Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this control
equipment must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and
safety requirements, including any applicable laws, regulations, codes
and standards.
The illustrations, charts, sample programs and layout examples shown in
this guide are intended solely for purposes of example. Since there are
many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability (to
include intellectual property liability) for actual use based upon the
examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,Installation, and Maintenance of Solid State Control (available from your
local Allen-Bradley office), describes some important differences
between solid-state equipment and electromechanical devices that should
be taken into consideration when applying products such as those
described in this publication.
Allen-Bradley publication ICCG-9.11, Software Licensing Agreement,
provides the licensing terms for the use of this software as both a
developer’s tool and a Runtime package. All software that is part of this
package is covered by the license including:
Reproduction of the contents of this copyrighted publication and software,
in whole or in part, without written permission of Allen-Bradley Company,
Inc., is prohibited.
Throughout this manual we use these notes to make you aware of
safety considerations:
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage or economic loss.
Attention statements help you to:
identify a hazard
avoid the hazard
recognize the consequences
Important: Identifies information that is critical for successful application
and understanding of the product.
Reference Information for the SDS InstructionA-1. . . . . . . . . . . . .
Reference Information for the DFA InstructionA-7. . . . . . . . . . . . .
iii
Distributed Diagnostics andMachine Control
T
able of Contents
iv
Using this Manual
Preface
Manual Objectives
Audience
This manual shows you how to implement and use a Distributed Diagnostics
and Machine Control (DDMC32) system. This system provides diagnostic
machine fault detection and automatic messaging capabilities. Diagnostic
messages provided by DDMC32 help reduce the downtime associated with
troubleshooting your equipment.
In this manual we provide procedures for:
installing DDMC32 system components
configuring DDMC32 software
monitoring a system, using DDMC32
We assume that if you are using this manual, you know or are familiar with:
PLC-5 hardware
6200 Series software
1771 I/O
Allen-Bradley operator interface and programming terminals
the line or machine for which you are developing the program
P-1
Preface
Using this Manual
What this Manual Contains
Overview of DDMC32 components and how they fit into the
system
Procedures for installing DDMC32 hardware components2 — Installing DDMC32 Hardware
Procedures for setting up your operator interface terminal;
procedures for installing 6200 Series and DDMC32 software
Overview of the Smart Directed Sequencer instruction in the
PLC-5 and the PLC-5/250 and procedures for entering data into
the instruction screens; naming steps; editing step descriptions
Overview of the Diagnostic Fault Annunciator instruction in the
PLC-5 and the PLC-5/250 and procedures for entering data into
the instruction screens; configuring instruction messages;
documenting the instruction
Procedures for importing the SDS instruction’s documentation into
the operator interface data base; message database options
Table P.A lists the chapters of this manual and the contents of each chapter.
T
able P
.A
Sections
If you want to read about:Refer to chapter:
of this Manual
1 — Understanding How a DDMC32
System Works
Components
3 — Installing DDMC32 Software
4 — Configuring SDS Instructions
5 — Configuring DFA Instructions
6 — Creating and Updating the
Message Database
Overview of the parts of the diagnostic message and procedures
for configuring the format of diagnostic messages for display
Software tools and techniques for debugging your system; error
list, I/O monitor, step history, input history, extended status, and I/O
history screen displays
Procedures for configuring output devices, Clock/Creep Option,
Start/Stop and other related options
Overview of the Report Generator; configuring and scheduling
fault logs
Smart Directed Sequencer execution times, control file
requirements, step description file requirements, maximum steps,
and step description file layout; Diagnostic Fault Annunciator
execution times, control file requirements; Data Highway Plus
message block layout and communication delay
7 — Configuring Diagnostic
Messages
8 — Debugging Your DDMC32
System
9 — Configuration and Operation of
the DDMC32 System
10 — Using the Report Generator
Software
Appendix A — Reference Information
P-2
Preface
Using this Manual
ATTENTION and Important
Notes
Terms and Conventions
Information that is especially important is identified with an ATTENTION or
Important note:
ATTENTION: identifies information about practices or
circumstances that can lead to personal injury or death, property
damage or economic loss.
Important: provides you with information that is critical for the successful
application and understanding of this product.
In this manual, we use the following terms:
DDMC32 (Distributed Diagnostics and Machine Control 32–bit) —
Industrial automation system containing hardware and software components
that help you configure a control and diagnostics system for your equipment
SDS (Smart Directed Sequencer) — An instruction that resides in ladder
logic, providing state machine control and up-to-date diagnostics for your
machine
DFA (Diagnostic Fault Annunciator) — A monitoring-only instruction
which resides in ladder logic, used to generate messages when a fault occurs
programmable controller — A solid-state control device that is
programmed to control process or machine operation
I/O — Input/Output
State — The current value of an input or output at a particular point in time
P-3
Preface
Using this Manual
In this manual, we use the following conventions to describe how you enter
information.
The Enter key and Function keys look like this:
[ENTER]
[ESC] [F2]
Words or commands that you enter appear in bold. For example:
SDS
Variables that you must enter appear in italics. For example:
N
xx:00
Messages on the screen look like this:
While
DRILL STATION 32R was AT FULL DEPTH the RETURNED LIMIT
SWITCH turned ON
“Type” means type in the information using your keyboard
“Enter” means type in the information and then press your keyboard’s
[ENTER]
key
P-4
Preface
Using this Manual
Related Publications
For more information about DDMC32 components, see the following
publications:
Data Highway/Data Highway Plus Protocol and Command Set
User’s Manual
Peer Communication Link Interface Module (cat. no. 1784-KT)
Product Data
5000-6.2.1
9313–5250
1770-6.5.16
1784-2.3
P-5
Preface
Using this Manual
Notes:
P-6
Chapter
1
Understanding How a DDMC32
System Works
What this Chapter Contains
How the DDMC32 System
Works
This chapter provides an overview of Distributed Diagnostics and Machine
Control (DDMC32). It contains the following sections:
Section:Page:
How the DDMC32 System Works1-1
Understanding the SDS Instruction1-3
Understanding the DFA Instruction1-7
Implementing DDMC32 Instructions in Levels1-8
DDMC32 System Components1-8
What to do Next1-12
Distributed Diagnostics and Machine Control (DDMC32) for
WindowsNTt is an industrial automation system built around
programmable controllers, operator interfaces, communications, and
software. The system architecture lets you configure DDMC32 to your
manufacturing needs. Ideal in transfer line and other machine applications,
DDMC32 can be configured for other industrial applications such as
material handling, packaging, and assembling.
DDMC32 is a flexible system based on the PLC-5 family of programmable
controllers. You can use single or multiple PLC-5 processors to create
either a centralized or distributed configuration. Processors communicate
with each other over the Data Highway Plus.
Special instructions in the PLC-5 processor — a Smart Directed Sequencer
(SDS) and a Diagnostic Fault Annunciator (DFA) provide diagnostic
machine-fault detection and automatic messaging capabilities in the
DDMC32 Monitoring system. You enter SDS and DFA instructions into
ladder logic in 6200 Series software.
When a fault is detected, the SDS instruction sends a message over the
Data Highway Plus to the operator interface terminal where the Monitoring
software automatically assembles the appropriate diagnostic message.
This diagnostic message helps reduce downtime associated with
troubleshooting your equipment, because it specifies the device that caused
the fault condition and the step in the sequence when the fault occurred.
1-1
Chapter 1
Understanding How a DDMC32 System W
orks
The DDMC32 System illustration (seen below) shows how DDMC32 uses
the SDS instruction to detect a fault condition and send the diagnostic
message to the operator interface.
1. SDS instruction detects a
fault condition.
SDS
PLC-5/20
Input to PLC-5
PLC-5/20
DDMC32
2. PLC sends encoded
message to operator
interface on Data
Highway Plus.
System
IMC 123
EMSG
Symbol
Data
Base
While SLIDE was
ADVANCING, the
returned LS
turned ON.
3. Background task
extracts information from
data base and constructs
message.
Operator Interface
1-2
IMC 120
4. Concatenated message
is displayed on CRT and
passed out COM 1 port.
Chapter 1
Understanding How a DDMC32 System W
orks
Understanding the SDS
Instruction
An integral part of the DDMC32 system is the Smart Directed Sequencer
(SDS) instruction (see the figure below). The SDS instruction provides
state-based control and resides in ladder logic. The SDS instruction lets
you develop control and diagnostic programs using state logic. The SDS
instruction is provided as a custom application routine (CAR) which is
downloadable into the PLC-5 processor through 6200 Series software prior
to instruction entry. The CAR occupies one program file and is declared
when entering an SDS instruction; it is referenced by the SDS instruction
at runtime.
Control File
Step Desc. File
Length
No. of Steps
Position/Step:
No. of I/O
Prog file number
N10:0
N11:0
144
12
(EN)
(ST)
(ER)
0
(ES)
8
3
Each SDS instruction contains a sequence of user-defined steps which
guide the logical flow of the instruction, for example, Ready, Advancing,
Advanced, etc. Each step represents a unique collection of I/O
(input/output) and subsequent step conditions (or destination steps you
define according to your application). Information for each step is easily
configured through a fill-in-the-blanks configuration template (see next
page). This template contains fields for the following:
inputs and outputs (you enter actual names for control items rather than
obscure addresses)
transitions of the inputs or equations for combined inputs
destination steps
output states
step timer (how long until a timeout occurs)
message on or off
1-3
Chapter 1
Understanding How a DDMC32 System W
orks
Sample
Step Configuration T
STEP 1 READY TIMER=0.0s – DISABLED MSG:OFF
No Input ID Equation Destination No Output ID State
0 RET’D LS OFF––>ON STEP 0 0 FORWARD MOTOR 1 OFF
1 ADV’D LS OFF––>ON STEP 10 1 REVERSE MOTOR 1 OFF
2 FULL DEPTH LS OFF––>ON STEP 0 2 DRILL MOTOR OFF
3 ADVANCE COMMAND OFF––>ON **STEP 2
4 RETURN COMMAND
Press a function key.
Program edit mode PLC–5/25 Addr 1
Display Step Step Edit Step Msg Input Output Marked
Symbol Name Type Step Timer On Transit State Exit
F2 F3 F4 F5 F6 F7 F8 F9 F10
emplate With SDS Instruction
How the Transitional SDS Instruction Handles Inputs
Transitional equations provide state-based control. Each transitional
equation defines the destination step based on the transition of a particular
input (ON ––> OFF or OFF ––> ON). When input state transition
conditions are used, the expected input states appear on the left side of the
equation column and the transition states on the right. The destination
column is on the right of the equation column (see the figure above).
