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Pointe Controller
User Guide
Nematron Corporation
February 2003
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Nematron, OpenControl, Pointe Controller, PointeControl, Optimation, and OptiLogic are trademarks
of Nematron Corporation. All other trademarks are the property of their respective holders.
Information in this document is subject to change without notice and does not represent a commitment
on the part of Nematron Corporation. No part of this manual may be reproduced or transmitted in any
form or by any means for any purpose without the express written permission of Nematron
Corporation.
Document 5.60.00 (2/3/2003 draft)
NEMATRON CORPORATION
5840 Interface Drive
Ann Arbor, MI 48103-9515
United States
Tel: 734-214-2000
Fax: 734-994-8074
NEMATRON, LTD.
1 The Briars
Waterberry Drive
Waterlooville, Hampshire
PO7 7YH
United Kingdom
Tel: +44 23 9226 8080
Fax: +44 23 9226 8081
OPTIMATION, INC.
2800 Bob Wallace Avenue, Suite L3
Huntsville, AL 35805-4157
United States
Tel: 256-883-3050
Fax: 256-883-3070
www.nematron.com
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Pointe Controller User Guide Table of Contents
Chapter 1: Introducing the Pointe Controller.................................................. 13
1.1 The Node Controller Concept ......................................................................................................14
1.2 Typical Applications........................................................................................................................17
1.3 Architecture Options ......................................................................................................................18
1.3.1 Stand-alone Operation ...................................................................................................18
1.3.2 Master Controller .............................................................................................................18
1.3.3 Network Node ...................................................................................................................19
1.4 Available Parts and Accessories ...................................................................................................20
Chapter 2: Initial Setup.................................................................................... 22
2.1 Getting to Know the Pointe Controller Base...........................................................................23
2.2 Supplying Power to the Pointe Controller ...............................................................................24
2.3 Installing the PointeControl Software.......................................................................................25
2.4 Configuring the Controller’s Network Settings ......................................................................26
2.5 Installing I/O Modules in the Controller....................................................................................30
2.6 Connecting the Controller to Your PC.......................................................................................31
Chapter 3: Quickstart Project........................................................................... 32
3.1 Starting a New Project ...................................................................................................................33
3.2 Defining Input, Output, and Memory Tags .............................................................................34
3.2.1 Defining input bits ...........................................................................................................34
3.2.2 Defining output bits ........................................................................................................36
3.2.3 Defining memory tags ....................................................................................................37
3.3 Associating Tags with I/O Points..................................................................................................38
3.4 Creating Your First Flow Chart ....................................................................................................42
3.5 Inserting a Second Decision Block...............................................................................................47
3.6 Assigning Outputs...........................................................................................................................48
3.7 Adding a Time Delay ......................................................................................................................53
3.8 Checking the Chart Integrity........................................................................................................55
3.9 Building the Project Runtime.......................................................................................................56
3.10 Downloading and Running Your Program ..............................................................................59
3.11 Monitoring Your Program While It Runs..................................................................................63
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3.12 Setting Breakpoints........................................................................................................................ 66
Chapter 4: System Design and Installation ......................................................70
4.1 Safety Guidelines............................................................................................................................. 71
4.2 Getting to Know the Pointe Controller Base .......................................................................... 73
4.2.1 PTC-5800 Pointe Controller Technical Description .................................................74
4.3 Supplying Power to the Pointe Controller............................................................................... 76
4.4 Installing the PointeControl Software ...................................................................................... 77
4.5 Addressing the Pointe Controller............................................................................................... 78
4.5.1 IP Address........................................................................................................................... 78
4.5.2 Modbus Address............................................................................................................... 82
4.6 Overview of OptiLogic I/O ............................................................................................................83
4.6.1 Digital Inputs..................................................................................................................... 84
4.6.2 Digital Outputs .................................................................................................................87
4.6.3 Analog Inputs.................................................................................................................... 89
4.7 Determining Your I/O Needs........................................................................................................ 93
4.7.1 Available I/O Modules..................................................................................................... 93
4.7.2 Available Operator Panels............................................................................................. 94
4.7.3 Calculating Your Power Budget ..................................................................................94
4.8 Installing I/O Modules in the Controller ................................................................................... 96
4.8.1 Slot Numbering................................................................................................................. 96
4.8.2 Installing Modules............................................................................................................ 97
4.9 Mounting Guidelines ..................................................................................................................... 98
4.9.1 Mounting the Base ..........................................................................................................98
4.9.2 Mounting the Controller Base to an Operator Panel ............................................ 99
4.10 Connecting the Pointe Controller to Your Network........................................................... 101
4.10.1 Point-to-Point Connection........................................................................................... 101
4.10.2 Single Hub and Switched Connections .................................................................... 102
4.11 Ethernet Connection Guide .......................................................................................................103
4.11.1 UTP Cable Characteristics............................................................................................. 103
4.11.2 Cable Connectors ...........................................................................................................103
4.11.3 10Base-T Connections ................................................................................................... 104
4.11.4 Straight-through Patch Cable..................................................................................... 104
4.11.5 Crossover Patch Cable...................................................................................................104
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Chapter 5: Developing Controller Programs ................................................. 105
5.1 Basic Concepts in PointeControl............................................................................................... 106
5.1.1 Multiple Programming Languages........................................................................... 106
5.1.2 Memory Allocation and Access.................................................................................. 106
5.1.3 The Scan Cycle ................................................................................................................ 107
5.2 The Visual Framework Editor (VFE)......................................................................................... 108
5.2.1 The Framework Editor toolbar .................................................................................. 109
5.2.2 The Project Workspace pane...................................................................................... 109
5.2.3 The Object Editor pane................................................................................................ 110
5.2.4 The Messages pane ....................................................................................................... 110
5.3 Managing PointeControl Projects............................................................................................ 111
5.3.1 Creating and opening projects.................................................................................. 111
5.3.2 Importing and exporting projects............................................................................. 111
5.3.3 Documenting your project.......................................................................................... 112
5.4 Defining Variables in Logic Memory....................................................................................... 113
5.4.1 Java reserved words...................................................................................................... 113
5.4.2 Defining Input, Memory, and Output tags ............................................................ 114
5.4.3 Defining strings in Logic Memory............................................................................. 116
5.4.4 Defining timers in Logic Memory ............................................................................. 117
5.4.5 Importing and exporting databases......................................................................... 118
5.5 Associating Tags with I/O points .............................................................................................. 121
5.5.1 Specifying your installed hardware.......................................................................... 121
5.5.2 Configuring I/O modules ............................................................................................. 127
5.5.3 Configuring operator panels...................................................................................... 128
5.5.4 Configuring additional OptiLogic RTUs .................................................................. 128
5.6 Building and Editing Flow Charts ............................................................................................ 129
5.6.1 Creating a new Flow Chart ......................................................................................... 131
5.6.2 Navigating the Flow Chart editor............................................................................. 132
5.6.3 Placing and configuring Flow Chart blocks............................................................ 135
5.6.4 Building logical expressions........................................................................................ 136
5.6.5 Moving, resizing, and deleting blocks in a Flow Chart....................................... 143
5.6.6 Adding comments to a Flow Chart........................................................................... 145
5.6.7 Logging changes in a Flow Chart.............................................................................. 146
5.6.8 Making a Flow Chart a reusable Subchart.............................................................. 147
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5.7 Types of Flow Chart Blocks......................................................................................................... 151
5.7.1 Process Block....................................................................................................................151
5.7.2 Terminator Block............................................................................................................ 154
5.7.3 Condition (If/Then/Else) Block.....................................................................................156
Repeat/Until Loop Block..............................................................................................................158
5.7.5 While/Do Loop Block..................................................................................................... 159
5.7.6 Subchart Block ................................................................................................................161
5.8 Building and Editing Ladder Diagrams...................................................................................163
5.8.1 Creating a new Ladder Diagram................................................................................163
5.8.2 Navigating the Ladder Diagram editor ...................................................................164
5.8.3 Adding new rungs and branches to a Ladder Diagram ...................................... 166
5.8.4 Placing and configuring a Ladder Diagram block ................................................167
5.8.5 Moving, copying, and deleting elements in a Ladder Diagram........................168
5.8.6 Adding comments to a Ladder Diagram .................................................................169
5.8.7 Making a Ladder Diagram a reusable Sub-Ladder ...............................................170
5.9 Types of Ladder Diagram Blocks............................................................................................... 171
5.9.1 Relays and Coils ..............................................................................................................171
5.9.2 Timer and Counter Blocks............................................................................................172
5.9.3 Math Blocks .....................................................................................................................172
5.9.4 Comparison Blocks......................................................................................................... 173
5.9.5 Logical and Bit Shift Blocks .........................................................................................174
5.9.6 Selection Blocks ..............................................................................................................174
5.9.7 String Blocks ....................................................................................................................175
5.9.8 Flow Control Blocks....................................................................................................... 176
5.9.9 Miscellaneous Blocks.....................................................................................................176
5.10 Other Framework Editor Tools.................................................................................................. 177
5.10.1 Finding and replacing text ..........................................................................................177
5.10.2 Zooming in and out on a chart.................................................................................. 177
5.10.3 Viewing tag cross references ......................................................................................178
5.11 Compliing your PointeControl project....................................................................................179
5.11.1 Configuring your project's Chart List .......................................................................179
5.11.2 Setting your project's scan interval........................................................................... 180
5.11.3 Checking your project’s chart integrity ...................................................................181
5.11.4 Building your project's runtime module .................................................................181
5.11.5 Activating the PointeControl Monitor.....................................................................182
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Chapter 6: Downloading to the Controller.................................................... 183
6.1 Launching the PointeControl Monitor ................................................................................... 184
6.2 Selecting and Attaching a Controller ..................................................................................... 185
6.2.1 Detaching from a controller....................................................................................... 186
6.3 Downloading a Project to the Controller .............................................................................. 187
6.3.1 Unloading a project...................................................................................................... 187
6.4 Starting and Stopping a Loaded Project................................................................................ 188
6.4.1 Stopping a project......................................................................................................... 188
6.4.2 Restarting a stopped project...................................................................................... 188
6.4.3 Enabling and disabling I/O.......................................................................................... 189
6.5 Assigning a Password to the Controller ................................................................................. 190
6.5.1 Overriding a password................................................................................................. 191
6.6 Saving a Project from the Controller ...................................................................................... 192
Chapter 7: Monitoring and Debugging ......................................................... 193
7.1 Monitoring a Running Project .................................................................................................. 194
7.1.1 The Charts Tab................................................................................................................ 194
7.1.2 The Browser Tab ............................................................................................................ 195
7.1.3 The Console Tab............................................................................................................. 198
7.1.4 The Controller Log Tab ................................................................................................ 201
7.2 Checking System Performance.................................................................................................. 202
7.2.1 Scanning........................................................................................................................... 202
7.2.2 Loading............................................................................................................................. 203
7.2.3 Errors................................................................................................................................. 204
7.3 Viewing and Debugging Charts ............................................................................................... 205
7.3.1 The Debugger Window ............................................................................................... 206
7.3.2 Zooming In and Out on a Chart ................................................................................ 207
7.3.3 Viewing Subcharts within a Chart ............................................................................ 207
7.3.4 Enabling Logic Flow in a Chart.................................................................................. 208
7.3.5 Enabling Debug Trace in a Chart .............................................................................. 208
7.3.6 Inserting Breakpoints in a Chart................................................................................ 210
7.3.7 Continuing Execution after a Breakpoint............................................................... 211
7.3.8 Forcing New Tag Values .............................................................................................. 212
7.3.9 Additional Tools for Flow Charts Only .................................................................... 215
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Chapter 8: Networked Operations .................................................................216
8.1 Networking via OptiLogic Remote I/O .................................................................................... 217
8.2 Networking via Modbus Data Mapping.................................................................................218
8.2.1 Modbus Address.............................................................................................................219
8.2.2 Types of Modbus data ..................................................................................................220
8.2.3 Enabling the Modbus driver .......................................................................................221
8.2.4 Mapping variables to Modbus addresses ................................................................ 222
Chapter 9: Troubleshooting............................................................................227
