Rockwell Automation 1772-AF3, D17726.5.2 User Manual

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Auxiliary Function PROM (Cat. No. 1772AF3) for the Mini-PLC-2/15 Controller

User Manual

Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purpose Audience 12 Programs Extended Data Comparison 12 Functions 13

Installation/Removal Precautions 21. . . . . . . . . . . . . . . . . . .

General 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 21 Removal 23

File Search Instruction 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming the File Search Instruction 31 Enabling Function Instruction Execution Time 37 Response To Errors in UserEntered Data 37 Example Programs 37

of This Publication

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fo Implementing Machine Diagnostics

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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the Instruction of Control Bits

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12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. . . . . . . . . . . . . .

35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

File Diagnostic Instruction 41. . . . . . . . . . . . . . . . . . . . . . . . .

General 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming Enabling Function Instruction Execution Time 48 Response To Errors in UserEntered Data 48 Example Programs 49

the File Diagnostic Instruction the Instruction of Control Bits

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42. . . . . . . . . . . . . . . . .

47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Programming Check List 51. . . . . . . . . . . . . . . . . . . . . . . . . .

General 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AF3 Recommendations & Precautions A1. . . . . . . . . . . . . . . .

AF3 PROM Handling Recommendations and Precautions A1. . . . . . .

Introduction

Chapter

General

The Auxiliary Function PROM (cat. no. 1772-AF3) lets you expand the instruction set of your Mini-PLC-2/15 controller to include the file search and file diagnostic instructions. These instructions are functionally similar to their counterparts in the PLC-2/30 controller but their user-entered instruction format is different.

For simplification throughout this manual we refer to the Auxiliary Function PROM (cat. no. 1772-AF3) as the AF3 PROM.

You can use the AF3 PROM only with the Mini-PLC-2/15 processor module (cat. no. 1772-LV) series A revision 11 or later, and series B revision 4; and with the Industrial Terminal (cat. no. 1770-T3) (Table 1.A).

Table 1.A AF3

PROM Response Controller

MiniPLC2/15 Controller User Program 2K Words

Series Revision Read Write Erase

A 6 and later Yes No No

[1]

B all Ye s Yes No

[1]

You can erase the 2K memory portion of the AF3 with ultraviolet light. However, the 2K memory for file

search and file diagnostic functions would be irretrievably lost.

The AF3 PROM has a 2K (16 bit) word memory into which you can transfer your ladder diagram program (for backup memory), and a 2K word memory for the file search and file diagnostic functions. You can transfer your program into the AF3 PROM with series B controllers but not with series A controllers (NO TAG). Mini-PLC-2/15 Processor EPROM (publication 1770-915) describes how you transfer your program to the backup PROM.

NOTE: The AF1 is sensitive to ultraviolet light, therefore when exposed to uv light, both the program and the auxiliary functions are erased. The AF1’s transparent window is covered with the product label to avoid accidental alteration of memory from uv light sources. Do not remove this label.

11

Chapter 1

Introduction

Purpose of This Publication

Audience

Programs fo Implementing Machine Diagnostics

This publication shows you how to install and use the AF3 PROM in your Mini-PLC-2/15 controller.

We assume that you are familiar with programming and operation of the Mini-PLC-2/15 controller and the Industrial Terminal (cat. no. 1770-T3). We also assume that you are familiar with files and file instructions.

WARNING: : Use only Allen-Bradley authorized programming devices to program Allen-Bradley programmable controllers. Using unauthorized programming devices may result in unexpected operation, possibly causing equipment damage and/or injury to personnel.

Programs for machine diagnostics minimize machine downtime and maintenance time. Troubleshooting time is also reduced by isolating failed machine components and devices. In cases where devices are direct inputs to the PC, such as mechanical components, diagnostic programs can be used to isolate problem areas by monitoring various critical machine or process parameters. Diagnostic routines can even warn of potential failures so that preventive maintenance can be performed at a convenient or scheduled time before the failure occurs. Machine failures can also be recorded by the PC to provide historical failure/reliability trend information.

Extended Data Comparison

12

All machine failures and malfunctions detected by the PC can be displayed directly by several methods. Fault code numbers related to specific faults can be displayed on an LED display, or alphanumeric messages can be displayed on a CRT or printer to describe the faulted device or malfunction.

There are several methods commonly used to implement machine diagnostics. One method is referred to as extended data comparison (EDC). This diagnostic method is a useful technique for automatically detecting an out of sequence or faulted I/O device. EDC can be summarized as follows: At each step in a particular sequence or operation, a word containing the actual I/O status is compared to a desired or standard I/O status word. If the machine or process is operating properly, the bit pattern of the actual I/O word will be identical to the bit pattern of the desired I/O status word.