At power up, the SDS instruction starts out in an “initialized” step. The
instruction searches through each defined step to find a match based on the
expected states of inputs. If it cannot find a match, the SDS instruction
looks for a set of conditions defined by a combinatorial equation (see the
figure on page 1-5). If a transition is specified, you must validate the
entry state or you will not see a transition and will be locked into a step.
Because all input states in each step may be important, you must consider
the logical progression of I/O sequencing when developing a step
configuration. These considerations differ from those you make with
traditional ladder logic, as the sequence of I/O changes are not relevant.
1-4
For example, in the figure below, the expected input conditions for step 1
are (in order): off, off, off, off, don’t care. The instruction will enter this
step only when inputs 0, 1, 2, and 3 are off. This figure shows another
example of the SDS instruction looking for a step to enter.
SDS
Instruction Looking for a Step to Enter
When transition conditions are
used the instruction looks for a
match of actual and expected
inputs. If inputs do not match,
the instruction continues its
search.
Chapter 1
Understanding How a DDMC32 System W
ACTUAL INPUTS
OFF
ON
OFF
ON
orks
When the instruction
finds a match, it enters
the step.
STEP 1 EXPECTED INPUTSSTEP 2 EXPECTED INPUTS
OFF
OFF
OFF
ON
––> ON
––> ON
––> ON
––> OFF
OFF
ON
OFF
ON
––> ON
––> OFF
––> ON
––> OFF
During runtime, an input change or a step timer timeout directs the SDS to
another step. If the instruction detects a mismatch (the actual inputs do not
match the expected inputs), it generates a mismatch fault. To aid you with
programming, the software looks for obvious programmed mismatches
before you accept an instruction.
How the Combinatorial SDS Instruction Handles Inputs
Combinatorial equations define destination steps based on input state
values and the relationship between a collection of inputs. The
combinatorial equation lets you accommodate complex combinations in
the instruction while keeping the number of steps within a configuration to
a minimum. (You can define up to 4 logical AND combinations in an
8-input SDS instruction; You can define up to 8 ANDed conditions in a
16- or 32-input instruction.)
1-5
Chapter 1
Understanding How a DDMC32 System W
orks
The instruction scans the inputs from the top of the input list to the bottom,
looking for a transition. When the actual inputs do not match the expected
inputs, the instruction begins scanning the combinatorial equations for a
match and remains in the step until all conditions for the equation(s) are
met. The combinatorial SDS instruction ignores the “expected” entry
states so that, even if possible, no mismatch error is generated.
When a valid transition, a set of conditions as specified by an equation, or
a timeout occurs, the instruction moves to the destination step to verify the
inputs before entering the step (this occurs for transition equations only,
not ANDed conditions). See the following section for information on how
the SDS handles outputs.
How the SDS Instruction Handles Outputs
The SDS instruction sets or resets outputs as it enters each step (based on
how you define outputs in the configuration template). The table below
shows what happens to outputs when the SDS enters an error step, step 0,
or the initialization step.
States
of Outputs Based on Destination Steps
If the SDS instruction enters:Then outputs:
an error stepare set as defined in that step
step 0reset to off
initialization stepstay in the last state
Message Generation
The SDS instruction generates an error message or status message when it
enters a new step which has its message bit enabled. This message is
displayed on the operator interface terminal and/or an annunciator panel if
you so specify. (The figure on page 1–4 shows where you can turn
messages on and off using the [F7] key.) Error messages are cleared from
the display device (operator interface terminal or annunciator panel) only
when the instruction goes to step 0. All other types of messages are
cleared when the instruction moves to the next step.
1-6
Chapter 1
Understanding How a DDMC32 System W
orks
Understanding the DFA
Instruction
The Diagnostic Fault Annunciator (DFA) instruction is a monitoring–only
instruction; that is, it monitors inputs you define, but it cannot control
outputs. Valid inputs can be:
storage points, such as binary bits
counter/timer done bits
outputs (real or logical)
lube level sensors
alarms
fault bits set by another device or by ladder logic
any valid bit address
The following figure shows a DFA instruction in a ladder program.
A
DF
A Instruction (PLC 5/250)
ASSEMBLY
MACHINE
DFA
DIAGNOSTIC FAULT ANNUNCIATOR
Control File
No. of I/O
Program file number
Msg Control Block
N27:0
0MSG0:0
16
(EN)
(ER)
3
If you currently have diagnostics programmed in ladder logic, you can use
the DFA instruction to generate messages when a fault occurs. In addition,
you can create other types of operational and diagnostic messages with the
DFA instruction, such as tool change messages and operating instructions.
1-7
Chapter 1
Understanding How a DDMC32 System W
orks
Implementing DDMC32
Instruction in Levels
You can implement DDMC32 instructions at three different operational
levels, depending on the amount of diagnostics and control that you need
for your application. Each level provides incremental increases in terms of
diagnostic coupling with the control. The figure and table below show the
levels of implementation.
Levels
The DFA instruction can be used on all levels since it is
used for global type errors. Unlike the SDS instruction, which
is constructed around a given mechanism and its associated
I/O, the DFA instruction is constructed around constantly
monitored conditions that do not fit into a state structure.
• Ladder Logic for Control
• SDS Instruction for
Level 1
• Ladder Logic for Control
and Diagnostics
• DFA Instructions for
Messages
Messages and Diagnostics
• DFA Instruction for Messages
of DDMC32 Implementation
Level 2
Important:
SDS instruction for control and diagnostics. You may also include Level
and Level 2 Implementations for diagnostics outside of the Level 3 SDS
1
instruction, for example, lube faults or overloads.
Level 3
• SDS Instruction for Control
and Diagnostics
• DFA Instruction for Messages
A Level 3 Implementation does not limit you to only using the
This levelUses this
1DFAladder logicladder logicDFA
2SDS and DFAladder logicSDSSDS and DFA
3SDS and DFASDS and ladder logicSDSSDS and DFA
DDMC32 System Components
1-8
Description
of DDMC32 Levels
DDMC32
instruction
Control is handled by:Diagnostics are
handled by:
Message
Generation is
handled by:
A typical DDMC32 system applies the following system components:
6400 Series Software
Monitoring software (6404-DDMC)
6200 Series Software
PLC-5 family of programmable controllers
Chapter 1
Understanding How a DDMC32 System W
orks
1771 I/O
6180 Industrial Computer with the following minimum configuration:
Cat.
# 6180 – AB C B D B A C A C Z A
100 MHZ Pentium Processor
10.4” TFT
PCI 2Mg DRAM Video Board
16Mg RAM
1.3G Hard Drive
3.5” Floppy Drive
Series
No Software
Windows NTt 4.0
120V Power Card
1784-KTX
Data Highway Plus
Dataliner message displays
DDMC32 Software
DDMC32 software contains several tools to help you monitor, generate,
annunciate, and store information about faults.
When a fault is detected by a PLC diagnostic instruction, a message packet
with the appropriate coded data is sent to the operator interface terminal.
The DDMC32 software assembles the data used during programming to
form the text of the fault message. If configured by the user, the terminal
automatically displays the message in a window reserved for alarm
messages. Because the software automatically assembles the message, you
do not have to create and store separate and unique diagnostic messages.
You have to configure the message templates using the Template Editor in
the DDMC32 software. The Template Editor permits you to design
templates to reflect individual types of DFA and SDS faults (per each
Processor/Control File combination for these instructions. When a DFA or
SDS instruction generates a fault, the corresponding template is used by
the DDMC32 software to build the appropriate message that will be
displayed.
For more information on the DDMC32 Message Template Editor see the
section on Accessing the Message Template Editor in Chapter 7 –
Configuring Diagnostic Messages.
1-9
Chapter 1
Understanding How a DDMC32 System W
orks
The DDMC32 software also provides:
a fault log that shows all fault messages generated by the software
an interface for marquees to optionally display diagnostic messages
a fault report which lets you see where and when each fault occurs by
frequency and duration
These selections are configured by the user who may direct the faults to
some or all of the above devices.
6200 Series Software
This software provides the capability to program and monitor your PLC-5
family programmable controller using your operator interface terminal.
6200 Series Software uses menu-driven screens and configuration utilities
that simplify entry. You can use 6200 Series Software to develop ladder
programs and configure DDMC32 instructions.
To learn more about 6200 Series Software, refer to the PLC-5
Programming Software Documentation Set (publication 9399-PLC5MAN)
or the PLC-5/250 Programming Software Documentation Set (publication
9313–5250).
PLC-5 Family of Programmable Controllers
The PLC-5 family of programmable controllers is the heart of the
DDMC32 system, providing a flexible framework for processing. You can
create:
a centralized configuration to control a large number of I/O from one
location
a distributed configuration to control I/O from several remote locations.
(All PLC-5 processors can be linked using the Data Highway Plus to a
common operator interface terminal where programming, monitoring,
and troubleshooting are performed.)
1-10
Chapter 1
Understanding How a DDMC32 System W
orks
All PLC-5 processors can still be programmed with familiar ladder logic in
addition to using the diagnostic instructions. In DDMC32, PLC-5
processors utilize the instructions that can automatically detect machine
faults and abnormal conditions. Using 6200 Series software, you can
program PLC-5 processors with industrial computers, the plant floor
terminals, or any IBM AT–compatible computer.
If you want to know more about the PLC-5 processor, refer to PLC-5
Family Programmable Controllers Installation Manual (publication
1785-10.4) or the Pyramid Integrator Design Manual (publication
5000-6.2.1).
1771
I/O
With DDMC32 you can select from more than 80 types of I/O modules to
create a configuration perfect for your manufacturing needs. I/O modules
can be discrete, analog, or intelligent. Refer to the Automation Systems
Product Catalog.
6180 Industrial Computer
The 6180 Industrial Computer provides an industrially hardened,
expandable hardware platform. This computer is versatile and modular,
and lets you design a configuration suitable for your individual application.
The 6180 computer is the common operator interface for your DDMC32
system.
You can use the 6180 computer to:
develop ladder logic rungs and SDS instructions using 6200 Series
Software and the SDS Configuration Utility
display diagnostic messages using Monitoring Software
define graphic displays of your equipment that can be used to monitor
the operation
For more information about the 6180 Industrial Computer, refer to the
6180 Industrial computer brochure (publication 6180-1.0).
1-11
Chapter 1
Understanding How a DDMC32 System W
orks
Data Highway Plus
Data Highway Plus (DH+) is the network that links the PLC-5
programmable controllers and the operator interface terminal so that they
can communicate with one another.