9.1 LED Boot Indicators ......................................................................................................................228
9.2 Hardware Reset .............................................................................................................................230
Appendix A: OptiLogic Technical Specifications ............................................231
A.1 OL2104 Relay Output Module...................................................................................................232
A.1.1 OL2104 Configuration Options.................................................................................. 233
A.2 OL2108 Relay Output Module...................................................................................................235
A.2.1 OL2108 Configuration Options.................................................................................. 236
A.3 OL2109 DC Sinking Output Module ........................................................................................ 239
A.3.1 OL2109 Configuration Options.................................................................................. 240
A.4 OL2111 AC Solid State Relay Module......................................................................................243
A.4.1 OL2111 Configuration Options.................................................................................. 244
A.5 OL2201 Digital Input Simulator Module ................................................................................247
A.5.1 OL2201 Configuration Options.................................................................................. 248
A.6 OL2205 AC/DC Input Module..................................................................................................... 249
A.6.1 OL2205 Configuration Options.................................................................................. 250
A.7 OL2208 DC Digital Input Module ............................................................................................. 252
A.7.1 OL2208 Configuration Options.................................................................................. 254
A.8 OL2211 AC Digital Input Module ............................................................................................. 255
A.8.1 OL2211 Configuration Options.................................................................................. 256
A.9 OL2252 Dual Pulse Counter........................................................................................................258
A.9.1 OL2252 Configuration Options.................................................................................. 261
A.10 OL2258 High Speed Pulse Counter........................................................................................... 264
A.10.1 OL2258 Configuration Options.................................................................................. 268
A.11 OL2304 Analog Voltage Output Module ............................................................................... 273
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A.11.1 OL2304 Configuration Options.................................................................................. 275
A.12 OL2408 Analog Voltage Input .................................................................................................. 276
A.12.1 OL2408 Configuration Options.................................................................................. 277
A.13 OL2418 Analog Current Input................................................................................................... 279
A.13.1 OL2418 Configuration Options.................................................................................. 280
A.14 OL2602 Dual Serial Port Module.............................................................................................. 282
A.14.1 OL2602 Configuration Options.................................................................................. 283
A.15 OL3406 Pushbutton/Indicator Panel........................................................................................ 284
A.15.1 OL3406 Configuration Options.................................................................................. 284
A.16 OL3420 Operator Terminal........................................................................................................ 288
A.16.1 OL3420 Configuration Options.................................................................................. 288
A.17 OL3440 Display Panel .................................................................................................................. 291
A.17.1 OL3440 Configuration Options.................................................................................. 291
A.18 OL3850 Keypad Terminal ........................................................................................................... 292
A.18.1 OL3850 Configuration Options.................................................................................. 292
Appendix B: Flow Chart Command Reference............................................... 297
B.1 General Commands...................................................................................................................... 298
B.1.1 Turn On and Turn Off .................................................................................................. 298
B.1.2 Assign................................................................................................................................ 298
B.1.3 Increment and Decrement.......................................................................................... 299
B.1.4 Clear.................................................................................................................................. 300
B.1.5 Enable and Disable........................................................................................................ 300
B.1.6 Get Tag Name................................................................................................................. 301
B.1.7 Wait................................................................................................................................... 302
B.2 Timer Commands.......................................................................................................................... 303
B.2.1 Timer Start and Timer Stop......................................................................................... 303
B.2.2 Timer Reset...................................................................................................................... 303
B.2.3 Timer Preset .................................................................................................................... 304
B.3 String Commands ......................................................................................................................... 306
B.3.1 String Copy...................................................................................................................... 306
B.3.2 String Concat .................................................................................................................. 307
B.3.3 String Left and String Right........................................................................................ 308
B.3.4 String Mid........................................................................................................................ 309
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B.3.5 String Insert ..................................................................................................................... 310
B.3.6 String Delete....................................................................................................................311
B.3.7 String Replace................................................................................................................. 313
B.3.8 String Format Integer ................................................................................................... 314
B.4 Diagnostics Commands................................................................................................................316
B.4.1 Diag Get Tag Status.......................................................................................................317
B.4.2 Diag Set Tag Status........................................................................................................318
B.4.3 Diag Clear Tag Status....................................................................................................319
B.5 Serial Commands...........................................................................................................................321
B.5.1 Serial Configure Port.....................................................................................................321
B.5.2 Serial Enable Port and Serial Disable Port...............................................................323
B.5.3 Serial Read Byte..............................................................................................................324
B.5.4 Serial Write Byte.............................................................................................................325
B.5.5 Serial Read MultiBytes.................................................................................................. 326
B.5.6 Serial Write MultiBytes.................................................................................................327
B.5.7 Serial Get Comm Errors ................................................................................................328
B.6 Date/Time Commands..................................................................................................................330
B.6.1 Date/Time Get................................................................................................................. 330
B.6.2 Date/Time Format..........................................................................................................331
B.6.3 Get Elapsed Time............................................................................................................332
B.7 Operator Panel Commands........................................................................................................333
B.7.1 Keypad Data Entry.........................................................................................................333
B.7.2 Arrow Adjust Data Entry..............................................................................................334
B.7.3 Button On and Button Off.......................................................................................... 336
Appendix C: Ladder Diagram Block Reference ...............................................337
C.1 Relays and Coils............................................................................................................................. 338
C.1.1 Normally Open Contact (XIC) .....................................................................................338
C.1.2 Normally Closed Contact (XIO)...................................................................................338
C.1.3 Rising Edge Relay (LEC) ................................................................................................339
C.1.4 Falling Edge Relay (TEC)...............................................................................................339
C.1.5 Output Coil (OC).............................................................................................................340
C.1.6 Negated Output Coil (NEGOC)................................................................................... 341
C.1.7 Latched Coil (LOC)..........................................................................................................341
C.1.8 Unlatched Coil (UOC).................................................................................................... 342
C.1.9 Rising Edge Coil (LEOC)................................................................................................343
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C.1.10 Falling Edge Coil (TEOC).............................................................................................. 343
C.1.11 Falling Edge Detector (F_TRIG).................................................................................. 344
C.1.12 Rising Edge Detector (R_TRIG)................................................................................... 345
C.1.13 Set-Dominant Bistable (SR)......................................................................................... 346
C.1.14 Reset-Dominant Bistable (RS)..................................................................................... 348
C.2 Timer and Counter Blocks.......................................................................................................... 350
C.2.1 Timer, Pulse (TP)............................................................................................................. 350
C.2.2 Timer, ON Delay (TON)................................................................................................. 351
C.2.3 Timer, OFF Delay (TOF) ................................................................................................ 352
C.2.4 Counter, Up (CTU)......................................................................................................... 353
C.2.5 Counter, Down (CTD) ................................................................................................... 355
C.2.6 Counter, Up/Down (CTUD).......................................................................................... 356
C.3 Math Blocks.................................................................................................................................... 359
C.3.1 Add (ADD) ....................................................................................................................... 359
C.3.2 Subtract (SUB)................................................................................................................. 360
C.3.3 Divide (DIV) ..................................................................................................................... 362
C.3.4 Multiply (MUL) ............................................................................................................... 363
C.3.5 Square Root (SQRT)....................................................................................................... 364
C.3.6 Modulus (MOD).............................................................................................................. 366
C.3.7 Sine (SIN).......................................................................................................................... 367
C.3.8 Cosine (COS).................................................................................................................... 368
C.3.9 Tangent (TAN)................................................................................................................ 369
C.3.10 Arc Sine (ASIN)................................................................................................................ 370
C.3.11 Arc Cosine (ACOS) ......................................................................................................... 371
C.3.12 Arc Tangent (ATAN)...................................................................................................... 372
C.3.13 Absolute Value (ABS).................................................................................................... 373
C.3.14 Logarithm (LOG)............................................................................................................ 374
C.3.15 Natural Logarithm (LN)................................................................................................ 375
C.3.16 Exponential (EXPT)........................................................................................................ 376
C.3.17 Natural Exponential (EXP)........................................................................................... 378
C.3.18 Expression (EXPR) .......................................................................................................... 379
C.4 Comparison Blocks ....................................................................................................................... 381
C.4.1 Greater Than (GT).......................................................................................................... 381
C.4.2 Greater Than or Equal to (GE) ................................................................................... 382
C.4.3 Equal to (EQ)................................................................................................................... 383
C.4.4 Not Equal to (NE)........................................................................................................... 385
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C.4.5 Less than or Equal to (LE).............................................................................................386
C.4.6 Less Than (LT)..................................................................................................................387
C.5 Logical and Bit Shift Blocks ........................................................................................................ 389
C.5.1 And (AND)........................................................................................................................389
C.5.2 Or (OR).............................................................................................................................. 391
C.5.3 Exclusive Or (XOR)..........................................................................................................393
C.5.4 Not (NOT)......................................................................................................................... 394
C.5.5 Shift bits Left (SHL)........................................................................................................396
C.5.6 Shift bits Right (SHR)..................................................................................................... 397
C.5.7 Rotate bits Left (ROL)....................................................................................................399
C.5.8 Rotate bits Right (ROR) ................................................................................................400
C.6 Selection Blocks............................................................................................................................. 402
C.6.1 Select minimum value (MIN).......................................................................................402
C.6.2 Select maximum value (MAX).....................................................................................403
C.6.3 Limit value (LIM).............................................................................................................405
C.6.4 Select one of two values (SEL)....................................................................................406
C.7 String Blocks................................................................................................................................... 408
C.7.1 Set string (SET)................................................................................................................408
C.7.2 Find string length (LEN) ...............................................................................................409
C.7.3 Extract sub-string from left (LEFT).............................................................................410
C.7.4 Extract sub-string from right (RIGHT).......................................................................411
C.7.5 Extract sub-string from middle (MID).......................................................................413
C.7.6 Concatenate strings (CAT)...........................................................................................414
C.7.7 Compare strings (CMP).................................................................................................416
C.7.8 Insert sub-string (INS)....................................................................................................417
C.7.9 Delete sub-string (DEL).................................................................................................419
C.7.10 Replace sub-string (REPL).............................................................................................421
C.7.11 Find sub-string (FIND) ...................................................................................................423
C.8 Flow Control Blocks...................................................................................................................... 425
C.8.1 Call sub-ladder diagram (CALL)..................................................................................425
C.8.2 Return to main diagram (RETN).................................................................................426
C.9 Miscellaneous Blocks.................................................................................................................... 427
C.9.1 Convert to Boolean (TO_BOOL).................................................................................427
C.9.2 Convert to Integer (TO_INT)........................................................................................428
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C.9.3 Convert to Float (TO_FLT)............................................................................................429
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C.9.4 Convert to String (TO_STRG)...................................................................................... 430
C.9.5 Truncate (TRUNC).......................................................................................................... 432
C.9.6 Integer to Character (TO_CHR).................................................................................. 433
C.9.7 Character to Integer (CHR_TO).................................................................................. 434
C.9.8 Integer to BCD (TO_BCD) ............................................................................................ 435
C.9.9 BCD to Integer (BCD_TO) ............................................................................................ 436
C.9.10 Move (MOVE) ................................................................................................................. 438
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Pointe Controller User Guide Chapter 1: Introducing the Pointe Controller
Chapter 1: Introducing the Pointe Controller
Welcome to the Pointe Controller. Nematron’s Pointe Controller is an important
part of the new generation of automation technology. The Pointe Controller
extends automation capabilities, previously available only in high-end PC-based
control systems, to low cost embedded control. It incorporates modular I/O and
advanced communications features in a controller built on advanced e-control
software architecture. The result is a very cost effective, easy to implement, high
performance controller that can be used either stand alone or as a node in a
larger e-control system.