Should an input fail, or be out of sequence, the bit patterns would differ, and your program would initiate a routine that would determine which bit of the input word represented a faulted input. the basic EDC concept is normally expanded to include a group or file of input words and a corresponding file of desired standard words. By comparison with a standard, each input is checked

Chapter 1

Introduction

for its proper bit status at a particular step or operation. The desired standard files can be loaded automatically by a process called a teach routine (described in the application note PLC-2/30 Diagnostics available from PC Systems Division, Application Engineering Department).

Program routines for EDC are very similar to a sequencer instruction that compares a file of input words with a file of standard words for a desired status at each particular step. Therefore, the routine should only be implemented on a sequential machine or operation. Keep in mind that the I/O must be at a static stage for the comparison to be valid. Dynamic I/O or asynchronous machining operations would result in invalid I/O fault detection.

Functions

The AF3 PROM performs the following functions:

File Search - This instruction locates all words in a file whose data is

identical to the data of a specified word.

File Diagnostic - This instruction is used to locate discrepancies between

actual and desired states of I/O or data table words on a bit by bit basis.

13

Chapter

Installation/Removal Precautions

General

Installation

The AF3 PROM can be damaged during routine handling if proper precautions are not taken to reduce static electricity discharges. Refer to appendix A for recommended handling and handling precautions.

You must take special car in handling the AF3 PROM to ensure the pins do not get bent or contaminated. Bent or contaminated pins can prevent proper AF3 PROM operation and use. Store the AF3 PROM in its shipping container. Also, the AF3 PROM transparent window is covered with the product label to avoid accidental alteration of memory from ultraviolet light sources. Do not remove this label.

The AF3 PROM fits into a 28-pin ZIF (zero insertion force) socket, which is located under a hinged door at the lower side of the Mini-PLC-2/15 processor (Figure 2.1).

Figure 2.1 PROM

Socket

10715I

21

Chapter 2

Installation/Removal Precautions

The position of the notch on the AF3 PROM, when installed, must correspond to the position of the notch shown on the label (Figure 2.2).

Figure 2.2 AF3

Installed

PROM Installation

PROM Notch

Lock

OFF

1772AF3

DO NOT

ERASE

Release

11590

To install the AF3 PROM, perform the following steps:

1. Turn the mode select switch to PROG position.

2. To maintain processor memory contents, connect an external battery pack

(Figure 2.3) to the processor with the Mini-Processor Transport Cable (cat. no. 1772-CD).

Figure 2.3 External

Battery Backup

MiniPLC2/15 Processor

(Cat. No. 1772LV)

MiniProcessor Transport Cable

(Cat. No. 1772CD)

Battery Pack

(Cat. No. 1771BB)

11182

3. Remove AC power from the I/O chassis.

22

4. Remove the processor module from the I/O chassis.

5. Check all AF3 PROM pins to ensure they are not bent or contaminated.

Chapter 2

Installation/Removal Precautions

6. Loosen the screw and lift the PROM door (Figure 2.1).

7. Push the ON tab toward the center to unlock the 28-pin ZIF socket.

8. Remove the PROM if there is one in the socket.

9. Position the AF3 PROM so its notch and arrow face the OFF tab as shown

in figure 2.2.

10.Carefully align all pins with their respective sockets. Gently seat the AF3

PROM by pushing it down into its socket. Misaligned pins can bend and miss their sockets.

11. Lock the AF3 PROM in place by pushing the OFF tab toward the center.

12.Close the PROM door and tighten the screw.

13.Install the processor module into the I/O chassis.

Removal

14.Connect AC power to the I/O chassis power supply.

15.Disconnect the external battery pack (Figure 2.3) from the processor along

with the mini-processor transport cable.

16.This completes the installation of the AF3 PROM into the Mini-PLC-2/15

controller.

To remove the AF3 PROM, perform steps 1 thru 8 of how to install the AF3 PROM. Then perform steps 12 thru 16.

23

File Search Instruction

Chapter

General

The auxiliary file search instruction is an output instruction. It searches a file looking for a match of data contained in any file word with data of a specified match word. The instruction starts at the beginning of the file and searches from lowest to highest word address (lowest to highest position number) and from lowest to highest bit number. When the instruction finds a match, it simultaneously stores the position of the file word (3-digit BCD number) and sets the true bit. The true bit signals that the instruction found a match. Your program logic can detect the setting of the true bit and perform the application logic associated with the match.

Your program must cycle the instruction’s enable bit through a false-to-true transition for each match of file data, until the instruction sets its done bit. The instruction sets a done bit after it finds the last match in the file or if it finds no match in the file. In the next false-to-true transition of the enable bit, instruction clears the stored position number, and resets the instruction’s control bits. If your program has cycled the enable bit, the instruction will immediately begin the search again from the beginning of the file.

Generally, a minimum of two scans is required to detect each match. In the first scan the instruction is enabled, it finds the match, stores the position number of the matched word, and sets the true bit. In the next scan, the instruction resets the true bit, and your program can reset the enable bit. Later in this chapter we will describe a program that detects a match on each scan.