The Data Highway Plus lets you:
download ladder logic with SDS instructions into multiple PLC-5s
receive diagnostic messages from multiple PLC-5s
implement a centralized common operator interface for all control
elements of the DDMC32 system
If you want to know more about Data Highway Plus, refer to Data
Highway/Data Highway Plus Protocol and Command Set Manual
(publication 1770-6.5.16).
What to Do Next
Dataliner Message Displays
Dataliner message displays (bul. no. 2706, series DL10) are highly visible
message display devices used for diagnostics, operator prompts, and status
messages. These displays can be used with your system as annunciator
panels for the messages sent by the DDMC32 software.
This chapter gave you an overview of how the DDMC32 system works to
diagnose faults and generate messages, and how the SDS and DFA
instructions work within the DDMC32 system. In addition, this chapter
described the components that make up a DDMC32 system.
Chapter 2 contains information for installing the DDMC32 hardware
components described in this chapter.
1-12
Chapter
Installing DDMC32 Hardware
Components
2
What this Chapter Contains
Hardware Configurations
Read this chapter to learn how to install your DDMC32 hardware
components when using a 6180 Industrial Computer.
In this chapter we overview DDMC32 hardware configurations and
provide procedures for installing the hardware components. In addition,
we reference specific hardware publications so that you can find more
information, if needed.
This chapter contains the following sections:
Section:Page:
Hardware Configurations2-1
Installing DDMC32 Components2-3
What to do Next2–4
You can have one or several PLC-5 processors in your DDMC32 hardware
configuration, in addition to a 6180 Series Industrial Computer. The
different DDMC32 hardware configurations are referenced in the
following table and on the subsequent pages.
DDMC32
One PLC-5 and the 6180 Industrial ComputerDDMC32 Component Configuration with one
Multiple PLC-5 (multi-drop peer communications
link) and the 6180 Industrial Computer
Hardware Configurations
If your configuration uses:Refer to figure:
PLC-5 Processor and a 6180 Industrial
Computer
DDMC32 Component Configuration with
multiple PLC-5 Processors and a 6180
Industrial Computer
2-1
Chapter 2
Installing DDMC32 Hardware Components
DDMC32
Computer
Component Configuration with one PLC-5 Processor and a 6180 Industrial
DDMC32 Software
DDMC32
Component Configuration with Multiple PLC-5 Processors and 6180
Industrial Computer
DDMC32 Software
2-2
Chapter 2
Installing DDMC Hardware Components
ATTENTION: If you are using your DDMC32 software
(cat. no. 6404-DDMC) with a PLC-5/250 processor, you must
make certain that the Remote Scanner Module (cat. no.
5150-RS) has a daughterboard (cat. no. 5150-MRS) with a part
number of 960456-05 or later (For example, -05, - 06, -07, etc.).
You can locate this part number along the bottom edge of the
removable 5150-MRS daughterboard. Failure to observe this
caution could result in erroneous data appearing in the input
image table or internal storage table.
Contact your local Allen-Bradley support office or call Technical Support
at (216) 646-6800 to arrange for shipment of updated modules.
Installing DDMC32
Components
The procedure for installing DDMC32 components varies depending on
the operator interface terminal you use. We describe procedures for 6180
Industrial Computer on the following pages.
Using a 6180 Industrial Computer
The table below lists the general procedure for installing your DDMC32
hardware components when using a 6180 Industrial Computer. Refer to
the manuals listed for more detail.
2-3
Chapter 2
C
X X X
Installing DDMC32 Hardware Components
Installing
DDMC32 Hardware Components when using a 6180 Industrial
Computer
To perform this task:Refer to this manual:Publication or Cat.
1. Install PLC-5 or PLC-5/250 and 1771 I/OPLC-5 Family Processor Installation
Instructions
Pyramid Integrator
Design/Installation/Startup and
Integration Manual
2. Install communications link:
a. Set the 6-switch assembly switches as follows:
1 2 3 4 5 6
OPEN
LOSED
(Based on the factory’s setting, only switches 2 and 3
must be modified.)
Important: When installing and configuring your 6200
series software, the switch setting for “on” will
correspond to a 1 and the switch setting for “off” will
correspond to a 0.
b. Install Data Highway Plus Interface Module (cat. no.
1784-KT) into an ISA slot .
X X X
Communication Interface Module
Installation Data
6180 Industrial Computer User’s Manual6160-6.5.1
Number:
1785-10.4
5110-ISET
1784-2.31
What to Do Next
c. Connect the 1784-CP cable from the 6180 to the
PLC-5 or 5/250.
If using a multiple PLC-5 configuration:
Connect PLC-5 processors with cables and 3-pin
connectors
Now that you have installed your hardware components, you can install
your software. Chapter 3 describes procedures for installing software for a
DDMC32 system.
PLC-5 Family Programmable Controllers
Hardware User Manual
Pyramid Integrator Design/Installation/
Startup and Integration Manual
1786-6.5.12
5110-ISET
2-4
Chapter
Installing DDMC32 Software
3
What this Chapter Contains
Setting Up Your Operator
Interface Terminal
Read this chapter to learn how to install your DDMC32 software. To
install your software, you perform the following tasks:
set up your operator interface terminal
install 6200 Series software
install DDMC32 Monitoring Software
This chapter contains the following sections:
Section:Page:
Setting Up Your Operator Interface Terminal3-1
Installing and Configuring the Software3-1
Installing DDMC32 Software3-2
Completing the DDMC32 Software Installation3-8
What to do Next3-8
Before you install your DDMC32 software, you must power up the 6180
Industrial Computer or your PC with 6200 Series software (v. 4.5 or later),
Microsoft Windows NTt 4.0, and RS Linx (v. 1.70.62 or later).
Installing and Configuring the
Software
Using a 6180 Industrial Computer
To power up the 6180 computer, turn the system power switch on the rear
of the computer to the ON position. The system performs a series of
self-tests to determine if its components are properly installed and
operating. You do not have to change the 6180 setup information to run
the DDMC32 software.
Install and configure Windows NTt on your PC according to your product
information.
Next, install and configure RSLinx on your operator interface terminal
(refer to the Rockwell Software Installation Guide for Windows-based
products for further information).
3-1
Chapter 3
Installing DDMC3Installing DDMC32 Software
Finally, install your 6200 Series software on your PC (reference the PLC-5
Programming Software documentation, publication 6200-N8.001).
Once you have the software installed, you must configure the 1784-KT
address to correspond with the switch assembly setting.
For the 6180 Industrial Computer, set the 1784-KT address to 001011.
This address is a recommended station address only. If you have
conflicting hardware installed, you must find your own settings.
Installing DDMC32 Software
There are several DDMC32 disks in the installation disk set. To install
your DDMC32 software, follow the procedure below. At this point, we
assume that you have formatted your hard disk and installed Windows
NTt.
1.Insert the first DDMC32 disk into the appropriate drive.
2.From the Start menu on the Windows NT Taskbar, choose R
un... to
begin the DDMC32 setup program.
3.In the Run dialog box, enter the drive letter and name of the
DDMC32 setup program (e.g., A:\setup.exe).
4.Ensure the drive letter is correct and click on OK.
Setup will begin. Follow the instructions as they appear on the
screen.
3-2
Chapter 3
Installing DDMC32 Software
The DDMC32 Welcome Setup screen appears.
DDMC32 Welcome screen
5.Click on the Next button to continue (or Cancel to quit the setup
program).
The Software License Agreement screen appears.
Software
License Agreement
3-3
Chapter 3
Installing DDMC3Installing DDMC32 Software
6.Click on Yes to accept or Back to return to the Welcome screen.
Click on No to terminate the program installation.
Once you have accepted the Software License Agreement, the
Choose Destination Location screen appears.
Choose
Destination Location screen
7.Click on the Browse button to select an alternate destination for the
program installation, or click on Next to accept the default destination
and continue with the setup.
Once you have verified your destination location, the Select Program
Folder screen appears.
Select
Program Folder Screen
3-4
Chapter 3
Installing DDMC32 Software
The Select Program Folder screen allows you to select a Program
Folder into which the DDMC32 program icon will be placed. The
default folder is named Rockwell Automation. You may use this
folder, select one from the Existing Folders window, or create a new
folder by typing in your folder name.
8.Click on the Next button.
The Select DDMC32 Option(s) screen appears.
Select
DDMC32 Option(s) Screen
9.Select one or both of the options you want to use with the DDMC32
software.
Important: At this point, if any changes need to be made to previous
entries, click on the Back button until the appropriate screen has been
reached. Make any corrections and continue with the setup as described.
3-5
Chapter 3
Installing DDMC3Installing DDMC32 Software
10.Click on the Next button.
The Add DDMC32 to Startup Folder screen appears.
Add
DDMC32 to Startup Folder screen
11.Select Yes to add DDMC32 to your Startup folder.
The default is No, in which case DDMC32 will not be added to your
Startup folder.
12.Click on the Next button.
The Start Copying Files screen appears.
3-6
Chapter 3
Installing DDMC32 Software
Your selections up to this point are listed. You can either go back
and change them, or click on the Next button to accept your
selections and begin copying files to your hard drive.
While files are being copied, the Progress screen is displayed.
Setup
DDMC32 Progress screen
This screen shows the progress the installation disk is making.
Follow the instructions on the screen to complete the setup.
The following window will appear each time a new disk is required
for the setup. Follow the instructions and click on the OK button to
continue.
Setup
Needs the Next Disk screen
3-7
Chapter 3
Installing DDMC3Installing DDMC32 Software
Completing the DDMC32
Software Installation
Once the installation of the software is complete, the Setup Complete
screen appears:
Setup
Complete screen
From this screen you may choose to read the latest release notes
concerning the DDMC32 software, and/or to launch the program by
clicking on the required box.
What to Do Next
Important: It is recommended that you read the release notes before
proceeding.
13.Click on the Finish button to complete the setup and activate your
selections.
Now that you’ve installed the software on your computer, you can begin to
set up the software for your particular application.
3-8
Chapter
Configuring SDS Instructions
4
What this Chapter Contains
Read this chapter to learn about the SDS instruction and procedures that
describe programming and configuring the SDS instruction:
Important: You can use an SDS instruction in either the PLC-5 processor or
the PLC-5/250 processor. There are some minor differences in the
procedures for programming and configuring the instruction, depending on
which processor you are using. We note these differences where applicable.
Examples in this chapter are for the PLC-5 processor.
