flat, smooth mounting surface free of blemishes
to seal properly to NEMA 4.
Clean and deburr the panel cutout before the OIT is installed.
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In stal la tion of OITs 13
Position 4 screw clamps
(2 each side)
Panel
Position screw clamps 6 places in slots provided:
2 screw clamps each side and one top and bottom
Panel
Side View
Screw clamp locking
tabs go through the
slots
Tighten all screw clamps until
they are uniformly snug
Ends of screws must not
protrude from the clamp
Screw Clamp Placement Clamps Tightened
Hold the OIT against
the panel until all screw
clamps are in position
PanelPanel
Mount the OIT to the Panel
In stall ing Screws on the OIT
STEPS:
1. Prepare the screw clamps for the OIT by positioning the metal brackets at the midpoints of the screws.
Position the screws so that the ends don’t protrude from the plastic portions.
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2. Set the OIT in the panel cutout and hold it in place until all clamps are in position.
3. Tighten the screw clamps until all are uniformly snug.
CAUTION: Do not over-tighten the screws beyond snugness, or you may damage the housing, or cause the
touchscreen to malfunction.
REINSTALLATION: Because the gasket will take a “set” to the panel, be sure to reinstall the OIT to the same
panel cutout when a NEMA 4 seal is required. For best results, also replace the gasket itself.
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15 Sil ver Se ries In stal la tion & Op er a tion Man ual
Con fig u ra tion Wir ing
The OIT must be configured for a particular protocol before use. The EZware software is used for configuring the
OIT. For detailed instructions on installing and using the software, please refer to the software documentation
section of this manual.
Con nect the OIT to the PC for Con fig u ra tion
To configure the OIT using Maple System’s configuration software, you will need either an Ethernet crossover
cable, Maple P/N 7431-0104 or a USB download cable, Maple P/N 7431-0115 depending upon the OIT model used.
If using a switch or router between the PC and the OIT, use a straight-through or crossover cable as required by the
switch or router.
If an Ethernet port is not available on the PC, you may be able to install a USB
Ethernet adapter. You can also transfer the project to the OIT with a Compact Flash or
USB memory device. Refer to Chapter 2, OIT Local Setup.
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16 Sil ver Se ries In stal la tion & Op er a tion Man ual
Please Use This Page For Your Notes:
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OIT Lo cal Setup 17
Chapter 2 - OIT Local Setup
Factory Configuration
Each OIT arrives from the factory with a demo project file that illustrates some of the most popular features of the
OIT. Please follow the directions enclosed in Chapter 4, Creating Your First Project, to configure your OIT for the
PLC that you are using.
The OIT also has a black reset push button and a four position DIP switch located through an access hole on the
back of the enclosure. The reset switch can be used to r einitialize the OIT if the OIT malfunctions. Only Dip
switch 1 has functionality. Dip switch 1 puts the OIT into Touch Calibration mode. For normal operation, all of
the DIP switches should be set to the OFF position.
This chapter describes how to use the Silver Series’ local setup options. The local setup allows touchscreen
calibration, transferring projects to and from the OIT, configuring the OIT’s IP settings, passwords, time and date,
screen contrast, as well as managing the storage of recipe and history files. Additionally, memory and other system
information can be viewed.
Calibrating the Touchscreen
The touchscreen of the OIT is fully calibrated before it leaves the factory so you shouldn’t need to adjust it.
However, with time the touchscreen may need to be recalibrated.
4To calibrate the touchscreen:
1. Turn Dip Switch 1 ON.
2. Cycle power to the OIT.
3. After the OIT displays a crosshair cursor, you are prompted to touch the cursor for:
a. Top left position
b. Top right position
c. Bottom right position
d. Bottom left position
e. Center position.
4. The OIT will then resume initializing.
Getting into Local Setup
Accessing the local setup menus requires a USB-mouse be connected to the OIT. Using the mouse, point to the
lower right-hand corner of the OIT. The open bar icon will appear.
Click on the icon to call up the setup toolbar: (note this tool bar is on HMI screen)
System settings
icon
System info icon
Small keyboard
icon
Virtual keyboard
icon
Open/close bar
icon
Large keyboard
icon
Please Note: the above tool bar is located on the HMI.
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Changing the System Settings
4 To change the system settings on the OIT:
1. Open the Setup Toolbar as described above, and click the System Settings icon.
2. A dialog will be displayed requesting the Local password. The default password is 111111.
You may have to move windows around a bit to gain access to the virtual keyboard.
You may also have to click inside the password field again.
3. Once the correct password has been entered, the System Settings dialog is displayed. For all
tabs, the Cancel, Apply, and OK buttons are available.
Cancel Close the System Settings dialog without saving any changes.
Apply Save the current settings without closing the System Settings dialog.
OK Save the current settings and close the System Settings dialog.