Programming the File Search Instruction

You enter the file search instruction into program logic by pressing the key sequence [SHIFT][EAF] 21 on the industrial terminal keyboard (series B or later), or [SHIFT][SCT] 21 on the keyboard of an earlier model that does not contain the [EAF] key. The instruction will appear as shown in Figure 3.1.

Enter the data address and result address into the instruction block as octal (BCD) numbers from 0020 thru 3577. Typically, choose addresses from middle to upper sections of the data table. A data address of 0400 and result address of 0406 are typical (Figure 3.2).

31

Chapter 3

File Search Instruction

Figure 3.1 Auxiliary

Numbers shown are default values and must be replaced by your values. The number of default address digits originally displayed, 3 or 4, depends on the size of the data table.

Function Format

Figure 3.2 Example File Search Instruction

Execute Aux

Function

Funtion Number: Data Addr: Rresult Addr:

Execute Aux

Function

Funtion Number: Data Addr: Rresult Addr:

01 010 010

21 0400 0405

Next, you will learn how to load data into addresses of the instruction.

You can load values into their respective addresses using the data monitor bit manipulation mode of the industrial terminal. Press the key sequence [SEARCH] [5] [3] followed by the word address. The industrial terminal will display the 16 bits of the word address you entered. Then you enter the binary equivalent of the values, one bit at a time (Figure 3.3).

Figure 3.3 Example

Word Bit Location

Location 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Description

0400 Nor used 0 0 0 0 0 0 0 1 0 0 0 0 File Length = 10 words

0401 Available for 0 1 0 0 0 0 0 1 0 0 0 0 Address of File, lower 3 digits,

0402 Bit Storage 0 0 0 0 0 0 0 0 0 0 0 0 Address of File, upper 3

0403 Application Dependent Data of match word

of UserEntered Data (Binary)

410

digits, 000

32

Chapter 3

File Search Instruction

You can also load these values in BCD. You can load BCD values into an instruction by means of a file-to-file move instruction. Enter a file-to-file move instruction below the file search instruction. Open the rung by inserting a branch end instruction. Open the rung by inserting a branch end instruction at the beginning of the rung (Figure 3.4). Make the file A address of the file-to-file move instruction the same as data address of the file search instruction. Press the key sequence [DISPLAY] 1. Then load data into the word identified by the cursor. When you load data into file A of the file-to-file move instruction, the data is automatically loaded into the file search instruction. The open branch allows you to load data, but prevents operation of the file-to-file move instruction when you switch the processor to run mode.

Figure 3.4 Rung for Loading AF3 PROM Instruction

Execute Aux

Function

Function Number: Data Addr: Result Addr:

21 0400 0405

030 EN

030

Branch End

FileToFile Move Counter Addr: Position: File Length: File A: File R; Rate Per Scan

030 001

004 0400-0403 0500-0503

004

You must load data into four addresses of the file search instruction starting with the data address.

Data Address - The data address is the first address that you entered into the instruction block. The data address is the first of four consecutive addresses into which you load the following data (figure 3.5).

First address - Length of the instruction file to be searched, three digits,

000-999

Second address - Address of the instruction file to be searched, lower three

digits

Third address - Address of the instruction file to be searched, upper three

digits

Fourth address - Data of the match word

Match Word - your match word is your reference word. It can be a fixed value that you enter before running your program. Or, it can be a variable that your program enters into that address according to your application (Figure 3.5).

33

Chapter 3

File Search Instruction

Word Bit Location

Location 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Description

0400 Not used 0 1 0 File Length = 10

0401 Available for 4 1 0 File Address, lower 3 digits

0402 Bit Storage 0 0 0 File Address, upper 3 digits

0403 Application Dependent Match word data

Figure 3.5 Example of UserEntered Data (BCD)

Instruction File Address ad Length - You can assign the file to any usable storage location in the data table. You may want to locate the file in the middle to upper sections of the data table (addresses 0410-0421 in Figure 3.6). Choose a file length in accordance with your programming requirements.

Result Address - The result address is the second address that you entered into the instruction block. It is the location of the result word (Figure 3.6). The result word is the location where the instruction momentarily stores the position number of the file word that matches the match word (003 in this example). Each time the instruction finds a match, it writes the BCD bit pattern of the new position number over the old position number in the result word. The instruction clears the result word after setting the done bit and after the next false-to-true transition of the enable bit.

Figure 3.6 Example Locations, Instruction File & Result W

Word Bit Location

Location 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Description

0405 0 0 3 Result Word

0410 FIrst word of Instruction File

0411

0412 Word Containing First Match (Position 003) Instruction File

ord

(10 Words)

34

. . . .