This chapter contains the following sections:
Section:
Smart Directed Sequencer Overview4-2
Programming the SDS Instruction4-5
Documenting the SDS Instruction4-18
Configuring the SDS Instruction4-22
Exiting the SDS Instruction4-31
Editing and Copying SDS Instructions4-34
What to do Next4-37
Page:
4-1
Chapter 4
Configuring SDS Instructions
Smart Directed Sequencer
Overview
The SmartDirected Sequencer (SDS) instruction resides in ladder logic and
provides state control that can be used to characterize normal and abnormal
conditions.
The figure below shows an SDS instruction in a ladder program.
An
SDS Instruction Ladder Program
DRILL
MACHINE
HEAD 1
SDS
SMART DIRECTED SEQUENCER
Control File
Step Desc. File
Length
No. of Steps
Position/Step:
No. of I/O
Prog file number
N10:0
N11:0
144
12
(EN)
(ST)
(ER)
0
(ES)
8
3
The SDS instruction permits the user to classify groups of input values into
equation form. When an equation is physically satisfied by input conditions,
the SDS transitions to the destination step appropriate to that equation and
applies the output control related to that step.
The SDS instruction allows two basic types of logic equations:
transitional
combinatorial
Transitional Equations
The SDS instruction which uses transition equations provides traditional
state-based control. Essentially, this type of SDS instruction is built around the
state transition concept, where each input transition directs the instruction to a
unique next step using a logical OR structure. In other words, one input change
directs the instruction to step A, another to step B, etc. See the next page for an
example of what is meant by transitional equations.
4-2
Chapter 4
Configuring SDS Instructions
Graphic
LS3 0FF–> ON
Example of Transitional Equations
Step
4
LS ON–> OFF
Step
1
Step
3
Step
2
PB ON–> OFF
LS2 ON–>OFF
This type of SDS instruction operates from a series of step tables that define
output states for each step, and input transitions as either normal or abnormal.
Normal transitions direct the SDS instruction to another step; abnormal
transitions can cause the instruction to send a message to the operator interface
terminal, where DDMC32 software automatically assembles and displays the
appropriate diagnostic message.
The SDS instruction also allows you to implement “shadow mode” diagnostics.
In “shadow mode” control is placed in the ladder logic; the SDS simply
monitors the I/O performing the control and performs diagnostics on that I/O.
Combinatorial Equations
In addition to the transitional equation, the SDS instruction can also use
combinatorial conditions or equations which allow for the ANDing of inputs in
addition to the OR function (as seen in transitional equations).
You can also use the NOT function, although it is not as true an operand as the
AND function is. The NOT function is concerned with input state only. This
allows complex combinations or mechanisms that are not easily defined by
individual state transitions to be accommodated more easily within the SDS
framework with a minimum number of steps. See the next page for an example
of what is meant by combinatorial equations.
4-3
Chapter 4
ON
AND
N
Configuring SDS Instructions
LS3 OFF
AND
LS1 OFF
Graphic
Example of Combinatorial Equations
LS2
Step
1
Step
3
LS1 O
Step
2
LS2 OFF
AND
LS3 ON
With traditional state-based programming, you need to take into account all of
the probable states for the implementation. (The number of possible states is 2
to the nth power, where n is the number of inputs.)
The SDS instruction that uses combinatorial equations eliminates this need to
account for all possible input states, and provides a means to enter Boolean
expressions similar to ladder logic. In this case, the SDS instruction will not
advance to another step until all conditions defined in an equation are fulfilled,
regardless of their order or timing relationship with each other.
Using the SDS instruction in combinatorial mode also allows you to replace
external ladder logic. By using combinatorial equations in the SDS instruction,
you can get diagnostic information on the logical conditions not yet fulfilled.
This feature can be useful in generating operator guidance messages, as well as
diagnostic messages.
4-4
Chapter 4
Configuring SDS Instructions
Programming the SDS
Instruction
Once you have determined where you want to apply the SDS instruction, you
can enter it into your ladder program and configure the instruction. Perform the
following tasks to program the SDS instruction:
download the SDS CAR
enter the SDS instruction
enter the configuration information
enter I/O information
To program the SDS instruction into your ladder program:
1.Access the PLC-5 or PLC-5/250 Programming Software main menu,
shown below, from the Allen-Bradley main menu interface.
Programming
+========================= PLC–5 PROGRAMMING SOFTWARE =========================+
| |
| A 6200 Series Software Product |
| |
| Copyright 1986, 1987, 1988, 1989, 1990, 1991, Allen–Bradley Company, Inc. |
| All Rights Reserved |
| |
| Release 4.3 |
| |
| This software is licensed to: Company Allen–Bradley Co. |
| Location 747 Alpha Drive |
| PSP Engineering |
| Serial Number: ZZ0AA0PP |
+==============================================================================+
| Fri June 14, 1991 9:39:09 am |
+––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––+
| Terminal Address: 77 Current Device: 1784–KT (DH+) PLC Address: 1 |
+==============================================================================+
Press a function key
Online Online Offline Offline Who Sftware File Reports Compare Exit
Program Configr Program Configr Configr Utils System
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Software Main Menu (PLC-5)
4-5
Chapter 4
Configuring SDS Instructions
2.Press [F1]
- Online Program
.
The system displays the online program directory (see the figure below).
Press a function key or enter a program descriptor.
>
Program PLC–5/25 Addr 5
Proc Save Return Change Who Memory Monitor Monitor
Functns Restore to Menu Station Map File SFC
F1 F2 F3 F4 F5 F6 F8 F9
The cursor is placed on the first user-accessible file.
If the program directory does not list the SDS CAR file, you will need to
download it to the PLC-5; otherwise your can go to the “Entering or
Modifying an SDS Instruction” on page 4–9.
Downloading the SDS CAR File
Important: To download the SDS CAR file you must be in online
programming mode.
Do the following to download the SDS CAR file into your program:
1.Press
[F2]-
Save Restore.
The system displays the Save Restore function keys.
4-6
Chapter 4
Configuring SDS Instructions
2.Press [F4]-
Restore Program.
The system displays a window containing a file directory of a specific
type (see the figure below).
Press a function key , or move cursor to select file.
>
Program PLC–5/25 Addr 5
Begin Define Select
Oper Dirctry Type
F1 F7 F8
indow (PLC-5)
3.Press [F8]
- Select Type
until the CAR files appear in the file
directory window.
4.Cursor to the desired CAR file.
Important: Program file numbers for the SDS and DFA instruction must be
unique. You need to specify only one SDS and one DFA CAR program file
number per processor, regardless of the number of SDS or DFA instructions
you use.
4-7
Chapter 4
Configuring SDS Instructions
5.Download the CAR file:
If you are using a PLC-5:
a.Press
[F1]
- Begin Restore.
The system prompts you to enter a file number.
b.Type the file number and press
[ENTER].
The system returns to the Program Directory.
If you are using a PLC-5/250:
a.Press
[F1]
- Begin Oper.
The system prompts you to enter a program descriptor.
b.Type the program descriptor, for example, 1CAR0, and press
[ENTER].
In the program descriptor, the first number refers to the number in
the thumbwheel window on the logic processor (in this case, 1). A
logic processor runs control logic which controls steps, transitions,
processor input interrupts, selectable timed interrupts, and
independent background programs.
4-8
CAR refers to the type of file; 0 refers to the program file number into
which the CAR will be downloaded.
The system returns to the Program Directory.
Chapter 4
Configuring SDS Instructions
Entering or Modifying an SDS Instruction
To enter or modify an SDS instruction in your ladder program:
1.Cursor to the program you want to edit in the Program Directory and press
[F8]
- Monitor File.
The system displays your ladder program and the Ladder Editor main
menu.
2.Cursor to the rung where you want to position the SDS instruction.
If you are modifying an existing rung, cursor to the SDS rung.
Important: When cursored on the R rung of an IR (Insert/Replace) rung
pair, the SDS configuration utility uses the configuration information from
the I rung.
3.Press
[F10]
- Edit.
The system displays the Ladder Editing screen.
4.If you are editing an existing rung, press
If you are entering a new rung, press [F4]
[F5]
- Modify Rung
- Insert Rung.
The system displays the Edit Rung screen.
5.If you want to change an existing instruction, press
Instruction.
If you are entering a new instruction, press [F4]
Instruction.
- Insert
The system prompts you for the instruction you want to add.
[F5]
.
- Modify
4-9
Chapter 4
Configuring SDS Instructions
6.Type SDS, if it does not already appear at the prompt, and press [ENTER].
(If you are modifying an existing instruction,
SDS already appears at the
prompt.)
As an alternate method of entering the instruction, you may:
Press [F10]
Press [F9]
Press [F6]
- Others
- Seqncer
- SDS
from the Shift Sequencer function keys
from the Instruction Classes function keys
The system displays the SDS instruction, seen below.
Enter the operand.
Enter the Control File address>
Program Forces:Disabled Edits:None PLC–5/25 Addr 5
4-10
Chapter 4
Configuring SDS Instructions
Entering or Modifying SDS Instruction Information
Once the SDS instruction is displayed, the system prompts you to enter the
Control File starting address. To enter or modify parameters into the SDS
instruction:
1.Type the Control File address and press
[ENTER].
The control file must be expressed in the following manner:
For the:Use this format:Where:
PLC-5Nfff:eee
PLC-5/250Nffff:eeeeffff = an integer file between 10 - 9999 and
fff
= an integer file between 10 - 999 and
eee = an element number between 0 - 999.
eeee = an element number between 0 - 9999.
In the PLC-5/250, when you enter the control file address, the system
displays a number (1, 2, 3, or 4) in front of the address. This number
represents the logic processor in the PLC-5/250.
Important: The control file and the step descriptor file addresses must be
local to the logic processor that is executing the associated SDS
instruction. Do not place either of these files in system memory. Do not
reference this step descriptor file in other logic processors.
The PLC-5/250 chassis supports up to four logic processor modules. For
more information on logic processors, refer to the PLC-5/250
Programming Software Documentation Set (publication 9313-5250).
When the Control File address is entered, the system prompts you to enter
the Step Description File address.
4-11
Chapter 4
Configuring SDS Instructions
2.Determine the Step Description File address.
The Step Description File address must be expressed in the manner shown
in the following table:
For the:Use this format:Where:
If you have this number
of I/O:
PLC-5Nfff:eee
PLC-5/250Nffff:eeeeffff = an integer file between 10 - 9999 and
fff
= an integer file between 10 - 999 and
eee = an element number between 0 - 999.
eeee = an element number between 0 - 9999.