4. Click on the Network tab to configure network settings. The Network dialog is displayed.
5. The Network tab allows configuration of the IP settings. The default setting is Auto Get IP
Address. Use this setting if the OIT will provide an IP address by a DHCP server. If
connected to a DHCP server, this dialog will display the IP settings obtained by the OIT. The
IP fields are disabled, and are not editable.
6. If using a static IP address, use the IP Address Get From Below option. The IP fields are
enabled. Enter the appropriate settings for your network.
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OIT Lo cal Setup 19
7. Click the Time/Date tab to configure time/date settings. The time/date dialog is displayed.
8. Configure appropriate time and date settings.
9. Click on the Security tab to display the security settings dialog. Here, you can select your
system passwords.
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10. Configure your password settings.
Local Password The password required to enter local setup.
Upload Password The password required to upload data from the OIT to a PC or memory module.
Download Password The password required to download data to the OIT from a PC or memory module.
Upload (History)
Password
The password required to upload history from the OIT to a PC or memory module.
11. The new password must be entered, and then entered again to confirm. As the password is
entered into the confirm field, an indicator will show if the two passwords match.
12. Click on the History tab to display the History dialog. This is where data stored in the OIT
can be cleared.
1010-1007W, Rev 06
OIT Lo cal Setup 21
This will not clear data stored on a Compact Flash or USB device.
Clear Recipe The OIT’s stored recipe data will be cleared when the Clear button is clicked.
Clear Eventlog The OIT’s stored event log data will be cleared when the Clear button is clicked.
Clear Datalog The OIT’s stored data log data will be cleared when the Clear button is clicked.
13. Click on the Backlight tab to disp lay the Backlight dialog. The Backlight tab adjusts the
brightness of the OIT’s backlight. Use the mouse or touchscreen to roll the wheel. Rolling to
the left decreases the brightness, rolling to the right increases the brightness.
System tags Backlight Up, Backlight Down, and Backlight Index can be used to adjust
the brightness at runtime.
14. Click on the CF Card tab to display the CF card dialog. The CF Card tab displays
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information about the Compact Flash module. If no CF card is present, the dialog will show
None. Otherwise, volume data about the CF card is displayed.
The Eject button will cause the OIT to ignore the CF device. It will not actually eject the card
from the OIT. If the Eject button is pressed, the CF card must be removed and re-inserted
before the OIT will recognize. Note that USB devices will not be displayed.
Viewing System Information
4 To view system information:
1. Open the Setup Toolbar as described above, and click the System Information icon. A dialog
will be displayed with two tabs.
2. Click on the Network tab to display the current IP settings.
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OIT Lo cal Setup 23
3. Click on the Version tab to display the current firmware information.
Transferring Projects and Data from USB/CompactFlash
When a USB or Compact Flash device is inserted into the Silver Series OIT, a dialog is displayed. The same dialog
is displayed for transferring projects or data.
Data is placed on the USB or CF device by EasyBuilder or Project Manager.
Download Project Transfer data from the USB/CF to the OIT
Upload Project Transfer data from the OIT to the USB/CF
Restart Project and exit Close the dialog and restart the OIT
Cancel Close the dialog without transferring
Restart after download/upload When checked, the OIT will restart after the transfer
Time Remaining
The dialog will automatically close after 10 seconds if no selection is
made; shows the time remaining
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24 Sil ver Se ries In stal la tion & Op er a tion Man ual
When Download is selected, a dialog will appear requesting the Download password and what data to download.
Password Enter the Download password.
Download Project Files When checked, the OIT will check the specified folder for project data, and transfer it if it exists.
Download History Files
When checked, the OIT will check the specified folder for history data, and transfer it if it exists.
History data includes Recipe , Event Log, and Data Log data.
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Con nect the OIT to the PLC or Controller 25
Chapter 3 - Con nect the OIT to the PLC or Controller
The Silver Series family of OITs can connect to one, two or more PLC/controllers. This is accomplished via two
9-pin D-sub serial communications connectors (Port A and Port B) and one Ethernet port. Each PLC/Controller has
its own wiring requirements. Maple Systems offers OIT-to-PLC/Controller communication cables that connect
directly to software controlled COM1, which is available on either Port A or Port B for most PLC/Controllers that
are built to any length and tested for high reliability. The Silver Series family has three software controlled
communications ports located on two physical connectors, designated as Port A and Port B (see Figures 1 & 2,
below).
Fig ure 1 - Com Ports - Rear View
Fig ure 2 - Com Ports - Bot tom View
The three software controlled ports are COM1, COM2, and COM3. Each software controlled communications port
can only be selected for one communication type. Once a communication type is selected for one of these software
controlled ports, that port cannot be used for another communication type. Each of these communication ports has
between one and three communication types. COM1 can be RS232, RS485 4-Wire, or RS485 2-Wire. COM2 is
strictly RS232. COM3 is either RS232 or RS485 2-Wire. COM1 cables are readily available for purchase from
Maple Systems. COM2 and COM3 cables are custom-made according to wiring diagrams that can be found on
Maple Systems' web site. Connecting multiple PLCs and controllers may require a s plitter.
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