Central to the Pointe Controller is the OpenControl software development
environment. OpenControl is Nematron’s industry leading PC-based control
software package that has been successfully used in recent years in large, high
performance manufacturing applications. It provides the means for advanced
application development in Visual Flowchart Language (VFL) or ladder logic. The
Pointe Controller is the result of Nematron’s development effort to develop
scaleable solutions. With the addition of Pointe Controller, Nematron now
provides the means to address a much larger range of data acquisition and
control applications.
Pointe Controller technology is both powerful and easy to use. It will enable you
to quickly implement application systems ranging from simple, stand alone
machine controllers to large, integrated, communications intensive systems.
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Chapter 1: Introducing the Pointe Controller Pointe Controller User Guide
1.1 The Node Controller Concept
Deployable, localized control with a high-speed, standards-compliant interface to
a larger network of devices – that’s the concept of a node controller.
The Pointe Controller is part of a new generation of control devices designed to
meet the needs of today’s more integrated world. It provides all of the features
and functionality of traditional PLCs together with advanced features that enable
it to become a node in a larger, more integrated system. That is the Node
Controller Concept – deployable, localized control with a high-speed, standardscompliant interface to a larger network of devices. The design architecture
enables this advanced functionality to be implemented easily and seamlessly.
All of the key features of the traditional PLC are incorporated into the design of
the Pointe Controller. These key features include the following:
Real-time local control;
Embedded, high reliability electronic design;
Modular I/O;
Pluggable terminal strip connectors;
Ladder logic programming capability; and
Compact, DIN rail mountable package.
Pointe Controllers also incorporate many advanced features that are typically not
found in traditional PLCs. Some of these advanced features include:
Advanced visual flow chart programming capability;
Ability to mix flowchart and ladder programming;
Application program deployment over an Ethernet link;
Firmware update deployment and management over an Ethernet link;
Advanced communications for development, deployment, monitoring and
coordination within a networked system;
Remote monitoring, programming and debug capability over Ethernet;
Powerful diagnostic tools for use during program development and
system monitoring;
Scalable solutions;
Remote Ethernet I/O options and ability to network Pointe Controllers;
Easy integration into larger systems and easy future expansion of systems;
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Coordinated operation within a larger system;
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Pointe Controller User Guide Chapter 1: Introducing the Pointe Controller
Real-time, open standard data sharing from production to the front
office; and
Direct connect operator panel interfaces available.
Since the mid 1970s, PLCs have been the foundation of traditional control
applications. PLCs have provided the advantages of localized control, modular
configuration, and rugged industrial packaging. Where traditional PLCs have
been weak has been in the areas of distributed architectures, communications
and more complex logic.
The 1990s brought new demands on control systems for deployability,
information collection and coordination. Since traditional PLCs are weak in these
types of capabilities, a new technology called “PC-based control” was launched
by Nematron and adopted by a number of other automation technology
companies. PC-based control has been very successful in mid-size to large systems
applications with distributed I/O and integration with other software systems for
e-manufacturing, MES, MRP, quality control and web access.
While “PC-based control” technology has brought the world of industrial
automation a number of improvements in processing power, communications,
performance and maintainability, it has had some current limitations. Those
limitations have been primarily based on the economics aspects of implementing
PC-based control being economically justifiable in only mid to high-end
applications.
Nematron developed the Pointe Controller to capitalize on the advanced features
of PC-based control while scaling the solution opportunity to medium and lowend applications. While the Pointe Controller has many applications in
independent, non-networked applications, its unique design also forms the basis
for control solutions for widely distributed yet integrated applications.
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Chapter 1: Introducing the Pointe Controller Pointe Controller User Guide
The figure below illustrates the power of the Pointe Controller. It shows a
number of Pointe Controllers connected into a larger network. Each Pointe
Controller interfaces local I/O and performs local control on a real-time dedicated
basis. Each Pointe Controller can also be accessed by the larger system (shown as
“Host Computer”) to be polled for data and status, to coordinate applications, be
reprogrammed and deployed on demand, and any other type of system-wide
activity that may be desired.
The Pointe Controller’s design implementation of a low cost, modular, embedded
real-time control platform creates a tremendous level of opportunity and changes
the way control solutions can be implemented.
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Pointe Controller User Guide Chapter 1: Introducing the Pointe Controller
1.2 Typical Applications
Pointe Controllers can be used for a wide variety of data acquisition and control
applications. The Pointe Controller’s low cost, flexible and easy to use design
makes it a perfect choice for many small control applications that traditionally
have used PLC type solutions. Its advanced capabilities, which emphasize
deployability and network interoperability make it particularly applicable to
larger, distributed control applications. Typical usage includes the following
applications:
Packaging machinery
Semiconductor equipment
Distributed manufacturing
Building automation
Data acquisition
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1.3 Architecture Options
1.3.1 Stand-alone Operation
The general discussion of the Pointe Controller has emphasized the
communications capability and capability to be deployed as a node on a network.
In reality, the Pointe Controller is just as applicable to stand-alone applications
that do not require remote communications.
1.3.2 Master Controller
As a Master Controller for distributed control solutions, the Pointe Controller is
capable of interfacing with up to four OptiLogic Remote I/O terminals via
Ethernet. This reduces wiring cost of the I/O devices back to the controller, while
providing high speed I/O control from the controller.
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1.3.3 Network Node
As a control node in a scalable network, the Pointe Controller performs dedicated
real-time local control, while maintaining communications with the designated
supervisory computer. Total system deployment, configuration, project
coordination, and data logging can be implemented from any authorized
network workstation.
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1.4 Available Parts and Accessories
The Pointe Controller system is designed to be extremely modular and flexible. As
such, all Pointe Controller parts and accessories are sold separately. For
availability and pricing, please call Nematron at 1-800-636-2876, or visit us on the
Web at http://www.nematron.com/Sales and find a certified Nematron distributor
near you.
A complete list of available parts and accessories follows:
PART # DESCRIPTION
PTC-5800 Pointe Controller base unit, 8-slot
NOTE: First-time users must also order at least one PointeControl
software CD (part # NS-PTC) and one RS-232 download cable (part # OLCBL-DNL). For more information, see below.
Software
NS-PTC PointeControl Development Framework and Runtime Monitor (software
CD), for Pointe Controller program development and debugging. Singleseat license that can be used to program multiple Pointe Controller
units. Runs on Microsoft Windows NT 4.0, Windows 2000, and Windows
XP.
Accesories
OL-CBL-DNL Pointe Controller Boot Program download cable — connect’s PC’s RS-232
OL-CBL-X01 Ethernet CAT5 crossover cable, 6 foot, red — for direct connecting PC to
OL-CBL-P01 Ethernet CAT5 patch cable, 6 foot, black — for connecting Pointe
CBL-PV10 Pointe Controller to Nematron PowerView™ Touchscreen HMI
OL-PS1 Power Supply — 120 VAC to 24 VDC, 1 Amp output, wall pluggable.
port to Pointe Controller’s RS-232 port for IP address setting.
Pointe Controller for program downloading.
Controller to an Ethernet network.
communication cable — supports Modbus protocol on Serial.
OptiLogic I/O Modules
OL0001 Blank Module — recommended to fill unused slots in base unit.
OL2104 4-point Relay Output Module, 5-30VDC or 5-132VAC, 2A/point @ 24VDC,
OL2108 8-point Relay Output Module, 5-30VDC or 5-132VAC, 2A/point @ 24VDC,
1A/point @ 120VAC, isolated contact outputs.
1A/point @ 120VAC, 4A/common, 2 commons.
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OL2109 8 points, 5-40VDC sinking output. 300 mA sinking capability / point.
OL2111 8 points, solid-state relay output. 15-132VAC, 0.5A/point.
OL2201 8-point digital input simulator.
OL2205 4-point AC/DC input. 10-30V (sourcing or sinking), isolated input and
return lines.
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PART # DESCRIPTION
OL2208 8-point DC input. 10-30VDC (sourcing or sinking).
OL2211 8-point AC input. 80-132VAC.
OL2252 Counter Input, 2 channels, 0-15 KHz.
OL2258 High Speed Counter. P&D, Quadrature, Up/Down Count. 0-80 KHz (0-160
OL2304 4-channel analog voltage output, 14-bit. 0-5v, 0-10v, +/-5v, +/-10v
OL2408 8-channel analog voltage input, 14-bit. 0-5VDC or 0-10VDC
OL2418 8-channel analog current input, 14-bit. 4-20 mA.
OL2602 2-channel RS232 serial.
KHz for Quad). Two high-speed open collector outputs.
configurable. 12-bit resolution.
conbfigurable.
OptiLogic Operator Panels and Interconnect Cables
OL3406 Pushbutton / Indicator Panel. 4 user-definable pushbuttons, 6 LED
OL3420 Terminal Panel. 2 line x 20 character alphanumeric LCD. LED backlit. 4
OL3440 Alphanumeric Display panel. 4 line x 20 character LCD. LED backlit.
OL3850 Keypad Terminal panel. 2 line x 20 character alphanumeric LCD. LED
OL-CBL-RIB1 OL Operator Panel interconnect cable, 1 inch (approximate). Comes with
indicators. Comes with OL-CBL-RIB1.
user-definable pushbuttons. Comes with OL-CBL-RIB1.
Comes with OL-CBL-RIB1.
backlit. Numeric keypad. Three large LED indicator light bars. 5 userdefinable pushbuttons. Comes with OL-CBL-RIB1.
each operator panel.
OL-CBL-RIB12 OL Operator Panel interconnect cable, 12 inches (approximate).
OL-CBL-RIB36 OL Operator Panel interconnect cable, 36 inches (approximate).
OptiLogic RTUs (remote I/O base units for networked systems)
OL4054 4-slot RTU base — 10BaseT Ethernet interface, 1 RS232 port, operator
OL4058 8-slot RTU base — 10BaseT Ethernet interface, 1 RS232 port, operator
OL4228 8-slot Modbus RTU base — 10BaseT Ethernet interface, 1 RS232 port,
panel interface, DIN rail mountable, 8-30VDC power required for
operation.
panel interface, DIN rail mountable, 8-30VDC power required for
operation.
operator panel interface, DIN rail mountable, 8-30VDC power required
for operation.
Complete technical specifications for all OptiLogic I/O modules and operator
panels listed above can be found in Appendix A, starting on page 231.
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Chapter 2: Initial Setup
This chapter describes how to quickly set up the Pointe Controller unit, including
connecting a power supply to the Pointe Controller unit, installing the
PointeControl software on your PC, setting the controller’s network address,
installing I/O modules in the card cage, and connecting the controller to an
Ethernet network.
This setup procedure is greatly abbrieviated, so that you can jump right into
simple program development as described in Chapter 3, “Quickstart Project,”
starting on page 32. For complete system design and installation instructions, see
Chapter 4, “System Design and Installation,” starting on page 70.
To set up a Pointe Controller unit, you must have at least the following items:
A Windows-based PC that meets the PointeControl system requirements
One PointeControl software CD (part number NS-PTC)
One PTC-5800 base unit, 8-slot (part number PTC-5800)
One AC power adapter and cord (part number OL-PS1)
One RS-232 download cable, DB-9 to RJ-11 (part number OL-CBL-DNL)
One 10BaseT crossover cable (part number OL-CBL-X01)
NOTE: All Pointe Controller parts and accessories are sold separately, as described
on page 20.
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2.1 Getting to Know the Pointe Controller Base
The figure below shows the layout of a Pointe Controller base:
The Pointe Controller base consists of a card cage containing the motherboard.