If you want to start your step description file at the end of the control file,
you need to leave enough memory for the control file. The amount of
memory used by the control file depends on the number of I/O that you
control in the SDS.
We recommend that you use a separate integer file for the step description
file.
Use the following table to determine the starting address of the Step
Description File if you want the file to start at the address immediately
following the control file.
Step
Description File Address
Then you must allow this number of words for
your Control File in the PLC-5:
Then you must allow for this number of words
for your Control File in the PLC-5/250:
4-12
86858
166858
326858
For example, in the PLC-5, if your control file address is N10:0 and you
are putting your step description file for an SDS with 8 I/O at the end of
the control file, your step description file must start at N10:69.
Similarly, in the PLC-5/250, if your control file address is 1N10:0 and you
are putting your step description file for an SDS with 8 I/O at the end of
the control file, your step description file must start at 1N10:59.
Chapter 4
Configuring SDS Instructions
3.Type your Step Description File address and press [ENTER].
The system prompts you for the number of steps. The table below lists
the number of steps you can enter per SDS instruction, depending on the
number of I/O you have.
If you have this number
of I/O:
876250
1645250
3223232
Number
of Steps Per SDS Instruction
Then you can enter this number of steps per
SDS instruction in the PLC-5:
Then you can enter this number of steps per
SDS instruction in the PLC-5/250:
4.Type the number of steps to be directed by the SDS instruction and press
[ENTER].
The system prompts you for the number of I/O you are using. Valid
number of I/O are 8, 16, or 32.
5.Type the number of I/O you are using and press
[ENTER].
The system prompts you for the Program File number. The program file
number refers to the program file number of the SDS file in the online or
offline program directory.
6.Type the Program File number and press
[ENTER].
The I/O Definition screen is displayed. If you have a PLC-5 processor,
continue with “Entering or Modifying I/O Information” on page 4-14.
In the PLC-5/250 processor, the system prompts you for the Message
Control Block address.
4-13
Chapter 4
Configuring SDS Instructions
7.If you have a PLC-5/250 processor, type the Message Control Block
address and press
[ENTER].
The Message Control Block address must be entered in the following
manner:
0
MSG
X:X
where:
0 is the Resource Manager global memory (must be set to zero)
X:X
message control block number (0-9999)
file number (0-9999)
For example, 0MSG0:0 is a valid message control block address.
The I/O Definition screen is displayed (see below).
Entering or Modifying I/O Information
The inputs and outputs you enter into the I/O Defines on the I/O Definition
screen are used by each step in the SDS instruction. You can enter logical
addresses and symbols into the I/O Definition screen.
The following figure shows the screen you see if you are modifying I/O
information. (If you are entering new information, you have additional function
key options.)
Operator Interface Station Addr : 77
Timebase for Step Timer : 0.01
Port Number for Message : 2
Press a key to change a parameter or <ENTER> to accept parameters.
>
Program Forces:Disabled Data:Decimal Addr:Decimal PLC–5/250 Addr 5
Station Timebas Port Documnt Modify
Address IO Addr
F1 F2 F3 F5 F7
4-14
Chapter 4
Configuring SDS Instructions
The Ins Cmt (Instruction Comment) window on the I/O Definition screen
displays the instruction comment associated with the instruction in the ladder
program. The Adr Cmt (Address Comment) window displays the address
comment for the cursored address in the I/O Defines field.
The maximum number of possible inputs and outputs in the I/O Defines field
correlates with the number of I/O you entered in the Number of I/O field when
programming the SDS instruction.
Important: Consider carefully the order in which you assign I/O points in
the I/O Defines field. The order of I/O assignments can make a significant
difference in the performance of the DDMC32 system.
The order in which an SDS instruction checks I/O information is based on the
equations assigned in a given step (the “current” step). The order of evaluation
is as follows:
single bit transitions –– This includes all inputs that have an equation
assigned to them as ON–> OFF or OFF–> ON
combinatorial equations –– This includes any operations that contain
multiple inputs with either an AND or NOT operand
timers –– This includes any transitions that are generated by a timer (no
inputs are used for this transition)
You can perform the following tasks from the I/O Definition screen:
If you want to:Press this key:
Enter an operator interface station address.[F1] - Station Address
Enter a new timebase for the step timer.[F2] - Timebas
Enter the port number for the message. (PLC-5/250
only)
Display the Documentation screen for the SDS
instruction.
Modify an I/O address at the cursored location.[F7] - Modify IO Addr
Insert an I/O address at the cursored location.
Delete an I/O address at the cursored location.
Remove an I/O address at the cursored location.
1
These
function keys do not appear on the screen if you have accepted edits once (for example, if you are
modifying the instruction).
[F3] - Port
[F5] - Documnt
1
[F8] – Insert IO Addr
1
[F9] – Delete IO Addr
1
[F10] – Remove IO Addr
4-15
Chapter 4
Configuring SDS Instructions
To insert or modify information in the I/O Definition screen, follow the
procedure below.
1.If you want to change the Operator Interface Station Address:
a.Press
[F1]
- Station Address.
b.Type the number of the Data Highway Plus node ( 0-77) where you
want the diagnostic messages sent, for example
[ENTER].
77, and press
Important: If you want to send diagnostic messages to other operator
interface stations, use the Message Instruction in 6200 Series software.
For procedures on sending messages with the Message Instruction, refer to
PLC-5 Programming Software Documentation Set (publication
6200-N8.001) or the PLC-5/250 Programming Software Documentation
Set (publication 6200-N8.002).
2.If you want to change the step timer timebase from 10 milliseconds to 1
second, or vice versa, do the following:
a.Press
[F2]
- Timebas.
b.Enter the new timebase.
4-16
3.If you have a PLC-5/250 and you want to change the port number:
a.Press
[F3]
- Port.
b.Enter the port number. The following table shows the port number to
enter for the specific link type.
Important: The port number is not selectable on these PLC-5 processors:
4.If you want to alter an existing address or enter a new address in a list of
I/O points:
a.Press
[F7]
- Modify IO Addr.
The system prompts you for an
address.
b.Type in your I/O address and press
[ENTER].
Valid entries include
any logical address specified to the bit level, with the exception of
indirect addresses.
c.After entering or modifying an I/O address, cursor to the next field
and repeat this step until you have completed all entries or changes.
5.After entering all your I/O addresses, press
Definition screen function keys, and then press
[ESC] to display the I/O
[ENTER].
The system returns to the SDS instruction.
6.Press
[ENTER].
The system displays the Edit Rung screen.
Edit
Rung Screen (PLC-5)
I DRILL I
I MACHINE I
I HEAD 1 I
I +SDS–––––––––––––––––––––––––+ I
I––––––––––––––––––––––––––––––––––––––––––+SMART DIRECTED SEQUENCER +–(EN)–I
I |Control File N10:0| I
I |Step Desc. File N11:0+–(ST) I
I |Length 156| I
I |No. of Steps 12+–(ER) I
I |Position/Step: 0| I
I |No. of I/O 8+–(ES) I
I |Prog file number 3| I
I +––––––––––––––––––––––––––––+ I
Press a function key for desired editing function, or type a mnemonic.
(file 2, rung 8)
Program Forces:None Edits:None Rung:Modify PLC–5/25 Addr 1
Branch Append Insert Modify Delete Undel Accept
* Instr Instr Instr Instr Instr Rung
F1 F3 F4 F5 F6 F7 F10
4-17
Chapter 4
Configuring SDS Instructions
Documenting the SDS
Instruction
7.Press [F10]
- Accept Rung
.
Important: You must accept the rung to save the information you entered
into the SDS instruction.
The SDS instruction provides a documentation function that lets you describe
the instruction and its associated addresses. The documentation function also
lets you assign symbols to addresses.
To document your SDS, Press
[F5]
- Documnt
from the I/O Definition screen.
The system displays the SDS Instruction Documentation screen.
Program Forces:None Data:Decimal Addr:Decimal PLC–5/25 Addr 1
Instr Address Modify Remove Display Save &
Comment Comment Symbol Symbol Symbol Contnue
F2 F3 F6 F7 F9 F10
4-18
Chapter 4
Configuring SDS Instructions
From SDS Instruction Definition screen you can perform the following
documentation tasks:
If you want to:Press this key:
Activate the cursor in the instruction
comment window and display the Instruction
Comment Editor.
Activate the cursor in the address comment
window and display the Address Comment
Editor.
Assign a symbol to an address or change an
existing symbol.
Remove the symbol from the current
address.
Save your work in the data base. If you are
editing off line, the archive file is updated
and the comment and symbol files are
saved. If you are editing on line, only the
comment and symbol files are saved.
[F2] - Instr Comment
[F3] - Address Comment
[F6] - Modify Symbol
[F7] - Remove Symbol
[F10] - Save & Contnue
4-19
Chapter 4
Configuring SDS Instructions
Editing Instruction and Address Comments
To activate the cursor in the instruction comment window:
1.From the SDS instruction screen:
Press [F2]
- Instr Comment
to edit instruction comments. The
system displays the Instruction Comment Editor screen, below.
Press [F3]
- Address Comment
to edit address comments. The
system displays the Address Comment Editor screen, next page.
Operator Interface Station Addr : 77
Timebase for Step Timer : 0.01
Enter instruction comment for : SDS,N10:0
Program Edit mode:Insert Col:1 Line:1 PLC–5/25 Addr 1
Delete Undel Delete Undel Delete Undel Accept/
Comment Comment Line Line Word Word Exit
F1 F2 F3 F4 F5 F6 F8
Operator Interface Station Addr : 77
Timebase for Step Timer : 0.01
Enter address comment for : I:001/14
Program Edit mode:Insert Col:1 Line:1 PLC–5/25 Addr 1
Delete Undel Delete Undel Delete Undel Accept/ Next Prev
Comment Comment Line Line Word Word Exit Address Address
F1 F2 F3 F4 F5 F6 F8 F9 F10
2.Edit the instruction or address comment. The function keys for both
Editor screens are the same, except that the Address Comment Editor
screen has function keys for moving the cursor to the next or previous
address:
If you want to:Press this key:
Delete the current comment.[F1] - Delete Comment
Re-insert the last deleted comment where the cursor is.[F2] - Undel Comment
Delete the line the cursor is on from the current
[F3] - Delete Line
comment.
Re-insert the last deleted line from a comment.[F4] - Undel Line
Delete the word the cursor is on from the current
[F5] - Delete Word
comment.
Re-insert the last deleted word from a comment.[F6] - Undel Word
Save the current comment and return to the I/O
[F8] - Accept/Exit
Definition screen.