0421 Last Word of Instruction File

Chapter 3

File Search Instruction

The result word also stores control bits of the instruction in addition to the position number. The control bits are stored in bits 17 thru 14. The 3-digit position number is stored as a BCD bit pattern in bits 13 thru 00 (Figure 3.7).

Figure 3.7 Example Result W

Word Bit Location

Location 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00

0405 EN LS DN TR 0 0 0 0 0 0 0 0 0 0 1 1

ord

Control

Bits

Position Number

(003 BCD in this example)

NOTE: The result word must be initialized to zero before you enable the file search instruction for the first time. If you want to change file data or the match word for a new search, you should do so after the instruction sets the done bit.

WARNING: Do not manipulate data in the following addresses or bits:

Data address or result address of the instruction Control bit 17-14 of the result word

Inadvertent changes to the above could cause the instruction to miss a match, or detect a match when one did not exist. If this instruction directly or indirectly controls an output, an inadvertent change to the values could result in unpredictable operation, with possible damage to equipment and/or injury to personnel. It could also cause a run-time error.

Enabling the Instruction

You enable the file search instruction in program logic using a separate rung that precedes the instruction (Figure 3.8). Address an output or latched output instruction to bit 17 of the file search instruction’s result address, 0405/17. Program the rung’s input conditions to cycle a false-to-true transition of the output instruction. This initiates a search for the next matching word in the file in accordance with your application.

35

Chapter 3

File Search Instruction

Figure 3.8 Example Minimum Logic

Function of Control Bits

010

Execute Aux

Function

Funtion Number: Data Addr: Rresult Addr:

0405

21 0400 0405

Control bits of the file search instruction are located in the result word, bits 17 thru 14 as follows.

Bit: 17 Function: Enable (EN) Description: Your program logic must cause a false-to-true transition of the

enable bit for the instruction to operate. Program logic must reset then set the enable bit before the instruction can search the file for the next match. This is the only bit that your program logic can manipulate.

36

Bit: 16 Function: Last State (LS) Description: The instruction toggles this bit from off to on to off each time the

instruction is enabled and then reset after each match. The last state bit is used by the instruction to remember the status of the enable bit in the previous scan, and to prevent the instruction from executing the next search until the enable bit undergoes another false-to-true transition.

Bit: 14 Function: True (TR) Description: The instruction sets this bit in the same scan that it finds a match

between data in the match word and data in a file word. The instruction resets this bit in the next scan. You can consider its operation a one-shot. Your program logic should detect the setting of this bit as a condition for initiating the logic associated with a match of data.

Chapter 3

File Search Instruction

Bit: 15 Function: Done (DN) Description: The instruction sets this bit in the same scan that it detects the last

match in the file. The done bit remains set until the next false-to-true transition of the enable bit. Then, the instruction resets bits 16 thru 00 of the result word (last state, done, and true bits and the position umber in bits 13 thru 00) and starts the search at the top of the file. The enable bit, bit 17 of this word, is controlled by program logic.

Instruction Execution Time

Response To Errors in UserEntered Data

The search of a file containing several consecutive match words takes less time than a file search containing no match words. The scan of a 100 word file with no match words takes approximately 5.5ms.

If you should enter an erroneous address, erroneous data, or erroneous function number when entering the instruction into your program logic, the processor will indicate a run-time error when switched from program mode to run or run/program mode. You will have to correct the error before the processor can execute your program.

Address Error - An address error occurs when you assign addresses that extend into illegal areas of memory. These areas include processor word spaces from addresses 0000-0007 and 0100-0107, and into the user program which is dependent upon the size of the data table. The industrial terminal will display the prompt ILLEGAL ADDRESS and the processor will not execute your program.

Data Error - A data error occurs when you set the file length to zero, or if your program inadvertently changes the position number in the result word to a value greater than the file length. The industrial terminal will display the prompt ILLEGAL DATA and the processor will not execute your program.

Example Programs

Function Number Error - A function number error occurs when you enter a function number not associated with the auxiliary function PROM being used. The industrial terminal will display the prompt ILLEGAL OPCODE and the processor will not execute your program.

The following examples of program logic should help you to design your own logic for using the file search instruction.

Search Each Scan - You can program the file search instruction to search for a match every scan by programming two instructions as shown in Figure 3.9.

37

Chapter 3

File Search Instruction

If the logic conditions of rung 1 are true, the enable bit, 0405/17, will latch on. Rung 2 will execute the file search instruction. Rung 3 will unlatch the enable bit because its logic conditions are identical to those of rung 1. The file search instruction in rung 4 will see the enable bit reset and will likewise reset the last state bit. Then execution can continue in the next scan. Both file search instructions must be identical.