The base unit has a built in Ethernet port, as well as an RS232 port. The Ethernet
port is the interface to the larger system. The RS232 port is provided for general
purpose communications (as defined by your application program). It is also
designed to allow you to load future program upgrades (to incorporate the
ability to interface future I/O boards and operator panels) into the base.
Both communications ports have status indicator LEDs which provide you with
visible indications of each port’s operation. The RS232 serial port indicates when
it is transmitting (TX) and receiving (RX). The Ethernet port provides indications
for good Ethernet link connection (L) and Ethernet port access by the base
processor (S), as well as transmit (T) and receive (R) indicators.
Power must be provided to the unit by an external DC power supply. Any DC
voltage within the range of 8-30VDC is acceptable.
Input and output modules can be plugged into the slots in the base. Most
modules can plug into any base slot (including slot 0).
NOTE: Slot 0 includes additional features used by certain 12-pin specialty
modules. These modules are documented as slot 0-specific.
The OptiLogic base can snap onto any standard DIN rail, including the rail molded
into the back of all OptiLogic operator panels. When attaching an OptiLogic base
to an OptiLogic operator panel, the 10-pin cable connection on the side of the
base is used.
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2.2 Supplying Power to the Pointe Controller
The Pointe Controller unit requires a 8-30VDC, 1 Amp power supply. This can be
provided either by using a wall-pluggable AC adapter (part number OL-PS1) or by
connecting the unit directly to a properly rated DC grid. The connection is made
at the Power Input screw terminals located at the bottom left corner of the base
unit.
To connect a power supply to the controller:
1. Make sure the power is OFF – the AC adapter should be unplugged and/or
the DC grid should be turned off.
2. Using a regular slotted screwdriver, loosen the Power Input screw
terminals.
3. Pass the power supply wires through the opening in the bottom of the
controller base unit. Insert the positive wire into the positive terminal (+)
and the negative wire into the negative terminal (-).
4. Retighten the screw terminals.
5. Tug gently on the wires to verify that they are properly secured to the
terminals.
The Pointe Controller unit can now be powered on.
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2.3 Installing the PointeControl Software
The PointeControl software CD (part number NS-PTC) includes the control
application development package and the various utilities needed to connect to
and configure the Pointe Controller unit.
System requirements:
200 MHz or faster Pentium processor
Operating system (any one):
o Microsoft Windows NT 4.0 Service Pack 5 or 6
o Microsoft Windows 2000
o Microsoft Windows XP
A CD-ROM drive
A 10BaseT Ethernet card
A DB-9 serial port
To install the PointeControl software on your PC:
1. Insert the PointeControl software CD into your CD-ROM drive.
2. Open the mounted CD (typically drive D: or E:) and double-click
SETUP.EXE.
3. Follow the onscreen installation instructions. No unusual installation
options are presented.
4. Restart your PC when prompted.
NOTE: As part of the PointeControl software installation, a Java Runtime Engine
(JRE) is also installed on your PC. This JRE is used only by the PointeControl
software and it is not included in the Windows registry. It should not conflict with
any other Java tools you may have installed on your PC.
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2.4 Configuring the Controller’s Network Settings
Each Pointe Controller unit has two distinct addresses: an IP address, for
communicating across an Ethernet network; and a Modbus address, for
communicating with serial Modbus devices such as operator panels and bar code
readers. In this initial setup, we will configure only the IP address.
The Pointe Controller unit comes preconfigured with a default IP address. You
must reset the address so that the unit can properly communicate on your
Ethernet network. This change is made via a direct serial connection between
your PC and the Pointe Controller unit.
Remember that each Pointe Controller unit on your network must have its own
unique IP address and node name, which is set prior to applying power to the
controller. Duplicate addresses will cause system communications to fail.
To set the IP address of the Pointe Controller unit:
1. Establish a serial connection between your PC and the Pointe Controller
unit, using the download cable (OL-CBL-DNL):
a. Before you connect the serial cable, make sure the Pointe
Controller is powered off. The unit looks for the cable when it is
first powered on.
b. Connect the cable's RJ-11 plug to the Pointe Controller's serial
port.
c. Connect the cable's DB-9 plug to your PC's serial port.
2. Power on the Pointe Controller unit.
NOTE: There is no power switch on the Pointe Controller unit itself. Either
the AC adapted must be plugged in or the directly connected DC grid
must be turned on.
3. From theWindows Start menu, choose Programs > PointeControl >
Update Tool.
NOTE: If you are running the Update Tool for the first time, you will be
asked to specify which COM (serial) port the tool should use. Enter the
number (1, 2, 3, or 4) to which you connected the serial cable in Step 1
above, and then click OK. After that, the tool will finish launching.
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The PointeControl/OptiLogic Update Tool application window appears.
4. Click Automatic Base Detection. The application should immediately
connect to your Pointe Controller unit. If it does not, check your serial
connection and try again. If it still cannot connect, click Manual Setup
and select PTC5800 from the drop-down menu.
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When the application successfully connects, the following window will
appear:
The Read Current Settings pane displays the current address settings on
the Pointe Controller unit. If you are addressing the unit for the first time,
the factory default settings are displayed.
5. Under New Settings, enter the new IP address and subnet mask for the
Pointe Controller unit. For example, an IP Address of “10.16.80.103” and a
Sub Net Mask of “255.255.255.00”.
The Pointe Controller unit should receive an address on the same subnet
as your PC. If you do not know what values to enter, contact your system
administrator.
NOTE: The Pointe Controller unit does not communicate directly with any
network gateway or router. Instead, it broadcasts to all machines on its
subnet. Therefore, you should enter "00.00.00.00" in the Default Gateway
field.
6. For the Default Server IP Address, enter the IP address of the PC with
which you are connecting to the Pointe Controller unit. For example,
“10.16.80.69”.
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The secondary server is the PC to which the Pointe Controller unit will
attempt to connect when it first powers on.
7. For the Node Name pane, enter the name by which the Pointe Controller
unit will identify itself to PointeControl Monitor. For example, “Gundam.”
NOTE: If you do not want or need to change the Node Name, you can skip
this step and leave the factory default setting.
For more information on PointeControl Monitor, see Chapter 6,
“Downloading to the Controller,” and Chapter 7, “Monitoring and
Debugging.”
8. Click the Save Settings button to save your settings to the Pointe
Controller unit. When the settings are saved, the fields will turn green.
9. Click the Read Current Settings button to verify that the new settings
were saved correctly. The current settings should now match the IP
address, subnet mask, secondary server, and node name that you entered.
10. Exit the Update Tool application by clicking the Exit button.
11. Power off the Pointe Controller unit.
12. Disconnect the RS-232 serial cable.
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2.5 Installing I/O Modules in the Controller
Each module occupies one slot in the controller base. Each slot position is
numbered as shown below. The slot number will provide a reference to your
application program for selecting the appropriate module for each particular
operation.
Slot numbering is simply left to right, starting with slot number 0.
Each slot has card guides along each side and a connector on the motherboard.
To install an I/O module, place the module’s circuitry board in the top and bottom
card guides. (Note that the board will not be tightly retained until it is
approximately 3⁄4 inch into the card guide.)
As you push the module into its mating connector, squeeze the ends together.
This will allow the board latches to travel inside the card cage. When you have
pushed the board into its mating connector and released, the latches should hook
the card cage and keep the module in place.
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2.6 Connecting the Controller to Your PC
An Ethernet network connection is used to download finished control
applications from your PC to the Pointe Controller unit. It is also used to monitor
the unit's runtime performance and to share Modbus TCP data between different
control devices. An RJ-45 Ethernet port is located at the left side of the Pointe
Controller unit.
The simplest system is a point-to-point connection. Point to point connections, as
illustrated below, require only a crossover type patch cable.
An Ethernet crossover cable, shown below, connects the transmitter on one side,
with the receiver on the other. This is a category 5 type UTP crossover patch cable.
Cable length is limited to less than 100 meters.
You can now power on the Pointe Controller unit and proceed to Chapter 3,
“Quickstart Project.”
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Chapter 3: Quickstart Project
The first project we will implement with the Pointe Controller is a very simple one
that involves setting up an automated timer and then adding a few different
types of indicators that can be used to display the progress of the timer. To
implement this project, you will need the following.
A Pointe Controller base unit, configured as described in “Initial Setup”
above
An OL2201 Digital Input Simulator module, installed in the first I/O slot
An OL2109 Digital Output module, installed in the second I/O slot
The program that we are going to develop will monitor the first toggle switch on
the OL2201 input module. If it is on, then the program will start the timer and
display its progress using the LEDs of the OL2109 output module and the four-line
LCD of the OL3440 display panel.
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3.1 Starting a New Project
Begin by launching the PointeControl Framework application and creating a new
project:
1. From the Windows Start menu, choose Programs > PointeControl >
Framework. The PointeControl Framework window will appear.
2. From the File menu, choose New Project.
3. In the New Project dialog box, enter the name of your project (e.g.
“Mytest”) and click OK.
Once you have done this, your new project will be opened. The project name will
be shown on the title bar on the top of the PC screen and a project tree,
containing Flow Chart, Ladder Diagram and Logic Memory definitions (all
undefined at this time) will show up in the left hand pane of the display.
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3.2 Defining Input, Output, and Memory Tags
The next thing that we’ll do is define our inputs, outputs and memory tags that
we’ll need for this project. In general, you can do I/O and data memory
definitions piecemeal, throughout the project development process – whenever
you find you need another variable or I/O point.
In this project, we will define all of the I/O points — eight input switches and
eight output LEDs — even though we’ll be using only one input switch. We will
also attach four string variables to the four lines of the display panel.
After we have defined all of the I/O, we will set up the timer that drives the
project
Lastly, we will need to define a few reusable data variables for use in our internal
calculations, but we will address those as we add each of the progress indicators.
3.2.1 Defining input bits
First, to define the input tags:
1. In the project workspace pane on the left, expand the list to show Logic
Memory > Inputs and then double-click %IX (Bits). This opens the input
tag editor window.
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2. Create a table entry for the first input tag (%IX1), either by clicking the
Insert button or by incrementing the Size counter up to 1.
3. In the Alias field, enter the name of the input tag: InSwitch1. (You will
need to click in the field before you can type in it.)
Now go ahead and define the rest of the tag names for the input module, even
though we’re not going to use them in this tutorial project. We’ve already used
the name InSwitch1 for the first switch, so let's name the rest of the inputs
InSwitch2 through InputSwitch8.
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4. Click the Copy button. The Copy Channels dialog box will appear.
5. Increment the Number of channels up to 7 and click OK. Seven more
input tags will be defined in numerical order, copied from the original
InSwitch.
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6. Close the input tag editor window using the button in the corner.
When asked to save changes, click Yes.
3.2.2 Defining output bits
Now let’s define our output tags using the same basic procedure as we used to
define our input tags:
1. In the project workspace pane on the left, expand the list to show Logic
Memory > Outputs and then double-click %QX (Bits). This opens the
output tag editor window.
2. Create a table entry for the first output tag (%QX1), either by clicking the
Insert button or by incrementing the Size counter up to 1.
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3. In the Alias field, enter the name of the output tag: Myout1. You will
need to click in the field before you can type in it.
4. Click the Copy button. The Copy Channels dialog box will appear.
5. Increment the Number of channels up to 7 and click OK. Seven more
input tags will be defined in numerical order, copied from the original
Myout.
6. Close the output tag editor window using the button in the corner.
When asked to save changes, click Yes.
3.2.3 Defining memory tags
Lastly, we’ll define the memory tags that will keep track of the state of the
program:
1. In the project workspace pane on the left, expand the list to show Logic
Memory > Memory and then double-click %MX (Bits). This opens the
output tag editor window.
2. Create a table entry for the first string (%MX1), either by clicking the
Insert button or by adjusting the Size counter up to 1.