For Address Comments Only:
[F9] - Next Address
Save the current comment and/or move the cursor to
the next address.
Save the current comment and/or move the cursor to
[F10] - Prev Address
the previous address.
3.When you are finished, press [F8]
- Accept/Exit
.
4-21
Chapter 4
Configuring SDS Instructions
Configuring the SDS
Instruction
Once you have entered your I/O information into the I/O Definition screen and
accepted the rung, you are ready to configure steps in the SDS instruction. To
do this, you must first access the Step Directory.
Using the Step Directory
The Step Directory is a list of all the steps in an SDS instruction and is accessed
from the Ladder Editing screen. The number of available steps in the directory
correlates to the number of steps you entered in the Number of Steps field when
programming the SDS instruction.
If you are configuring your SDS instruction, the Step Directory contains Step 0
(the Initialization step) and an entry for each step. Each time you configure a
new step, the Step Directory adds that step to its list by displaying a step’s title.
To access the Step Directory:
1.Cursor to the SDS instruction using the arrow keys.
Press a function key or enter step number.
STEP 10
Program edit mode Current Step 0 PLC–5/25 Addr 1 Proc Name
Change Update Exit Edit Extnded I/O Accept
Mode Msg DB Step Edit Monitor Edits
F1 F2 F3 F5 F6 F8 F10
4-22
Chapter 4
Configuring SDS Instructions
You can perform the following functions from the Step Directory:
If you want to:Press this key:
Change between remote/run program mode
[F1] - Change Mode
and test mode.
Update the internal SDS data base
[F2] - Update Msg DB
documentation for diagnostic messages.
Exit the configuration utility. (This key is
[F3] - Exit
active only when the Step Directory is your
point of entry into the SDS instruction.)
Configure or edit your combinatorial or
[F5] - Edit Step
transitional equations
Display the Extended Edit screen.[F6] – Extnded Edit
Display the I/O Monitor screen. (Refer to
[F8] - I/O Monitor
Chapter 8 - “Debugging Your DDMC32
System” for information on the I/O Monitor
screen.)
Accept all entries/edits. The system prompts
[F10] - Accept Edits
you to confirm your decision.
Display error list.
1
[F9] is displayed only
configuration.
1
[F9] -Display Err Lst
as a result of pressing [F10] - Accept Edits when errors exist in the
Configuring or Editing Steps
From the Step Directory, cursor to the appropriate step and press
[F5]
- Edit Step
shown below.
(you cannot edit Step 0). You see the Edit Step screen as
Edit
Step screen (PLC-5)
STEP 1 LOADING TIMER=5.00s STEP 11 MSG:ON
No Input ID Equation Destination No Output ID State
0 PART IN POSITION ON –> OFF **STEP 2 1 VALVE 4 OFF
1 CLAMP LS1 2 CLAMPS OPEN ON
2 CLAMP LS2 3 CLAMPS CLOSED OFF
3 CLAMP LS3 4 SOLENOID LAST
4 CLAMP LS4 5 LIGHT LAST
5 HAND 6 MOTOR 2 ON
6 AUTO
7 JOG PB
8 PERMISSIVE
Press a function key.
Enter destination step number or ’INIT’ >
Prog edit mode 5/25 Addr 5 SDSTEST
Equatn Display Step Step Edit Step Msg Equatn Output Marked
List Symbol Name Type Step Timer Off Editor State Exit
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
4-23
Chapter 4
Configuring SDS Instructions
You can perform all of the tasks necessary to configure steps from the Edit Step
screen:
If you want to:Press this key:
Display all equations related to a particular step and enter
your equations.
Toggle between address comment, symbolic name, or
logical address of I/O. The function key always displays
the next format; for example, if address comments are
being displayed, then [F2] reads Display Symbol.
Enter or modify step name. Step name may be up to 20
characters long.
Select between normal step label or error step label.
Normal is displayed as STEP; error is displayed as
ERSTEP. See chapter 7, “Configuring Diagnostic
Messages” for details regarding selection of this field as it
relates to diagnostics.
Switch to another step without leaving the Edit Step
screen. System prompts you for step you want to edit.
Enter or change the timer preset value and destination step
of step timer. The step timer can be used as a watchdog
timer to ensure an input transition occurs within a specified
time (by entering WARN as a destination step), or as a
dwell timer.
You can enter up to 10 characters in the step timer field.
Valid ranges for step timers are:
– time base 1.0 (32767 seconds)
– time base 0.01 (327.67 seconds)
Select between message ON and message OFF on the
operator interface display. Function key displays the
opposite function. The function is normally off for a normal
step and on for an error step to generate a message.
Switch between the input transitions of ON->OFF,
OFF->ON, AND, or NOT. Function key is active only when
cursor is in input transition field.
Switch between output state of ON, OFF, and LAST. LAST
maintains the last state of the output. This key is active
only when the cursor is in the output state field.
Select the one valid exit out of the step; that is, select the
“normal” path for the operation.
[F1] - Equatn List
[F2] - Display Comment/Symbol/LogAdr
[F3] - Step Name
[F4] - Step Type
[F5] - Edit Step
[F6] - Step Timer
[F7] - Msg On/Off
[F8] - Equatn Editor
[F9] - Output State
[F10] – Marked Exit
4-24
See the following sections for information on configuring or editing transitional
and combinatorial equations:
If you want to:See page:
Configure or edit transitional equations4-25
Configure or edit combinatorial equations4-27
Chapter 4
Configuring SDS Instructions
Configuring or Editing Transitional Equations
To edit or configure steps based solely on transitional equations, start at the Edit
Step screen on page 4–23:
1.Press
[F3]
- Step Name
from the I/O Edit screen.
The system prompts you to type in the name for your step. (When you
enter the step name, the Step Directory is automatically updated to contain
that step name.)
Important: When assigning names to your steps, use names that will fit
into your expected diagnostic message layout. The step name is used for
the message generation and should be as descriptive as possible of the
operation being performed in that step. Think about how you intend to
present diagnostic messages in DDMC32 and assign messages
accordingly. For example:
Step Name: Possible Message:
WAITING FOR PARTLIMIT SWITCH 1 is ON while WAITING FOR PART
MOVING PART ON CONVEYORLIMIT SWITCH 1 turned ON while MOVING PART ON
CONVEYOR
2.Type your step name and press [ENTER] to accept it.
The system returns you to the Edit Step screen.
3.Press
[F4]
- Step Type
.
This key toggles the step between a normal step and an error step (see the
upper left corner of your screen). Select the appropriate option.
4.Enter the equation:
a.Cursor to the equation field and press
[F8] - Equatn Editor
(You see the transitional equation in the lower left corner of your
screen if you are editing. If you are configuring the step for the first
time, the lower left corner is empty.)
b.Press
[F8]-ON–>OFF
or [F9]-OFF–>ON to set the equation.
5.Cursor to the destination field. You are prompted:
Enter
destination step or ’INIT’ >
Type the destination step and press [ENTER].
.
4-25
Chapter 4
Configuring SDS Instructions
6.Cursor to the output field and press [F9]
- Output State
This key toggles the cursored output state which will be applied for
control between ON, OFF, and LAST (no changes).
7.Press
[F6]
- Step Timer.
The system prompts you to enter your step timer preset value and your
destination step number. The destination step number can be:
a step
an error step
a warning (The instruction displays a Warning message without
stopping the program execution. For example, a warning message can
be displayed to notify the operator that a transition is taking too long.)
INIT (Initialize). Do not confuse INIT with Step 0 (Initialization) on
the step directory. These steps react differently, as noted below:
INIT
vs. Step 0
.
If you specify this
destination:
INITOutputs remain in their current state. The step timer is disabled. For
two program scans and beginning at Step 1, the system searches all
normal steps with defined input transitions, looking to match current
input states with expected input states. When current inputs match
expected inputs, that state is entered. If no match is found in two
program scans, the program enters Step 0.
Important: INIT can not enter an error step or step with no defined
input transitions.
Step 0All outputs are turned off. Starting at Step 1, the system searches all
steps with defined input transitions, looking to match current input
states with expected input states. When current inputs match
expected inputs, the program enters that step; otherwise it stays in
Step 0. You cannot configure Step 0.
Important: Step 0 can enter a status step or error step, unless the
step has no defined input transitions.
This happens:
ATTENTION: Because the instruction does not recognize
transitions when in INIT, outputs may stay on for up to 2 program
scans.
4-26
Chapter 4
Configuring SDS Instructions
8.Press [F7]
- Msg On/Off.
This key is a toggle key which allows you to choose whether or not you
want the message related to this step to appear on the operator interface
display.
Important: If you do not specify information for a field, it is assigned a
default setting. Defaults settings for fields are:
This setting:Has this default:
outputsoff
type of stepnormal step
destination steptimer destination step
timer0.00 (disabled)
messagingoff
Configuring or Editing Combinatorial Equations
With the addition of the combinatorial function, the step configuration utility
lets you use AND and NOT functions, in addition to the traditional ON>OFF
and OFF>ON transitions. This lets you:
enter an equation that will solve steady state conditions and expressions
select the traditional transition conditions
Important: The order in which you configure your steps is
important. Step assignment should reflect as closely as possible the
order that operations occur on the particular machine (e.g. step 1 —
machine startup, step 2 — first machine operation, step 3 — second
machine operation, etc.) This will help you organize your SDS
instruction in a format that can be understood at a later date if
troubleshooting is necessary.
More important than organizational considerations is the functional impact that
order has on the SDS instruction. By logically presenting your steps in order
of machine operation, you will avoid going to improper destinations when step
destinations are zero or initialize.
4-27
Chapter 4
Configuring SDS Instructions
To configure or edit combinatorial equations, you must enter some additional
information not needed in transitional equations:
1.Access the Edit Step screen, seen below. If you are editing, cursor to
EQx (x is equal to the number of the equation within the step); if you are
adding the equation, the equation field is blank. Press
[F1]-Equatn
List.
The system displays the Equation List screen seen below:
Equation
List Screen (PLC-5)
STEP 4 CLAMPING
Eq# |Equation
1 0 ON—>OFF
2 1 OFF–>ON
3 2 EQ1
4 3
Press a function key.
Rem RUN 5/25 Addr 1 DB_TEST
Equatn Cancel Toggle Edit
Zoom Equatn Equatn Equatn
F1 F5 F9 F10
From the Equation List screen, you can perform the following tasks:
If you want to:Press this key:
4-28
View a large equation which will not fit in the
[F1] - Equatn Zoom
equation list..
Remove an equation from the equation list.[F5] - Cancel Equatn
View the equation in an alternate form
[F9] - Toggle Equatn
(abbreviated or expanded).