Figure 3.9 Example Logic for Search Every Scan

010

011

Execute Aux

Function

Funtion Number: Data Addr: Rresult Addr:

Execute Aux

Function

Funtion Number: Data Addr: Rresult Addr:

0400 0405

Example Program to Demonstrate the File Search Instruction

0405

OFF 17

38

You can watch the results of the file search instruction by observing the change in position number each time the instruction finds a match. The program repeatedly counts in 1.5 second intervals from 000 thru 999.

Enter the program in Figure 3.10 into processor memory. Clear the memory before entering the program using [CLEAR MEMORY] 99. Enlarge the data table to accommodate the size of your files (nine 128-word data table sections in this example). Enter [SEARCH] [5] [0] followed by the number of data table sections.

Enter data into the addresses as shown in Figure 3.11 using [SEARCH] 53. With a match word of zero and the instruction file containing all zeros, the program stops and finds a match at each word.

Chapter 3

File Search Instruction

030

0040

000

Figure 3.10 Example

File Search Logic

Execute Aux

Function

Funtion Number: Data Addr: Rresult Addr:

0030

RTO

0.1 PR 015 AC 000

040

0030 RTR

PR 015 AC 000

21 0031 0040

0041 PUT

000

Figure 3.11 Example Data Entry

Word Bit Location

Location 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Hex Equivalent

0031 0032 0033 0034 0040 0041

where values are astored as follows:

0031 file length of 999 0032 address of instrucction file, lower 3 digits (131) 0033 address of instruction file, upper 3 digits (000) 0034 match word data 0040 zero at start up 0131 instruction file words all containing zeros . . .

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . . .

1 0 0 1 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . . .

1 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . . .

999 131

000 0000 0000 0000

39

Chapter

File Diagnostic Instruction

General

The auxiliary file diagnostic instruction is an output instruction. It compares data in a file of actual values with another file of user-entered reference values, word-by-word and bit-by-bit. The instruction starts at the beginning of the files and searches from lowest to highest word address and from lowest to highest bit number. When the instruction finds a mismatch, it stops at the word containing the mismatch and sets a bit. The instruction sets the true bit (described later) to signal that a new mismatch was found. Then, in the same scan, it temporarily stores the following information:

Word address and bit number found mismatched in the file of actual values Number of mismatched values found to that point in the file Status of the bit in the file of actual values that did not match the reference

bit

The instruction stores the above information in a 3-word result file. Your program logic can detect the setting of the true bit, and perform the application logic associated with the mismatch. On the next execution of the instruction, the comparison search continues from the word/bit address where the previous mismatch was found.

Your program must cycle the instruction’s enable bit through a false-to-true transition for each mismatch of file data, until the instruction sets its done bit. The instruction sets a done bit after it finds the last mismatch in the file, or if it finds no mismatch in the file. In the next false-to-true transition of the enable bit, the instruction clears its stored data and resets its control bits. If your program has cycled the enable bit, the instruction will immediately begin the search again from the beginning of the files.

Generally, a minimum of two scans is required to detect each mismatch. In the first scan that the instruction is enabled, it finds the mismatch, stores the information, and sets the true bit. In the next scan, the instruction resets the true bit, and your program can reset the enable bit. Later in this chapter we will describe a program that detects a mismatch on each scan.

41

Chapter 4

File Diagnostic Instruction

Programming the File Diagnostic Instruction

You enter the file search instruction in program logic by pressing the key sequence [SHIFT] [EAF] 20 on the industrial terminal keyboard (series B or later), or [SHIFT] [SCT] 20 on the keyboard of an earlier model that does not contain the [EAF] key. The instruction will appear as shown in Figure 4.1.

Figure 4.1 Auxiliary

Numbers shown are default values and must be replaced by your values. The number of default address digits originally displayed, 3 or 4, depends on the size of the data table.

Function Format

Execute Aux

Function

Function Number: Data Addr: Result Addr:

01 010 010

Enter the data address and result address into the instruction block as 4-digit BCD numbers from 0020 thru 3577. Typically, choose these addresses from middle to upper sections of the data table. The data address is the first word of a 5-word file. The result address is the first word of a 3-word file. A data address of 0500 and result address of 0520 are typical (Figure 4.2).

Figure 4.2 Example

File Diagnostic Instruction

Execute Aux

Function

Function Number: Data Addr: Result Addr:

0500 0520

Next, you will learn how to load data into addresses of the instruction.

42

Chapter 4

File Diagnostic Instruction

Word

Location

0500

0501

0502

0503

0504

Figure 4.3 Example

17 16 15 14 13 12 11 10 07 06 05 04

000 0 00 0 1 00 0 0

Not Used

Available

for bit

Storage

010 1 00 1 0 00 1 1

000 0 00 0 0 00 0 0

010 1 00 0 0 01 0 1

000 0 00 0 0 00 0 0

User Entered Data (Binary)

Bit Location

You can also load these values in BCD. You can load BCD values into an instruction by means of a file-to-file move instruction. Enter a file-to-file move instruction below the file diagnostic instruction. Open the rung by inserting a branch end instruction at the beginning of the rung (Figure 4.4). Make the address of the source file, file A, of the file-to-file move instruction the same as the data address of the file diagnostic instruction. Press the key sequence [DISPLAY] 1. Then load data into the word identified by the cursor. When you load data into file A of the file-to-file move instruction, the data is automatically loaded into the file diagnostic instruction. The open branch allows you to load data, but prevents operation of the file-to-file move instruction when you switch the processor to run mode.