3. In the Alias field, enter the name of the input tag: rightOn. You may
need to click in the field before you can type in it.
4. Close the memory tag editor window using the
When asked to save changes, click Yes.
button in the corner.
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3.3 Associating Tags with I/O Points
At this point, we have tag-names defined. However, we haven’t configured our
I/O and haven’t associated our tag-names with particular I/O points. Let’s do that
now:
1. From the Project menu, choose Configure I/O. The I/O Configuration
window will appear.
2. Next to Slot 1 module type, click the drop-down menu and select
OL2201. This configures the OL2201 module in slot 1 of the Pointe
Controller base unit.
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NOTE: Configuring slot 1 activates the I/O button to the right of the slot.
3. Click the I/O button for slot 1. The OL2201 I/O Map window will appear.
At this point of our project development, we have defined input tag names and
selected an input module. What we haven’t done is associate each input tag
name with a particular point on the input module. That is what we will do now.
4. To the right of Input 1, click the
button. A list of available input tags
will appear.
5. From the list of available input tags, select InSwitch1.
6. Repeat steps 4 and 5 for each of the remaining seven inputs, associating
InSwitch2 to Input 2, InSwitch3 to Input 3, and so on.
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7. Click OK to close the OL2201 I/O Map window.
Now repeat the procedure to associate the eight output tags with the OL2109
module in slot 2:
8. Next to Slot 2 module type, click the drop-down menu and select
OL2109. This configures the OL2109 module in slot 2 of the Pointe
Controller base unit.
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9. Click the I/O button for slot 2. The OL2109 I/O Map window will appear.
10. To the right of Output 1, click the
button. A list of available output
tags will appear.
11. From the list of available output tags, select MyOut1.
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12. Repeat steps 10 and 11 for each of the remaining seven outputs,
associating MyOut2 to Output 2, MyOut3 to Output 3, and so on.
13. Click OK to close the OL2109 I/O Map window.
14. Click OK to close the I/O Configuration window.
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3.4 Creating Your First Flow Chart
We’re going to do our first application with a flow chart. To create a new flow
chart:
1. In the project workspace window on the left, select Flow Chart. Then
from the File menu, choose New.
When you do this, a new flow chart will be created and added to the
project tree.
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We could give our flow chart a name right now. In most cases, you would
immediately name your flow chart based on the function it performs in your
application. Typical names include “Gantry 1,” “IPA Tank,” “Purge Cycle,” and so
on. We’re going to wait to give our program a name and use the default name
“Chart1” for right now.
As you can see on your screen right now, a flow chart with nothing but a “Start”
block and a “Return” block comes up on your screen. We’re ready to enter our
program.
Since we want to flash the outputs if Switch 1 is on, lets start with adding a
decision block based on Switch 1’s state:
2. Click the Decision Block tool on the toolbar, and then click on the flow
line between the existing Start and Return blocks.
A generic decision block will be placed in your flow chart.
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3. Double-click on the decision block to open its associated Block Properties
window.
The Block Properties window is where you define what the block will do.
As you can see, there are a number of properties that you can configure.
Caption determines the text description of the block. This is useful in
documenting the project, but we shall leave it unchanged for now and
come back to it later.
Line Labels determines the type of decision to be made by the block. We
shall use the standard If/Then/Else labels.
Switch T/F Paths determines in which direction the logic flow will
proceed, depending on whether the decision resolves as True or False. In
the default No setting, True (Then) continues downward while False (Else)
branches to the right. In the Yes setting, False (Else) continues downward
while True (Then) branches to the right. This choice affects the overall
readability of the flow chart and how the rest of the blocks will be
oriented. For this quickstart project, let’s switch the paths:
4. In the Block Properties window, click the Switch T/F Paths drop-down
menu and select Yes.
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When the property is changed, the Then and Else paths are switched.
Timeout Value is an optional override that we won’t use here.
Condition Type is an Expression (the default). We want to define our
expression as “If InSwitch1 = ON”:
5. To the right of the Expression property, click the
button. The Build
Condition window will appear.
6. In the Arg Type list on the left, select Inputs. A list of available inputs will
appear under Selection List.
7. In the Selection List, select InSwitch1. The InSwitch1 tag will be added to
the Condition pane.
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8. Click the = button to add “=” to the condition.
9. Click the ON button to add “ON” to the condition.
10. Click OK to close the Build Condition window and enter the condition in
the Expression property.
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11. Close the Block Properties window.
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3.5 Inserting a Second Decision Block
So far, all we’ve done is check to see if InputSwitch1 is on. If it is on, we want to
flash the first two output LEDs out of phase. To do so, we turn the first output on
and the second off for a period of time, then turn the first output off and the
second on for a time period. Our flow chart will use the flag that we previously
defined, rightOn, to keep track of which state we are in.
1. Click the Decision Block tool on the toolbar, and then click on the Then
branch to the right of your “InSwitch1 = ON” decision block. A new
decision block will be inserted.
2. Double-click on the new block to open its associated Block Properties
window.
3. Define the block’s Expression as “rightOn = TRUE,” as described
previously. Remember that rightOn is a Memory tag rather than an Input
tag.
4. Close the Block Properties window.
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3.6 Assigning Outputs
Now we are going to add the first of the two output patterns — turn off the first
output LED (MyOut1) and turn on the second output LED (MyOut2).
1. Click the Process Block tool on the toolbar, and then click on the Then
branch below your “rightON = TRUE” decision block. A new Process block
will be inserted.
2. Open the Process block’s Block Properties window, as described
previously.
3. To the right of the Command property, click the button. The Select
Process Command window will appear.
4. In the Type list, select General. A list of general commands will appear.
5. In the Command list, select Assign.
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6. Click OK to close the Select Process Command window and enter the
Assign command in the Command property.
7. You will see that a Statement sub-property is added to the Command
property.
8. To the right of the Statement sub-property, click the
Assignment window will appear.
9. Select the MyOut1 output tag, as described previously.
button. The Build
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10. Move the cursor to the Expression field, either by clicking in it or by
pressing the Tab key.
11. Click the OFF button to add “OFF” to the expression.
12. Click OK to close the Build Assignment window and enter the assigment
in the Statement sub-property.
13. Now let’s add a second Assign command to this same Process block.
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14. Click on and highlight the existing Command property, and then click the
Insert button. A second Command property will be inserted.
15. Define the second Command property as “MyOut2 = ON,” as described
previously.
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Now we have two Assign commands in the Process block, as shown below.
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Let’s add just one more statement to set rightOn to TRUE. This will force the
decision block to take the other branch on the next scan through. In that branch,
we’ll set the output states to the opposite values. That will create the flashing
effect that we are looking to achieve.
16. Insert a third Command property, as described previously.
17. Define the third Command property as “rightOn = TRUE,” as described
previously. Remember that rightOn is a memory tag rather than an
output tag.
18. Close the Block Properties window.
Now we need to add the second of the two output patterns — turn on MyOut1,
turn off MyOut2, and set rightOn to FALSE.
19. Insert a new Process block in the Then branch to the right of “rightOn =
TRUE” decision block.
20. Open the Process block’s Block Properties window.
21. Using the same procedure as before, define three Assign commands in the
Process block:
o “MyOut1 = ON”
o “MyOut2 = OFF”
o “rightOn = FALSE”
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The Process block should appear as shown below.
22. Close the Block Properties window.
Looking at our flow chart, we can now see that if the toggle switch (InSwitch1) is
on, then the output LEDs (MyOut1 and MyOut2) will flash back and forth. As
soon as the chart reaches the end, it returns to the start and scans through again.
If the toggle switch is off, then the output LEDs freeze in their last state until the
switch is on again.
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3.7 Adding a Time Delay
Unfortunately, when the toggle switch is on, the output LEDs flash too rapidly for
us to see. We need to put in a time delay of 500 milliseconds — just enough to
slow the flashing to an observable speed.
1. Insert a new Process block after the two Process blocks that you defined
earlier.
NOTE: If you place the block in the wrong place, there are two ways to fix
it. The first way is to simply delete the block and insert it again. (For more
information on deleting Flow Chart blocks, see page 143.)
The second way is to click on and drag the block to the correct position in
the flowchart. The chart will automatically redraw itself to incorporate
the block wherever you place it.
2. Open the new block’s Block Properties window.
3. Set the Command property to Wait.
A Wait Value sub-property will be added.
4. To the right of the Wait Value sub-property, click the
Argument window will appear.
button. The Build
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5. In the Argument field, enter a numerical value of 500.
6. Click OK to close the Build Argument window and enter the argument in
the Wait Value sub-property.
7. Close the Block Properties window.
Your flow chart should now appear as shown below.
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3.8 Checking the Chart Integrity
The final step in entry, or modification, of a flow chart is an integrity check. This
integrity check will automatically check the chart for errors in the flow chart
function blocks. It will not tell you if your flow chart logic is correct – it will only
tell you if the statements have been entered properly.
To perform an integrity check, click the Check Integrity tool on the toolbar.
The results of the integrity check will appear in the Message and Error Window
Pane (the box below the editor window). The figure on the right illustrates the
message that you will get if your flow chart contains no statement errors. If an
error is found, a message listing the error and the flow chart block where it is
located, will appear in the Message and Error Window.
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3.9 Building the Project Runtime
Once all of the flow charts have been created, we are ready to build the project
runtime.
First, we must define the list of charts that make up the project. A project can be
comprised of many flow charts and/or ladder diagrams. When a chart is created, it
is not automatically added to the project list. This allows you to incrementally edit
charts and keep optional charts within your development environment. When its
time to build the project runtime, you can place the required charts in the project
list.
To configure your project’s chart list:
1. From the Project menu, choose Configure Chart List. The Chart List
window will appear, showing all charts in the current project build and all
other available charts. We’ve only created one chart. — it is listed as
available.
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2. In the Available Charts list, select Chart1 and click the button to move
the chart to the active Chart List.
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The result should be as shown on the right.
3. Click OK to close the Chart List window.
After you have configured the project’s chart list, you must define the scan
parameters. Your project’s runtime operation actually occurs in a repetitive cycle
of updating inputs, logic solve, updating outputs and communications.
4. From the Edit menu, choose Preferences. The Preferences window will
appear.
Logic Solve scan interval is the time between the beginning of one
logic solve pass and the next.
Monitor update interval is how frequently, the monitor, which we’ll
use next for debug purposes, talks to the Pointe Controller to update its
information. The lower the update interval number, the faster the
monitor will react — but the more load it places on the Pointe Controller
processor for handling communications.
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Controller Timeout Interval is a watchdog timer for the chart
execution. If the chart logic solve is greater than this value the project will
stop.
Download Source when checked will send the project source code to
the Pointe Controller. If this is un-checked the source will not be present
in the Pointe Controller and the Pointe Control Monitor will not be able
to view or debug the application.
For our application, a 15 millisecond scan time setting and 250 millisecond
monitor update interval are more than sufficient (actually, in most cases, you’ll
want to increase the monitor interval to 500 to 1000 milliseconds to reduce the
CPU loading caused by the monitoring activities).
5. In the Logic Solve scan interval, enter 15 milliseconds.
6. In the Monitor update interval, enter 250 milliseconds.
7. Controller Timeout Interval to 5000 milliseconds.
8. Download Source must be checked.
9. Click OK to save your changes and close the Preferences window.
Now we can build our project runtime:
10. Click the Build Runtime tool on the toolbar.
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When the project builds, messages will come up in the Message Window,
informing you of the progress of the build. The screen shot shown above
illustrates a successful build. Two key message lines are the “No errors found” line
and the “Project build successful” line. Most of the other messages are
informative about the progress of the build.
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3.10 Downloading and Running Your Program
Downloading a finished program to the Pointe Controller unit is performed via
the PointeControl Monitor. The Monitor is launched separately from the
development framework, either by choosing it from the Windows Start menu
(Start > Programs > PointeControl > Monitor), or by “activating” it from
within the framework itself.