Edit an existing or enter a new equation.[F10] - Edit Equatn
Chapter 4
Configuring SDS Instructions
2.Press [F10]
- Edit Equatn.
The system displays the Equation Editor screen, below. If you are editing
an existing equation, that equation appears in the lower left corner of your
screen. If you are configuring the equation for the first time, the lower
left corner is empty.
Press a function key.
0&4
Program 5/25 Addr 1 DB_TEST
Select Display & ! ON>OFF OFF>ON Accept
Input Symbol AND NOT Equatn
F1 F2 F4 F6 F8 F9 F10
3.Cursor to an input in the selection window that you want to place in your
equation and press
[F1]
- Select Input.
All available input operands appear in the selection window. As you
select an input, it disappears from this window.
The system displays the input you select in the lower left corner of the
screen.
4.Select the operator you want to use in your equation:
If you want to:Do this:
combine 2 or more inputs1. Select an input and press [F1]-Select Input
2. Press [F4]-AND.
Select the next input and press
3.
(See the Important note on page 4-30.)
negate an input1. Combine the inputs as shown above.
2. Place the cursor on the input you wish to negate and
press [F6] - NOT.
[F1]-Select
Input
4-29
Chapter 4
Configuring SDS Instructions
Important: Since it is concerned with state only, the NOT function is
used to negate the state associated with that particular input. For example:
!1&4 means that if the state in equation 1 is NOT true AND the state in
equation 4 is true, then proceed to the destination step.
The system displays the operator in the window on the lower left corner of
the screen, next to the input, forming your equation as you continue.
Important: The following procedure is another method by which you
can AND your inputs. From the Equation Edit screen:
Press [F1]
- Select Input
to select the first input of your
equation.
Press [F1]
- Select Input
again to select your second input.
Using this method, the AND is automatically placed between your inputs.
5.Continue selecting inputs and operands until your equation is complete.
The following conditions apply to every equation you enter:
If you want to use a single input in more than one equation within a
single step, you need to duplicate it in the I/O Defines on the I/O
Definition screen.
Inputs do not have to be contiguous. The order in which each input
occurs or goes true is not significant as long as the Boolean expression
is fulfilled.
More than one expression can be entered and mixed with transitions to
create logical OR functions.
4-30
Up to four logical AND combinations can be defined in an 8 input SDS,
which would be the equivalent Boolean of A+B or C+D or E+F or
X+Y. Up to eight AND conditions can be defined for a 16 or 32 I/O
SDS.
6.When you have finished entering your equation, press
[F10]
- Accept Equation.
Chapter 4
Configuring SDS Instructions
Important: After you have accepted an equation, the label EQx (where x
is equal to the number of the equation within the step) appears on the Step
Edit screen.
Exiting the SDS Instruction
7.Press
[ESC] to return to the Equation List screen.
On the Equation List screen, it is possible to view your equation in two
different forms:
Abbreviated form — shows the input numbers and operands.
For example:
0&1&2
Expanded form — uses input address comments. For example:
Start/Stop
You can use the [F9]
= 1 AND All Sta.s Returned = 1 AND Start Auto = 1
- Toggle Equatn
key from the Equation List or
Equation Zoom screens to view the different forms of your equation.
8.Press
[ESC]
again and the system returns you to the Edit Step screen.
Once you have configured all of your steps, you can save and exit the SDS
instruction.
To save the SDS instruction:
1.Press
[ESC]
.
The system displays the Step Directory.
2.Press
[F10]
- Accept Edits
.
The system prompts you to confirm your decision.
3.Press
[F8] - Yes
.
If your configuration is correct, the system returns to the Step Directory.
Continue with Step 4.
4-31
Chapter 4
Configuring SDS Instructions
If your configuration contains errors, the system displays an error list
that describes each error in the configuration. To correct errors:
a.Press
[ESC]
.
The system displays the Step Directory, which now contains
[F9]
- Display Err Lst
. To view the list at any time, press [F9].
b.Reconfigure steps from the Edit Step screen as needed to correct the
errors, and repeat Steps 1, 2, and 3. Refer to the chapter entitled,
“Debugging Your DDMC32 System” for correcting step
configuration errors.
Important: If this is a new SDS instruction, or if you updated an existing
instruction (changed an address, comment, or step name), press
[F2]
– Update Msg DB
The system flashes a
(update message database).
Working...
prompt, indicating that a 6200
database export file is being created. (Later, you will need to import this
file.) The processor name is used as the name of the export file with an
extension of
.SDS
. For example, if your processor name is DRILL, the
system creates an export file DRILL.SDS. Export files are stored in the
directory:
4-32
C:\IPDS\ARCH\PLC5 or
4.Press
[F3] - Exit
C:\IPDS\ARCH\PLC5250
to exit the SDS instruction configuration utility.
If your edits produced errors in your configuration, the system prompts
you to save your work.
5.Press
[F8]
- Yes
.
The system displays the Ladder Editor main menu. If you have other SDS
instructions to configure or edit, you can do so as described in the “Enter
or Modify SDS Instructions” section in this chapter. If not, you may exit
the program as described in the next chapter.
Chapter 4
Configuring SDS Instructions
Copying the SDS Instruction Database
After you update the message database, you may want to copy it to disk to be
used at another workstation. To do this:
1.Insert a disk into the disk drive.
2.Exit to DOS.
3.From any directory on the hard drive, type:
ATTRIB
4.Type:
XCOPY \IPDS\ARCH\PLC5\
XCOPY
5.Insert the disk in the system to which you are transferring the database.
+A \IPDS\ARCH\PLC5\
processor name
.SDS /S
and press [ENTER].
This command turns on the archive bit of all files so the next command
knows which ones to copy.
The system displays all the files being transferred.
The
/M in the xcopy command (see above) turns off the archive bit after a
file is copied. If you fill up one disk during the copying process,
re-execute step 3 and the copying process on the next disk will pick up
where you left off.
6.Type:
XCOPY
disk drive:
and press
\IPDS\ARCH\PLC5\
[ENTER].
processor name
For example:
XCOPY
A:\IPDS\ARCH\PLC5\PROC1.SDS C: /S
The system now copies the database to your disk.
and press
.
SDS
hard drive:
[ENTER].
/S
4-33
Chapter 4
Configuring SDS Instructions
Editing and Copying SDS
Instructions
To save time when configuring instructions, you may want to copy information
from one instruction to another. To do this, you can edit and copy information
from steps that you have already configured. You do this from the Extended
Edit screen.
Editing Steps
To access the Extended Edit screen (next page) press [F6]
from the Step Directory.
Extended
Edit Screen (PLC-5)
+================== Step Directory for DRILL MACHINE HEAD 1 ===================+
| |
| Control File: N10:0 Step Description File: N10:102 |
| |
| Step # Step Name Step # Step Name |
| 0 INITIALIZATION 11 STOPPED |
| 1 READY 12 |
| 2 READY TO ADVANCE |
| 3 ADVANCING |
| 4 ADVANCED |
| 5 AT FULL DEPTH |
| 6 FULL DEPTH DWELL |
| 7 FWD & RETURNING |
| 8 ADV’D & RETURNING |
| 9 RETURNING |
| 10 ERROR |
+==============================================================================+
Press a function key or enter step number.
STEP 1
Program edit mode Current Step 0 PLC–5/25 Addr 1
Clear Copy Copy Change
Step Step Config Config
F1 F2 F3 F4
– Extnded Edit
4-34
You can perform the following tasks from the Extended Edit screen.
If you want to:Press this key:
Remove the configuration of the cursored step.[F1] - Clear Step
Copy an existing step to the cursored location. The
system prompts you to enter the step number of the
existing step from which you want to copy.
Copy the configuration of an SDS instruction to a file.
You may want to do this if you are using an SDS
instruction as a template for other SDS instructions.
Retrieve an existing SDS configuration from a file into
this instruction.
[F2] - Copy Step
[F3] - Copy Config
[F4] - Change Config
Chapter 4
Configuring SDS Instructions
Copying an SDS Configuration to a File
To copy an SDS configuration to a file:
copy
1.Press
2.Type in the file name.
Copying an SDS Configuration File to a Disk
You can copy SDS configurations to a disk to transfer to other workstations. To
copy an SDS configuration to a disk:
1.Insert a disk into the disk drive.
2.Exit to DOS.
3.From any directory, type:
hard drive
[F3]
– Copy Config
from the Extended Edit screen.
The system prompts you for a file name. The file name can be up to 8
characters.
The system adds a .SLS extension to the file name. For example, if the
file name is DRILL, the system changes it to DRILL.SLS.
Comments for I/O are not copied as part of this file.
Important: To copy an existing SDS configuration from a file into
another instruction, the number and order of inputs in the saved
configuration must match exactly the number and order of inputs in the
new SDS into which it is being copied.
If they do not match, an error is reported when you accept the edits. You
see a message telling you to clear the step (you cannot edit invalid steps).
The PLC-5/250 allows 32 bits for the timer preset value; the PLC-5 allows
only 16. If you are copying a PLC-5/250 configuration into a PLC-5
configuration, timer preset accuracy is limited to 16 bits. The other 16 bits
are not lost by the PLC-5, they are just not used.
4-36
Chapter 4
Configuring SDS Instructions
To retrieve an SDS instruction from a file:
1.Press
[F4]
– Change Config
from the Extended Edit screen.
The system displays the Change Configuration screen (below).
Change
Configuration Screen (PLC-5)
DRILLSDS.SLS 06–08–90 09:35:26
+–––––––––––––––––––––––––––––––––+
|DRILL MACHINE HEAD 1 |
|NUMBER OF STEPS: 12 |
|NUMBER OF IO: 8 |
+–––––––––––––––––––––––––––––––––+
Use up or down arrow to choose a configuration and RETURN to select.
Program PLC–5/25 Addr 1
What to Do Next
2.Cursor to the file you want to copy and press [ENTER].
If the file contains too many steps or I/O, the system displays a message
telling you that you cannot copy the configuration. Otherwise, the
configuration is copied.
The system returns to the Step Directory screen.
Once you have configured all of your steps, save the SDS instruction. Chapter
5 describes how to configure a DFA instruction. Chapter 6 describes how to
create and/or update a message database with the documentation you import.
4-37
Chapter 4
Configuring SDS Instructions
Notes:
4-38
Chapter
5
Configuring DFA Instructions
What this Chapter Contains
Read this chapter to learn about the DFA instruction and procedures that
describe:
programming the DFA instruction
configuring the DFA instruction
Important: You can use the DFA instruction in either the PLC-5
processor or the PLC-5/250 processor. There are some minor differences
in the procedures for programming and configuring the instruction,
depending on which processor you are using. We note these differences
where applicable.