03 02 01 00

Description

File Length = 10 words

Address of actual value file, lower 3 digits

upper 3 digits

Address of reference file, lower 3 digits

upper 3 digits

Figure 4.4 Example

Rung for Loading Instruction

Branch End

Execute Aux

Function

Function Number: Data Addr: Result Addr:

FileToFile Move Counter Addr:

Position: File Length: File A: File R: Rate Per Scan

0500 0520

030 001

015 0500  0516 0600  0616

015

030 EN

030

43

Chapter 4

File Diagnostic Instruction

Load data into the five word file associated with the data address as follows. Data Address - The data address is the first address that you entered into the

instruction block. The data address is the first of five consecutive addresses into which you load the following data (Figure 4.5).

First address - length of both files to be searched (they are equal), three digit,

000-999

Second address - Address of the file of actual values, lower three digits Third address - Address of the file of actual values, upper three digits Fourth address - Address of the file of reference values, lower three digits Fifth address - Address of the file of reference values, upper three digits

Figure 4.5 Example

UserEntered Data (BCD)

Word

Location

0500

0501

0502

0503

0504

Bit Location

17 16 15 14 13 12 11 10 07 06 05 04

Not Used

Available for

Bit Storage

010

523

000

505

000

Data Address File and Reference File - You can assign these files to any usable storage location in the data table. For convenience of loading data, assign the 5-word file of the data address and your reference file to consecutive addresses (0500-0516 in Figure 4.6) because you will load data into both files. Load the reference file with values which represent correct operation for each step in your sequential application.

03 02 01 00

Description

File Length = 10 (BCD)

Address of actual value file, lower 3 digits

upper 3 digits tal

Address of reference file, lower 3 digits

upper 3 digits

44

File of Actual Values - You can assign this file to any usable storage location in the data table. You may want to assign this file to addresses in the I/O image tables or to some other file into which your program moves actual or application values (0523-0534 in Figure 4.6)

Chapter 4

File Diagnostic Instruction

Word

Location

0505

0506

0507

•

0516

0520

0521

0522

0523

0524

0525

•

0534

Figure 4.6 Example

17 16 15 14 13 12 11 10 07 06 05 04

Map of File Locations

Bit Location

First word of Instruction File

Last Word of Reference File

First Word of Result File

Last Word of Result File

First Word of Actual Value File

First Mismatch found at 0525/02

Last word of Actual Value File

03 02 01 00

Description

Reference File (10 words)

Result File (3 words)

Actual Value File (10 words)

Mismatch found at 0525/02

Result Address - The result address is the second address that you entered into the instruction block. It is the first word of the result file. The result file is where the instruction momentarily stores the following information (0520-0522 in Figure 4.7):

First word - * Control bits 17-14

* Error count, 0 to 999 (BCD), bits 13-00

Second word - * Status of the bit in the file of actual values that did not

match, bit 17 * Instruction work area, bits 16-14 (Do not use these bits for any purpose) * Address of word containing the mismatch, upper 3 BCD digits, bits 13-00

Third word - * Address of word containing mismatch, lower 2 BCD

digits, bits 17-10 * Bit number in word containing mismatch, 2 BCD digits, bits 07-00

45

Chapter 4

File Diagnostic Instruction

Figure 4.7

File

Result

Word

Location

0520

0521

0522

1 2

17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00

1 1 1 1

work area

Address of Mismatch, lower 2 digits, 25

Control bits, 17-14 Status of mismatch bit 0525/02 in file of actual values

Bit Location

Description

001EN LS DN TR

2-digit bit number of mismatched bit, 02

Error count in bits 13-00, 001

Address or Mismatch, upper 3 digitd, 005

Each time the instruction finds a mismatch (at address 0515/02 in this example), it writes the binary bit pattern of new data over old data in the result file. After the instruction sets the done bit, it clears all data in the result file after the next false-to-true transition of the enable bit.

NOTE: The result file must be initialized to zero before you enable the file diagnostic instruction for the first time. If you want to change file data for a new search, you should do so after the done bit is set.

46

WARNING: Do not manipulate data in the following addresses or bits:

Data address or result address of the instruction Control bits 16-14 in the first result word Instruction work area, bits 16-14 in the second result word

Manipulating this data could cause the instruction to miss a mismatch or to detect a mismatch when one did not exist. If this instruction directly or indirectly controls an output, an inadvertent change to these values could result in unpredictable operation and cause possible damage to equipment and/or injury to personnel. It could also cause a run-time error.