To activate the monitor from within the framework, click the Activate
Monitor button on the toolbar
Alternately, you can choose Activate Monitor from the Window menu.
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Once the PointeControl Monitor window is active, you can download your project
runtime to the Pointe Controller unit:
1. Click the Controller drop-down menu and select the Pointe Controller
unit from the listed devices.
2. Click the Project drop-down menu and select your project runtime. If you
have followed the examples given in the quickstart, your project runtime
should be named “Mytest.”
3. Click the Load button. Your PC will spend several moments preparing the
download. (The exact time depends on the processing speed of your PC.)
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TIP: You can get a detailed view of the download process by selecting the
Console tab, as shown below. The console messages are generated by
PointeControl Monitor as it prepares your project to run on the Pointe
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Controller’s Java-based processor. In most cases you can ignore these
messages; they are useful only when troubleshooting a faulty download.
A progress bar in the Pointe Control Monitor window shows your project
runtime is downloaded to the Pointe Controller unit.
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When the download is complete, the Start button will become active.
4. Click the Start button to run the project.
5. Select the Charts tab, as shown below.
The PointeControl Monitor window should show that your one chart (as
configured in the Chart List) is running. The Pointe Controller unit is now
executing your project as a real-time control progam.
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3.11 Monitoring Your Program While It Runs
From your PC, you can monitor logic flow, view snapshots of tag values, change
tag values, set breakpoints, single-step through your program, and get
performance and loading information.
To monitor your program while it is running:
1. In the PointeControl Monitor window, click the Charts tab. A list of all
currently running charts will be displayed.
2. In the Charts tab, double-click Chart1. The chart will be displayed in a
separate monitor/debug window.
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3. In the Chart1 monitor/debug window, click the Enable Logic Flow and
Enable Debug Trace tools on the toolbar.
You now have a snapshot of the program’s logic flow, highlighted in yellow and
updated at a regular interval. The logic flow shown is the last 200 program blocks
executed each time the monitor collects a snapshot. The snapshot is taken based
on the Monitor update interval that you defined previously. (See “Building the
Project Runtime” above.) If the interval is set to 100 milliseconds, then a snapshot
will be taken every 100 milliseconds.
Flip the first switch on the OL2201 module and watch what happens. Depending
on whether the switch is on or off, you should see the logic flow change. Watch
the lights on the OL2109 output module. When the switch is in the on position,
lights for module outputs 0 and 1 should alternate. You should be able to see this
same alternating pattern in the logic flow.
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4. Double-click on any of the flow chart blocks (except the Start and Stop
blocks). A Block Watch window for that block will appear, showing all of
the tags referenced by that block.
The Block Watch window shows all of the tags used in the block and the
running value of each tag.
NOTE: The value shown for each tag is not the real-time value of the tag
as the Pointe Controller is actually executing the block. It is the value of
the tag at the time of last snapshot, which is generally more useful for
debugging purposes.
5. Close the Block Watch window.
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3.12 Setting Breakpoints
Sometimes you’ll want to check if your program gets to a particular point in your
chart. You may also want to step through the execution of the program one
block at a time in order to debug your logic. This is achieved by setting break
points in the logic flow:
1. Make sure your program is running and Debug Trace is enabled. (See
“Monitoring Your Program” above.)
2. Select a block in the flow chart. The block will be highlighted green.
3. Click the Insert/Remove Breakpoint tool on the toolbar.
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When you do this, an alert window will pop up on your screen, warning
you that stopping the flow of a running program could cause problems (if
you were actually controlling a machine) and asking you to verify that
you do in fact want to insert the break point.
4. Click Yes. A break point will be set on the selected block.
In a project as small as this (a single small flow chart), the executing program
should hit the break point almost immediately. Note the pink rectangle around
the block and the red diamond on the left side of the block. The pink rectangle
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indicates that a break point is set for this block. The red diamond indicates that
the program has hit the break point.
Now that we have hit a break point, we can step through the program one block
at a time:
5. Click the Single Step tool on the toolbar.
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6. Continue to click the Single Step tool and watch the Pointe Controller
step through your program.
Each time you click the Single Step tool, the program will step to and
highlight the next block in the flow. All blocks will execute as they
normally would, updating tag values and changing outputs as they go.
NOTE: You may wish to disable Debug Trace as you step through the
program, in order to reduce screen clutter.
The simple program that you have just written, downloaded and monitored has
given you a firm basis for any future program development. We have gone
through all of the basic operations. You should be ready to develop and
implement more complex “real” applications by following the same procedures.
As you begin development of your target application programs, recognize that in
most such applications, it makes sense to use multiple flow charts, ladder
diagrams, or a combination of both. You can experiment with the process on
your own, or you can read the rest of the manual to get more detailed
information.
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Chapter 4: System Design and Installation
Now that you understand the basics of the Pointe Controller, you can design a
complete machine control system using it. Good system design includes defining
your I/O needs, selecting the appropriate modules and panels, calculating the
power budget of the system, wiring the I/O to the equipment, and observing
proper safety guidelines.
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4.1 Safety Guidelines
WARNING: Providing a safe operating environment for personnel and equipment
is your responsibility and should be your primary goal during system planning and
installation. Automation systems can fail and may result in situations that can
cause serious injury to personnel or damage to equipment. Do not rely on the
automation system alone to provide a safe operating environment. You should
use external electromechanical devices, such as relays or limit switches, that are
independent of the Pointe Controller program to provide protection for any part
of the system that may cause personal injury or damage.
Every automation application is different, so there may be special requirements
for your particular application. Make sure you follow all national, state, and local
government requirements for the proper installation and use of your equipment.
Plan for Safety
The best way to provide a safe operating environment is to make personnel and
equipment safety part of the planning process. You should examine every aspect
of the system to determine which areas are critical to operator or machine safety.
If you are not familiar with Pointe Controller system installation practices, or your
company does not have established installation guidelines, you should obtain
additional information from the following sources.
NEMA — The National Electrical Manufacturers Association, located in
Washington, D.C., publishes many different documents that discuss
standards for industrial control systems. You can order these publications
directly from NEMA. Some of these include:
o ICS 1, General Standards for Industrial Control and Systems
o ICS 3, Industrial Systems
o ICS 6, Enclosures for Industrial Control Systems
NEC — The National Electrical Code provides regulations concerning the
installation and use of various types of electrical equipment. Copies of the
NEC Handbook can often be obtained from your local electrical
equipment distributor or your local library.
Local and State Agencies — many local governments and state
governments have additional requirements above and beyond those
described in the NEC Handbook. Check with your local Electrical Inspector
or Fire Marshall office for information.
Safety Techniques
The publications mentioned provide many ideas and requirements for system
safety. At a minimum, you should follow these regulations. Using the techniques
listed below will further help reduce the risk of safety problems.
Orderly system shutdown sequence in the Pointe Controller program.
Emergency stop switch for disconnecting system power.
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Orderly System Shutdown
The first level of protection can be provided with the Pointe Controller program
by identifying machine problems. Analyze your application and identify any
shutdown sequences that must be performed. Typical problems are jammed or
missing parts, empty bins, etc. that do not pose a risk of personal injury or
equipment damage.
WARNING: The control program must not be the only form of protection for any
problems that may result in a risk of personal injury or equipment damage.
System Power Disconnect
By using electromechanical devices, such as master control relays and/or limit
switches, you can prevent accidental equipment startup. When installed properly,
these devices will prevent any machine operations from occurring.
For example, if the machine has a jammed part, the Pointe Controller program
can turn off the saw blade and retract the arbor. However, since the operator
must open the guard to remove the part, you must include a bypass switch to
disconnect all system power any time the guard is opened.
The operator must also have a quick method of manually disconnecting all system
power. This is accomplished with a mechanical device clearly labeled as an
Emergency Stop switch.
After an emergency shutdown or any other type of power interruption, there
may be requirements that must be met before the Pointe Controller program can
be restarted. For example, there may be specific register values that must be
established (or maintained from the state prior to the shutdown) before
operations can resume. In this case, you may want to use retentive memory
locations, or include constants in the control program to ensure a known starting
point.
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4.2 Getting to Know the Pointe Controller Base
The figure below shows the layout of a Pointe Controller base:
The Pointe Controller base consists of a card cage containing the motherboard.
The base unit has a built in Ethernet port, as well as an RS232 port. The Ethernet
port is the interface to the larger system. The RS232 port is provided for general
purpose communications (as defined by your application program). It is also
designed to allow you to load future program upgrades (to incorporate the
ability to interface future I/O boards and operator panels) into the base.
Both communications ports have status indicator LEDs which provide you with
visible indications of each port’s operation. The RS232 serial port indicates when
it is transmitting (TX) and receiving (RX). The Ethernet port provides indications
for good Ethernet link connection (L) and Ethernet port access by the base
processor (S), as well as transmit (T) and receive (R) indicators.
Power must be provided to the unit by an external DC power supply. Any DC
voltage within the range of 8-30VDC is acceptable.
Input and output modules can be plugged into the slots in the base. Most
modules can plug into any base slot (including slot 0).
NOTE: Slot 0 includes additional features used by certain 12-pin specialty
modules. These modules are documented as slot 0-specific.
The OptiLogic base can snap onto any standard DIN rail, including the rail molded
into the back of all OptiLogic operator panels. When attaching an OptiLogic base
to an OptiLogic operator panel, the 10-pin cable connection on the side of the
base is used.
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4.2.1 PTC-5800 Pointe Controller Technical Description
Physical (Base Unit)
• DIN rail mount to 35mm DIN rail
• Overall dimensions: 8.4”L x 3.25”H x 3.00” D
• Color: Dark gray
• Material: Polycarbonate plastic
• # I/O slots: 8
Environmental
• Storage Temperature : -20 to 70 C
• Ambient Operating Temperature : 0 to 55C
• Humudity : 0 - 95% non-condensing
Electrical
• Power: 8 - 30 VDC input power
• Minimum load current (no I/O boards or operator panel attached):
o 75mA @ 24VDC
o 150mA @ 12VDC
• Maximum load current (actual depends on the particular modules
attached):
o 700 mA @ 24VDC
o 1.4A @ 12VDC
• Power available to I/O modules : 2.8A @ 5VDC
• Power Connection: Terminal block, 2 terminal
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Communications, Ethernet
• Type: 10Base-T Ethernet
• Data Rate: 10 Mbps
• Connection: RJ45
• Ethernet Protocols: TCP/IP, OptiLogic UDP/IP, Modbus
TIP: For a complete description of Ethernet connections, see page 103.
Communications, Serial
• Baud rates: 300, 1200, 2400, 4800, 9600, 19.2K (selectable)
• Data bits: 7 or 8 (selectable)
• Parity: odd, even, or none (selectable)
• Stop bits: 1 or 2 (selectable)
• Connection: RJ12
Pin # Description
6 GND
5 5V power out
4 Transmit data (TX)
3 Receive data (RX)
2 Reserved (do not connect)
1 GND
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4.3 Supplying Power to the Controller
The Pointe Controller unit requires a 8-30VDC, 1 Amp power supply. This can be
provided either by using a wall-pluggable AC adapter (part number OL-PS1) or by
connecting the unit directly to a properly rated DC grid. The connection is made
at the Power Input screw terminals located at the bottom left corner of the base
unit.
To connect a power supply to the controller:
1. Make sure the power is OFF – the AC adapter should be unplugged and/or
the DC grid should be turned off.
2. Using a regular slotted screwdriver, loosen the Power Input screw
terminals.
3. Pass the power supply wires through the opening in the bottom of the
controller base unit. Insert the positive wire into the positive terminal (+)
and the negative wire into the negative terminal (-).
4. Retighten the screw terminals.
5. Tug gently on the wires to verify that they are properly secured to the
terminals.