Chapter 4

File Diagnostic Instruction

Enabling the Instruction

You enable the file diagnostic instruction in program logic using a separate rung that precedes the instruction (Figure 4.8). Address an output or latched output instruction to bit 17 of the file diagnostic instruction’s result address, 0520/17. Program the rung’s input conditions to cycle a false-to-true transition of the output instruction. This initiates a search for the next mismatched word in the file in accordance with your application.

Figure 4.8 Example

010

Minimum Logic

Execute Aux

Function

Function Number: Data Addr: Result Addr:

0520

20 0500 0520

Function of Control Bits

Control bits of the file diagnostic instruction are located in the first result word, bits 17 thru 14 as follows.

Bit: 17 Function: Enable (EN) Description: Your program logic must cause a false-to-true transition of the

enable bit for the instruction to operate. Program logic must reset then set the enable bit before the instruction can search the file for the next mismatch. This is the only bit that your program logic should manipulate.

Bit: 16 Function: Last State (LS) Description: The instruction toggles this bit from off to on to off each time the

instruction is enabled and then reset after each match. The last state bit is used by the instruction to remember the status of the enable bit in the previous scan. This prevents the instruction from executing the next search until the enable bit undergoes another false-to-true transition.

47

Chapter 4

File Diagnostic Instruction

Bit: 14 Function: True (TR) Description: The instruction sets this bit in the same scan that it finds a data

mismatch between a word in the file actual values and a word in the file of reference values. The instruction resets this bit in the next scan. you can consider it operation a one-shot. Your program logic should detect the setting of this bit as a condition for initiating the logic associated with a mismatch of data.

Bit: 15 Function: Done (DN) Description: The instruction sets this bit in the same scan that it detects the last

mismatch between files. The done bit remains set until the next false-to-true transition of the enable bit. Then, the instruction resets the result file (except for enable bit 17) and starts the search at the beginning of both files.

Instruction Execution Time

Response To Errors in UserEntered Data

File comparison takes less time when the instruction finds several consecutive mismatches. Comparison of two 50 word files with no mismatches takes approximately 5.0ms.

Data Error - A data error occurs when you set the file length to zero, or if your program inadvertently makes the result address greater than the last address in the file of actual values. the industrial terminal will display the prompt ILLEGAL DATA and the processor will not execute your program.

48

Chapter 4

File Diagnostic Instruction

Example Programs

The following examples of program logic should help you to design your own logic for using the file diagnostic instruction.

Search Each Scan - You can program the file diagnostic instruction to search for a mismatch every scan by programming two instructions as follows (Figure 4.9).

Figure 4.9 Example Logic for Search Every Scan

010

011

Execute Aux

Function

Function Number: Data Addr: Result Addr:

011

0520

OFF17

20 0500 0520

0520

OFF 17

Execute Aux

Function

Function Number: Data Addr: Result Addr:

20 0500 0520

If rung 1 logic conditions are true, the enable bit, 0520/17, will latch on. Rung 2 will execute the file diagnostic instruction. Rung 3 will unlatch the enable bit because its logic conditions are identical to those of rung 1. The file diagnostic instruction in rung 4 will see the enable bit reset and will likewise reset the last state bit. Then execution can continue in the next scan. Both file diagnostic instructions must be identical.

Example Program to Demonstrate the File Diagnostic Instruction

You can observe the operation of the file diagnostic instruction using the following example. The program finds errors in all bits of words 0130 and 0132 for a total of 32 errors. You can observe the progression of the error count (1-32) and the progression of the bit pointer (00-17) as the program repeatedly counts in 0.1 second intervals from 000 thru 015.

Enter the program in Figure 4.10 into processor memory. Clear the memory before entering the program by entering [CLEAR MEMORY] 99. Enlarge the

49

Chapter 4

File Diagnostic Instruction

data table to accommodate the size of your files (two 128-word data table sections in this example). Enter [SEARCH] [5] [0] followed by the number of data table sections.

Enter data into the addresses as shown in Figure 4.11 using [SEARCH] [5] [3].

You can watch the results of the file diagnostic instruction by observing the data in the Get instruction in rung 5. First Get instruction (result word one) shows the error count. Third Get instruction (result word three) shows the mismatched bit number.

Figure 4.10 Example

030

File Diagnostic Logic

0030

RTO

0.1 PR 015 AC 000

040

030

0040

000

0041

000

0042

000

Execute Aux

Function

Function Number: Data Addr: Result Addr:

0030 RTR

PR 015 AC 000

20 0031 0040

0043 PUT

000

410

Figure 4.11 Example Data Entry

Chapter 4

File Diagnostic Instruction

Bit Number

Address

0031 0032 0033 0034 0035

0040 0041 0042

0137 0140 0141 0142

0131 0132 0133 0134

Where the storage words hold the following values:

17 16 15 14 13 12 11 10 07 06 05 04

0000 0

0 0 0 0

0 0 0

0 0 0 0

1 0 1 0

0031 file length value of 004 0032 0033 0034 0035

0040 0041 0042

address, file of actual values, lower 3 digits (131 octal) address, file of actual values, upper 3 digits (000) address of reference file, lower 3 digits (137 octal) address of reference file, upper 3 digits (000)

first result word, 0000 (hex) second result word, 0000 third result word, 0000

0 0

0000 0000 0100

0 0

1 0 1 0

0 0 0

0 0 0 0

1 0 1 0

Hex Equivalent

004 999 000 137 000

0000 0000 0000

0000 0000 0000 0000

FFFF 0000 FFFF 0000

03 02 01 00

0 0 0 0

0 0 0

0 0 0 0

1 0 1 0

0 0

0 0 0

0 0 0 0

1 0 1 0

0 0

0137 0140 0141 0142

0131 0132 0133 0134

0 0

first word in reference file, 0000 (hex) second word in reference file, 0000 third word in reference file, 0000 forth word in reference file, 0000

first word in file of actual values, FFFF (hex) second word in file of actual values, 0000 third word in file of actual values, FFFF forth word in file of actual values, 0000

0 0

411

Programming Check List

Chapter

General

Use the following check list as an aid when entering the file search or file diagnostic instruction into your ladder diagram program.

1. Do you have the correct function number?

2. Is your data table large enough to hold all of your files?

3. Are your address values in octal (BCD 0-7)?

4. Have you made sure that the file of actual values and the file of reference

values do not overlap (file diagnostic instruction)?

5. Have you made sure that the match word address is not an address of the

instruction file (file search instruction)?

6. Have you entered a file length greater than zero but less than or equal to

999 (BCD) in the address file?

7. If you use the [SEARCH] 53 bit monitor mode to enter data, did you

correctly position each of the bits that you set?

8. Have you enabled the instruction using correct logic (false-to-true

transition of the enable bit), and correct enable bit address (bit 17 of the result address)?

51

Appendix

AF3 Recommendations & Precautions

AF3 PROM Handling Recommendations and Precautions

Recommended precautions include:

Handle the AF3 PROM by the case without touching its pins.

Use a static-free work station.

Wear a conductive wrist strap that has a minimum 200k ohms resistance and

is connected to earth ground.

Ground tools prior to contacting the AF3 PROM.

Connect static-free work station to ground through a minimum 200k ohm

resistance.

Control the relative humidity of the installation area - ideal conditions are

40% to 60% relative humidity.

The following is a list of things that should not be done:

Do not handle styrofoam, plastic, or cellophane-covered articles such as

combs, cigarette packages, and candy immediately prior to handling the AF3 PROM.

Do not hand the AF3 PROM to someone who is not antistatic protected.

Do not install the AF3 PROM in areas that might contaminate or foul the

pins of the AF3 PROM.

Do not handle the AF3 PROM by its pins.

Do not slide the AF3 PROM across any surface.

Do not place the AF3 PROM in a non-conductive plastic bag.

When these precautions are followed, the potential difference between the AF3 PROM pins is reduced thereby reducing the problems associated with static discharges.

A1

Index

Symbols

[SEARCH] [5] [0], 38

[SEARCH] [5] [3], 32, 42, 410

Control bits

Done, 37, 48 Enable, 36, 47 Last state, 36, 47 True, 36, 48

Data address, 33, 44

Enabling the instruction, 35, 47

Erasing, 11

Errors, response to

Address, 37, 48 Data, 37, 48 Function number, 37, 48

Example programs, 37, 49

Execution time, 38, 48

Extended data comparison, 12

Result, 45

Handling precautions, A1

Installation, 21

Instruction file, 34

Loading data, 32, 43

Machine diagnostics, 13

Match word, 33

Mini-processor transport cables, 22

Programming

Check list, 51 Examples, 38, 49

File diagnostic instruction, 41

File length, 34

File of actual values, 44

File search instruction, 31

Files

Actual values, 44 Instruction, 34 Reference, 44

Reference file, 44

Removal, 23

Result address, 34, 45

Result file, 45

Result word, 34

Search each scan, 37, 49

AllenBradley has been helping its customers improve productivity and quality for 90 years. AB designs, manufactures and supports a broad range of control and automation products worldwide. They include logic processors, power and motion control devices, manmachine interfaces and sensors. AllenBradley is a subsidiary of Rockwell International, one of the world's leading technology companies.

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Publication

Supersedes

17726.5.2 - March 1984

Publication 1772-827 - March 1984

1984 AllenBradley Company

P/N

955094-46

, Inc. Printed in USA

Rockwell Automation 1772-AF3, D17726.5.2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Index