The Pointe Controller unit can now be powered on.
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4.4 Installing the PointeControl Software
The PointeControl software CD (part number NS-PTC) includes the control
application development package and the various utilities needed to connect to
and configure the Pointe Controller unit.
System requirements:
200 MHz or faster Pentium processor
Operating system (any one):
o Microsoft Windows NT 4.0 Service Pack 5 or 6
o Microsoft Windows 2000
o Microsoft Windows XP
A CD-ROM drive
A 10BaseT Ethernet card
A DB-9 serial port
To install the PointeControl software on your PC:
1. Insert the PointeControl software CD into your CD-ROM drive.
2. Open the mounted CD (typically drive D: or E:) and double-click
SETUP.EXE.
3. Follow the onscreen installation instructions. No unusual installation
options are presented.
4. Restart your PC when prompted.
NOTE: As part of the PointeControl software installation, a Java Runtime Engine
(JRE) is also installed on your PC. This JRE is used only by the PointeControl
software and it is not included in the Windows registry. It should not conflict with
any other Java tools you may have installed on your PC.
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4.5 Addressing the Pointe Controller
Each Pointe Controller unit has two distinct addresses: an IP address, for
communicating across an Ethernet network; and a Modbus address, for
communicating with serial Modbus devices such as operator panels and bar code
readers.
4.5.1 IP Address
The Pointe Controller unit comes preconfigured with a default IP address. You
must reset the address so that the unit can properly communicate on your
Ethernet network. This change is made via a direct serial connection between
your PC and the Pointe Controller unit.
Remember that each Pointe Controller unit on your network must have its own
unique IP address and node name, which is set prior to applying power to the
controller. Duplicate addresses will cause system communications to fail.
To set the IP address of the Pointe Controller unit:
1. Establish a serial connection between your PC and the Pointe Controller
unit, using the download cable (OL-CBL-DNL):
a. Before you connect the serial cable, make sure the Pointe
Controller is powered off. The unit looks for the cable when it is
first powered on.
b. Connect the cable's RJ-11 plug to the Pointe Controller's serial
port.
c. Connect the cable's DB-9 plug to your PC's serial port.
2. Power on the Pointe Controller unit.
NOTE: There is no power switch on the Pointe Controller unit itself. Either
the AC adapted must be plugged in or the directly connected DC grid
must be turned on.
3. From theWindows Start menu, choose Programs > PointeControl >
Update Tool.
NOTE: If you are running the Update Tool for the first time, you will be
asked to specify which COM (serial) port the tool should use. Enter the
number (1, 2, 3, or 4) to which you connected the serial cable in Step 1
above, and then click OK. After that, the tool will finish launching.
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The PointeControl/OptiLogic Update Tool application window appears.
4. Click Automatic Base Detection. The application should immediately
connect to your Pointe Controller unit. If it does not, check your serial
connection and try again. If it still cannot connect, click Manual Setup
and select PTC5800 from the drop-down menu.
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When the application successfully connects, the following window will
appear:
The Read Current Settings pane displays the current address settings on
the Pointe Controller unit. If you are addressing the unit for the first time,
the factory default settings are displayed.
5. Under New Settings, enter the new IP address and subnet mask for the
Pointe Controller unit. For example, an IP Address of “10.16.80.103” and a
Sub Net Mask of “255.255.255.00”.
The Pointe Controller unit should receive an address on the same subnet
as your PC. If you do not know what values to enter, contact your system
administrator.
NOTE: The Pointe Controller unit does not communicate directly with any
network gateway or router. Instead, it broadcasts to all machines on its
subnet. Therefore, you should enter "00.00.00.00" in the Default Gateway
field.
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6. For the Default Server IP Address, enter the IP address of the PC with
which you are connecting to the Pointe Controller unit. For example,
“10.16.80.69”.
The secondary server is the PC to which the Pointe Controller unit will
attempt to connect when it first powers on.
7. For the Node Name pane, enter the name by which the Pointe Controller
unit will identify itself to PointeControl Monitor. For example, “Gundam.”
NOTE: If you do not want or need to change the Node Name, you can skip
this step and leave the factory default setting.
For more information on PointeControl Monitor, see Chapter 6,
“Downloading to the Controller,” and Chapter 7, “Monitoring and
Debugging.”
8. Click the Save Settings button to save your settings to the Pointe
Controller unit. When the settings are saved, the fields will turn green.
9. Click the Read Current Settings button to verify that the new settings
were saved correctly. The current settings should now match the IP
address, subnet mask, secondary server, and node name that you entered.
10. Exit the Update Tool application by clicking the Exit button.
11. Power off the Pointe Controller unit.
12. Disconnect the RS-232 serial cable.
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4.5.2 Modbus Address
The addressing that you, the system designer, must set is the address set via
rotary address switches in the Pointe Controller base unit. Each controller in your
system must have its own unique address. This address, a value between 00 and
97, is how the software in the master PC identifies each controller.
NOTE: Addresses 98 and 99 are reserved for performing hardware resets. For
more information, see page 230.
To get to the address switches, you must first remove the end cover from the base
unit. To do this, simply squeeze the latching tabs, shown in the figure below, and
lift the cover off.
Removing the end cover will expose the base motherboard. The address switches
will be found near the connector for slot 0.
To set the controller’s Modbus address, rotate the switches to the desired values.
The switch on the left is the “tens” digit. The switch on the right is the “ones”
digit. A small flat blade screwdriver is the only tool you need. The address shown
on the figure above is “25.”
Remember that each Pointe Controller unit on your network must have its own
unique Modbus address, which is set prior to applying power to the controller.
Duplicate addresses will cause system communications to fail.
For more information on configuring Modbus communications, see Chapter 8,
“Networked Operations,” starting on page 216.
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4.6 An Overview of OptiLogic I/O
The Pointe Controller system achieves its modularity and flexibility by integrating
with Optimation, Inc.’s complete line of OptiLogic I/O modules and operator
panels. (Optimation is a wholly-owned subsidiary of Nematron.) OptiLogic
components can be plugged together in nearly any combination. This chapter
covers the currently available modules that plug into the card cage.
TIP: Additional I/O modules are always under development. Please check our Web
site at http://www.nematron.com/PointeControl for a complete list of available
modules.
Most OptiLogic modules can be installed in any card cage slot and used in any
combination and quantity that will fit in the card cage. This applies to all general
purpose digital and analog I/O. If you need all digital inputs — plug in digital
input modules only. If you need a mixture of analog and digital inputs and
output — select the mixture that fits your needs. Snap together modularity gives
you the ability to optimize your system for your needs.
OptiLogic I/O modules are designed to meet your needs in real world application.
They are all small circuit boards with a few available points to minimize your
system cost. Most module connectors are pluggable terminal strips for easy
connection, and easy maintainability. The snap-together design means low labor
costs — or costs on your time. Visual status indicators on digital I/O and
communications modules provide a convenient means for monitoring operation.
All together, the result is a cost effective, easy to use and maintain set of
industrial control hardware.
This manual covers general I/O characteristics and applications first. Specific I/O
boards are covered in the latter pages. The general pages should serve as a guide
to selecting and installing I/O boards in your application.
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4.6.1 Digital Inputs
Digital I/O modules are used to either monitor (input) or control (output) the
“state” of something. “State” being on or off, active or inactive, open or closed
— etc. In the “real world” digital I/O requirements come in a variety of shapes
and sizes. Therefore, there are a variety of available modules designed to meet
the variety of needs.
Typical digital inputs are connected to switches, buttons, digital outputs from
other equipment, discrete level sensors, thermostats and other on/off sensing
devices.
Digital status is sensed by a controller, such as an OptiLogic system, by passing
current through an input sensor. When the current is on, the input state is active.
When it is not there, the input state is inactive.
Input Isolation
In most cases, it is important to “isolate” the real world inputs from the internal
electronics of the controller. You want to prevent some external situation from
“zapping” the controller’s electronics.
An effective means of providing such electrical isolation is optical isolation. The
figure below illustrates the basic concepts of optical isolation of a digital input
circuit:
As shown, when the digital input contact closes, the circuit path is complete and
current will flow. On the input module this circuit path passes through a device
which emits light when current flows through it. The light emitter is in very close
physical proximity to (actually in the same chip) a photo sensor, which will turn
on when it senses light. In this way, a digital input module can sense whether the
input device is closed (current flow) or open (no current flow) without a direct
electrical connection between the external sensor and the internal electronics.
DC Inputs
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DC digital inputs are typically supplied by a DC power supply. The most common
DC supplies used in industry are 12VDC and 24VDC.
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Typical DC digital input circuits are shown below:
As shown, the physical optical emitter on the input module is an LED (light
emitting diode). OptiLogic DC inputs use bidirectional LEDs — i.e. Your inputs
may either source or sink current. The top figure shows a sourcing input. The
figure below it shows a sinking input. When inputs are connected to a “common”
(most instances), inputs must be either all sourcing or all sinking.
AC Inputs
AC digital inputs are typically supplied either directly from line voltage or
transformed down from line voltage. The most common AC inputs are 120VAC
and 24VAC, although any voltage range is possible.
A typical AC input circuit is shown below:
As shown, the physical optical emitter on the input module consists of two LEDs
of opposite polarity. An AC (alternating current) connection flows current one
way, then the other. Light is emitted in both cases.
There is a short period when voltage, and therefore current flow, switches from
one direction to the other when no current flows. This is called zero crossover.
During zero crossover, the digital input circuit must “debounce” the signal to
ensure that the system does not provide a false indication that the input contact
is not closed when it is, in fact, closed. OptiLogic AC digital inputs handle such
zero crossover conditions.
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Digital Input Voltage
Any digital input module, AC or DC, is designed to operate within an input
voltage range. The input voltage directly controls the amount of current flowing
through the circuit. The minimum voltage corresponds to a voltage that creates
enough current to produce LED light sufficient to be sensed by the optical sensor.
The maximum voltage corresponds to the maximum current the optocoupler can
handle without being damaged.
I/O “Common” Terminals
For a digital input circuit, one input terminal and one output terminal is necessary
for operation. For practical application, one of these two terminals may be
“common” to several circuits.
In most systems, the power source for all digital inputs is from the same supply. In
such cases, connecting all of the circuit return lines together results in reduced
equipment costs as well as simpler system wiring.
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The example above illustrates a digital input board that has eight inputs and two
commons. This can be accomplished with a 10 terminal connector block.
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4.6.2 Digital Outputs
Digital outputs are used to turn “loads” on and off. “Loads” may be lights,
motors, solenoids, or any type of on/off device found in the “real world.”
Digital outputs in the OptiLogic series come in three types — relay, transistor and
solid state relay. Each type has applications it is best suited for. The following is a
general list of application characteristics for each output type:
Relay
Low contact loss
AC or DC
Moderate to high
current rating
Low cost
Should not be used
for:
o Ultra low current
switching (less than
10mA)
o Switching loads at
high frequency
Transistor
DC application only
Low current rating
High frequency
switching
Low cost
Solid State Relay
AC application
Moderate current
Any switching
frequency
Moderate cost
Relay Outputs
Relays are basically electrically controlled mechanical switches. All current
OptiLogic Relay output boards utilize form A relays — i.e. the contact is either
open or closed.
Relays are affected by the type of load that is switched. Inductive loads
(solenoids, motors, etc.) tend to wear the relay much more than resistive loads
(lights, heaters, etc.).
Inductive load wear is due to the fact that inductive loads will continue to
conduct current for a period, even after the circuit is broken. This current flow
builds up opposing polarity charges between the contact segments that just
separated. This makes the two segments attract each other — making opening
the contact more difficult. It also can result in arcing while the contact is being
opened. Arcing, in turn, builds up carbon deposits, i.e. wear.
This situation can be improved for DC inductive circuit loads by the addition of
external diode protection of the circuit. The figure below illustrates diode
protection:
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When the contact is closed, the diode is reverse biased and no current flows
through it. When the contact opens, current will continue to flow through the
inductive load. The diode provides a path for current flow. The result that is the
energy is dissipated in the inductive coil and not the relay contact.
NOTE: Do not use this circuit for AC loads.
Transistor Outputs
An NPN transistor sinking output provides a path to ground. A typical circuit is
shown below:
There is a small voltage drop across the transistor in such a circuit. The voltage
drop will generate heat in the transistor. Therefore NPN transistor outputs are
generally limited to lower current applications.
Transistor outputs can be operated at high frequency. There is no effective wear
on a transistor output from switching, as there is in a mechanical relay.
Diode protection applied to inductive loads is recommended in cases where the
load current approaches the rated current limit of the output. In most cases
OptiLogic outputs are designed to withstand voltages of at least twice the rated
output voltage. However, diode protection like that shown above will ensure that
turn off voltage spikes will never get to that level.
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Solid State Relay Outputs
Solid state relays are semiconductor switches that operate very much like
mechanical relays. They have an advantage over mechanical relays by virtue of
the fact that they are semiconductors. Solid state relays can be switched at
relatively high frequencies and they do not wear out. However they are more
expensive and there is a small voltage drop across the contact.
The figure below illustrates a typical solid state relay output:
OptiLogic Solid state relays are designed for AC load operation.
4.6.3 Analog Inputs
Analog inputs are used to monitor the value of some continuously variable
measurement. Typical analog inputs are measurements of temperature, pressure,
weight, liquid level, pH, flow rate and many other “real world” parameters.
The purpose of an analog input module is to convert the measurement into a
format that is usable by the data acquisition or control system. To be usable by an
computer-based system, the analog measurement must be converted to digital
format. Doing so accurately and, in some cases, quickly, is the goal of the analog
to digital converter module.
A good understanding of analog input modules includes an understanding of
isolation, accuracy, single and differential inputs, multiplexing, resolution and
range. The following paragraphs provide an overview of these subjects.
Isolation
In many applications there is a good deal of benefit to be derived from isolating
the analog measurement source from the RTU’s power supply. In some cases,
signal inputs may contain voltages or noise signals which could adversely affect
the main processor’s operation. Likewise, noise on the main power bus can
degrade the accuracy of the analog value measurement. Both potential problems
can be solved by isolating the analog inputs from the main power supply.
Isolation involves totally isolating the analog to digital (A/D) converter from the
main power bus. This can be accomplished in two ways. The A/D input module
can use a separate power source input, which is isolated from the power input to
the base. The A/D module can also use the main power supply and isolated power
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via a switching power converter and a transformer. There are OptiLogic analog
input modules in both categories. Neither is functionally superior to the other.
The on-board power generation may save the cost of an additional external
power supply.
The other aspect of isolation is the fact that the measured value must be
transmitted from the analog to digital converter, operating on one power supply,
to the main system, which is operating on another power supply. This is
commonly accomplished through optical isolators.
Resolution
Resolution is the number of significant bits of information the A/D converter uses
to express the value of the measured input. A 12-bit A/D converter uses 12 bits of
information, meaning the entire range is covered by a number between 0 and
(12)-1) or 0 to 4095. A 14-bit A/D expresses the same range as a number
(2
between 0 and 16,383. In other words, the more bits used, the finer the
increment. In general terms, the higher the resolution, the better.
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Accuracy
Accuracy is expressed as the worst case deviation from the “ideal value” across
the entire input range. For example, for a 0 to 5V input range and a 12-bit A/D
module, a 2.0 volt input should yield a value equal to 1638 (0.4 x 4096). If it
returns a value of 1636, and this is the worst case error across the entire range of
0 to 5V, the accuracy is 12 bits +/- 2 counts.
Range
The analog input range is the minimum and maximum voltage, or current level,
measured by the A/C converter. Typical ranges are 0 to 5 volts, 0 to 10 volts, +/- 5
volts, +/- 10 volts, and 4 to 20 mA.
You should try to match the input range to the range of the signal that you are
measuring.
Multiplexing
Analog to digital converter devices are typically quite expensive. In order to keep
the cost per channel of analog inputs down, a multiplexer is commonly used.
A multiplexer switches one analog input at a time into the A/D converter. Each
input is converted in sequence. The trade off is reduced sampling rate for a
particular channel versus reduced cost per channel measured. In most industrial
applications, the conversion rate is so fast in relation to the rate of change in the
measured value, that sampling rate is not a factor.
Single Ended Inputs
Single ended inputs are all referenced to the same ground point. In many
applications, single ended inputs produce significant advantages. Single ended
inputs require only one ground connection and one signal input per measured
value. The result is reduced wiring costs along with the reduced cost per channel
on the analog input module.
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In order to use single ended inputs, the ground connection must be very good.
The measurement devices must also be capable of being referenced to a common
ground.
Differential Inputs
There are cases when the individual analog inputs cannot be connected to a
common ground. In those cases, a differential input A/D converter should be
used.
With a differential analog input, both a positive and negative signal line must be
connected for each signal. The analog input module then measures the difference
between the positive and negative. The effect of one channel’s signal on another
channel’s signal should be as little as possible. That relationship of the effect on
the measured value of one channel to the value input on a second channel is
called “common mode.” The higher the “common mode rejection ratio (CMRR)”
the better.
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4.7 Determining Your I/O Needs
The Pointe Controller system offers the following ways to add I/O to the system:
Local I/O – consists of I/O modules installed in the Pointe Controller unit
itself.
Remote I/O – consists of I/O modules installed in OptiLogic RTU bases
connected to the Pointe Controller unit through the Ethernet network.
A Pointe Controller system can be developed using many different arrangements
of these configurations. All I/O configurations use the standard complement of
OptiLogic I/O modules and bases.
TIP: For complete technical descriptions of all OptiLogic modules and panels, see
Appendix A, “OptiLogic Technical Specifications,” starting on page 231.
4.7.1 Available I/O Modules
The following is a list of I/O and operator panel modules available at the time of
this printing. Keep in mind that the range of avaliable OptiLogic modules is
always expanding. Many more modules will be available in the near future. To
get a current list of available modules, visit our Web site at
http://www.nematron.com/PointeControl.
The following I/O modules are currently available (generally off the shelf):
Digital Inputs
OL2201 8 Digital input simulator (toggle switch input)
OL2205 4 AC/DC (10-30V) In -- Each input has a separate common
OL2208 8 DC (10-30VDC) In
OL2211 8 AC (80-132VAC) In
OL2252 2 high speed counters (up to 20KHz) inputs. 6 additional inputs configurable
OL2258 High speed counter input for pulse encoder type devices. Up/Down count,
Digital Outputs
OL2104 4 Relay (2A resistive @ 24VDC, 1A @120VAC)
OL2108 8 Relay (2A resistive @ 24VDC, 1A @120VAC)
OL2109 8 Transistor (500mA sink)
OL2111 8 AC Solid State Relay (1A)
Analog Inputs / Outputs
as general purpose DC inputs or control signals.
Pulse & Direction or Quatdrature inputs accepted. Pulse counting to 80KHz
(160KHz for quadrature). Two high speed transistor outputs.
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OL2304 4 channel voltage output, 0-5V, 0-10V, +/-5V, +/-10V
OL2408 8 channel 0-5VDC or 0-10VDC in
OL2418 8 channel 4-20mA in
Communications
OL2602 2 Port RS232
4.7.2 Available Operator Panels
The following is a list of currently available OptiLogic Operator Panels:
Pushbutton / Indicator Panels
OL3406 6 Indicator/4 Pushbutton Alphanumeric Display
OL3440 4 Line x 20 Character backlit LCD alphanumeric display
Terminal Panels
OL3420 2 Line x 20 character backlit LCD display, 4 pushbuttons
OL3850 2 line x 20 character backlit LCD display, 5 user definable pushbuttons,
numeric keypad, 3 indicator light bars
4.7.3 Calculating Your Power Budget
Each I/O module and operator panel that you install in your Pointe Controller unit
requires a certain minimum amount of power to operate. Each controller base
has a maximum of 2.8 A (2800 mA) total power available.
To calculate the power budget for your Pointe Controller, simply add up the
power required for all of the I/O modules and operator panels that you want to
install in the controller. If the total power required is less than or equal to 2.8 A,
then the controller will be able to power everything. If the total power required
is greater than 2.8 A, then you must redesign your application to use a different
combination of modules.
The table below provides a quick reference to the power requirements for all of
the available I/O modules and operator panels. Again, for complete technical
descriptions of these components, see Appendix A, “OptiLogic Technical
Specifications,” starting on page 231.
Module Type Description Power Req.
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OL2104 Relay Output, 4-point 250 mA
OL2108 Relay Output, 8-point 375 mA
OL2109 DC Sinking Output, 8-point 140 mA
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Module Type Description Power Req.
OL2111 Solid State Relay Output, 8-point 120 mA
OL2201 Digit Input Simulator, 8-point 60 mA
OL2205 AC/DC Digital Input, 4-point 100 mA
OL2208 DC Digital Input, 8-point 60 mA
OL2211 AC Digital Input, 8-point 100 mA
OL2252 Dual Pulse Counter 100 mA
OL2258 High Speed Pulse Counter 400 mA
OL2304 Analog Voltage Output, 4-channel 700 mA
OL2408 Analog Voltage Input, 8-channel 700 mA
OL2418 Analog Current Input, 8-channel 700 mA
OL2602 Dual Serial Port 110 mA
Panel Type Description Power
OL3406 Pushbutton/Indicator Panel 50 mA
OL3420 Operator Terminal 115 mA
OL3440 4-line Display Panel 150 mA
OL3850 Keypad Terminal 525 mA
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4.8 Installing I/O Modules in the Controller
Each Pointe Controller application will differ in the number and type of I/O
modules, the operator panels used (if any) and how the devices must be
distributed. The modular design of the Pointe Controller system allows you to mix
and match to meet your exact application requirements.
System configuration entails an early process of defining exactly what type and
quantity of I/O you need at each location. If operator interaction, alarm
annunciation, or status display are required at the various points, the appropriate
operator panel should be chosen. Once that is done, you can custom tailor your
controllers by selecting and installing standard I/O modules in your Pointe
Controller base units and snapping the appropriate operator panel onto each.
4.8.1 Slot Numbering
Each module will occupy one slot in the controller base. Each slot position is
numbered as shown below. The slot number will provide a reference to your
application program for selecting the appropriate module for each particular
operation.
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Slot numbering is simply left to right, starting with slot number 0.
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4.8.2 Installing Modules
Each slot has card guides along each side and a connector on the motherboard.
To install an I/O module, place the module’s circuitry board in the top and bottom
card guides. (Note that the board will not be tightly retained until it is
approximately 3⁄4 inch into the card guide.)
As you push the module into its mating connector, squeeze the ends together.
This will allow the board latches to travel inside the card cage. When you have
pushed the board into its mating connector and released, the latches should hook
the card cage and keep the module in place.
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4.9 Mounting the Pointe Controller
Pointe Controller units are intended to be mounted on a standard DIN rail. That
DIN rail can be a commercial DIN rail attached to any flat surface. It can also be
the DIN rail built into OptiLogic operator panels.
4.9.1 Mounting the Base on a DIN Rail
A DIN rail is simply a standard “U” shaped channel which is designed to be
mounted horizontally on any flat surface. DIN rail can be purchased at nearly any
electrical supply outlet.
There are a few standard DIN rail sizes available. Pictured below is a cross
sectional view of the standard 35 mm DIN rail the Pointe Controller base unit is
designed to clamp on:
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The key dimensions are the 35mm overall width and a minimum 7.5mm depth.
The precise channel shape is not important.
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