This chapter contains the following sections:
Section:Page:
Diagnostic Fault Annunciator Overview5-2
Programming the DFA Instruction5-2
Documenting the DFA Instruction5-12
Configuring Messages for the DFA Instruction5-16
Exiting the DFA Instruction5-18
What to do Next5-18
5-1
Chapter 5
Configuring DF
A
Instructions
Diagnostic Fault
Annunciator Overview
The Diagnostic Fault Annunciator (DFA) instruction is a monitoring only
instruction; that is, it monitors inputs you define, but it cannot control
outputs. Valid inputs can be:
storage points, such as binary bits
counter / timer done bits
discrete outputs (real or logical)
any valid bit address
fault bits set by another device (like an IMC motion controller) or by
ladder logic
The following figure shows a DFA instruction in a ladder program.
A
DF
A Instruction (PLC-5/250)
ASSEMBLY
MACHINE
DFA
DIAGNOSTIC FAULT ANNUNCIATOR
Control File
No. of I/O
Program file number
Msg Control Block
1N10:0
0MSG0:0
16
(EN)
(ER)
1
Programming the DFA
Instruction
5-2
If you currently have diagnostics programmed in ladder logic, you can use
the DFA instruction to generate messages when a fault occurs. In addition,
you can create other types of operational and diagnostic messages with the
DFA instruction, such as tool change messages and operating instructions.
Once you have determined where you want to apply the DFA instruction,
you can enter it into your ladder program and configure the instruction.
You perform the following tasks to program the DFA instruction:
download the DFA CAR
enter the DFA instruction
enter the configuration information
enter I/O information
Chapter 5
A
Configuring DF
Instructions
To enter the DFA instruction into your ladder program:
1.Access the PLC-5 or PLC-5/250 Programming Software main menu
(below) from the Allen-Bradley Main Menu interface.
Programming
+========================= PLC–5 PROGRAMMING SOFTWARE =========================+
| |
| A 6200 Series Software Product |
| |
|Copyright 1986, 1987, 1988, 1989, 1990, 1991, 1992 Allen–Bradley Company, Inc |
| All Rights Reserved |
| |
| Release 4.3 |
| |
| This software is licensed to: Company Allen–Bradley Co. |
| Location 747 Alpha Drive |
| PSP Engineering |
| Serial Number: ZZ0AA0PP |
+==============================================================================+
| Fri June 14, 1992 9:39:09 am |
+––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––+
| Terminal Address: 77 Current Device: 1784–KT (DH+) PLC Address: 1 |
+==============================================================================+
Press a function key
Online Online Offline Offline Who Sftware File Reports Compare Exit
Program Configr Program Configr Configr Utils System
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Press a function key or enter file number or name.
>
Program PLC–5/25 Series A Revision H 5/25 Addr 1 SDSC5
Proc Save Return Change Who Memory Monitor
Functns Restore to Menu Station Active Map File
F1 F2 F3 F4 F5 F6 F8
5-3
Chapter 5
Configuring DF
A
Instructions
If you are configuring a new program, you need to download the
DFA CAR file. If not, go to “Entering or Modifying a DFA
Instruction” on page 5-5.
Download the DFA CAR file
Important: To download the DFA CAR file you must be in online
Program mode.
To download the DFA CAR file into your program, do the following steps:
1.Press
[F2]
- Save Restore
.
The system displays the Save Restore function keys.
2.Press
[F4] - Restore Program.
The system displays a window containing a file directory of a
specific type (see the figure below).
Press a function key or enter file name or move cursor to select file.
>
Program PLC–5/25 Series A Revision H 5/25 Addr 1 SDSC5
Begin Define Select Save Fl Conv
Restore Dirctry Type Config Utility
F1 F7 F8 F9 F10
indow (PLC-5)
5-4
3.Press
[F8] - Select Type
file directory window.
until the CAR directory appears in the
Chapter 5
A
Configuring DF
Instructions
4.Cursor to the desired CAR file.
Important: The program file number for the DFA file must be different
than that of the SDS file.
5.Enter the CAR file:
If you are using a PLC-5:
a.Press
[F1] - Begin Restore.
The system prompts you to enter a file number.
b.Type the file number and press
[ENTER].
The system returns to the Program Directory.
If you are using a PLC-5/250:
a.Press
[F1] - Begin Oper.
The system prompts you to enter a program descriptor.
b.Type the program descriptor, for example, 1CAR0, and press
[ENTER].
In the program descriptor, the first number refers to the number
in the thumbwheel window on the logic processor (in this case,
1). A logic processor runs control logic, which controls steps,
transitions, processor input interrupts, selectable timed
interrupts, and independent background programs.
CAR refers to the type of file; 0 refers to the program file to
download the CAR into.
The system returns to the Program Directory.
Enter or Modify a DFA Instruction
To enter or modify DFA instruction in your ladder program:
1.Cursor to the file you want to edit in the Program Directory and press
[F8]
- Monitor File
.
5-5
Chapter 5
Configuring DF
A
Instructions
The system displays your ladder program and the Ladder Editor main
menu.
2.Cursor to the rung where you want to position the DFA instruction.
If you are modifying an existing rung, cursor to the DFA rung.
3.Press
[F10]
- Edit.
The system displays the Ladder Editing screen.
4.If you are:
editing an existing rung, press [F5]
entering a new rung, press [F4]
- Modify Rung
- Insert Rung
The system displays the Edit Rung screen.
5.If you are:
changing an existing instruction, press [F5]
Instruction.
entering a new instruction, press [F4]
- Modify
- Insert Instruction
The system prompts you for the instruction you want to add.
6.Type
DFA, and press [ENTER]. (If you are modifying an existing
instruction, DFA already appears at the prompt.)
.
.
.
5-6
Important: As an alternate method of entering the instruction, you may:
Press [F10]
Press [F9]
Press [F5]
- Others
- Seqncer
- DFA
from the Sequencer function keys.
.
from the Instruction Classes function keys.
Chapter 5
A
Configuring DF
Instructions
The system displays the DFA instruction (see the figure below).
Enter the operand.
Enter the Control File address>
Program Forces:Disabled Edits:None PLC–5/25 Addr 5
Enter or Modify DFA Instruction Information
Once the DFA instruction is displayed, the system prompts you to enter the
Control File Starting Address. To enter parameters into the DFA
instruction:
1.Type the Control File address and press
The control file must be expressed in the following manner:
For the:Use this format:Where:
PLC-5Nfff:eee
PLC-5/250Nffff:eeeeffff = an integer file between 10 - 9999 and
In the PLC-5/250, when you enter the control file address, the system
displays a number (1, 2, 3, or 4) in front of the address. This number
represents the logic processor in the PLC-5/250.
The PLC-5/250 chassis supports up to four logic processor modules.
For more information on logic processors, refer to the PLC-5/250
Programming Software Documentation Set (publication 9313-5250).
[ENTER].
fff
= an integer file between 10 - 999 and
eee = an element number between 0 - 999.
eeee = an element number between 0 - 9999.
5-7
Chapter 5
Configuring DF
A
Instructions
When the control file address is entered, the system prompts you to
enter the number of I/O. Valid entries of I/O are 8, 16, or 32.
Important: The control file address must be local to the logic processor
executing the associated DFA instruction. Do not place this file in system
memory.
2.Type the number of I/O you are using and press [ENTER].
The system prompts you for the program file number. The program
file number refers to the number of the DFA CAR file in the online
or offline program directory.
3.Type the DFA CAR program file number and press
[ENTER].
In the PLC-5 processor, the system displays the I/O Definition
screen. If you have a PLC-5 processor, continue with “Enter or
Modify Input Information” on page 5-9.
In the PLC-5/250 processor, the system prompts you for the Message
Control Block address.
4.If you have a PLC-5/250 processor, type the Message Control Block
address and press
[ENTER].
The Message Control Block address must be entered in the following
manner:
0
MSG
X:X
where:
0 is the Resource Manager global memory (must be set to zero)
X:X
5-8
message control block number (0-9999)
file number (0-9999)
For example, 0MSG0:0 is a valid control block address.
The system displays the Input Definition screen (see the figure on the
next page).
Chapter 5
A
Configuring DF
Instructions
Enter or Modify Input Information
The inputs you enter into the Input Defines on the Input Definition screen
are monitored by the DFA instruction. You can enter logical addresses and
symbols into the Input Definition screen. The screen on the next page
shows the Input Definition Screen for entering inputs.
Important: If you are modifying information, you see fewer function key
options (see the table on pages 5-9 and 5-10).
Input
Definition Screen (for entering inputs)
Diagnostic Fault Annunciator Input Defines
Definition for Control Block 0:
N27:0 1: I:001/10
2: SWITCH1
3: B3/30
+=Ins Cmt==+ +=Adr Cmt==+ 4: 0:002/02
|ASSEMBLY | |new input | 5: 0:002:01
|MACHINE | | | 6: I:001/11
| | | | 7:
| | | | 8:
| | | | 9:
+==========+ +==========+ 10:
11:
Operator Interface Station Addr : 77 12:
13:
14:
15:
Press a key to change a parameter or <ENTER> to accept parameters,
>
Program Forces: None Edits: None PLC–5/25 Addr 5
Station Documnt Modify Insert Delete Remove
Address Inputs Inputs Inputs Inputs
F1 F5 F7 F8 F9 F10
The Ins Cmt (Instruction Comment) window on the Input Definition
screen displays the name of the instruction from the ladder program. The
Adr Cmt (Address Comment) window displays the address comment for
the cursored address in the Input Defines field.
The number of inputs in the Input Defines field correlates with the number
of inputs you entered when programming the DFA instruction.
You can perform the following tasks from the Input Definition screen:
If you want to:Press this key:
Enter an operator interface station address.[F1] - Station Address
Enter the port number for the message.
PLC-5/250 only)
[F3] - Port
5-9
Chapter 5
Configuring DF
A
Instructions
Display the Documentation screen for the
DFA instruction.
Modify an input address at the cursored
location.
Insert an input address at the cursored
1
location
Delete an input address at the cursored
1
location
Remove an input address at the cursored
1
location
1
These
function keys do not appear on the screen if you are modifying the instruction.
[F5] - Documnt
[F7] - Modify Inputs
[F8] – Insert Inputs
[F9] – Delete Inputs
[F10] – Remove Inputs
To insert or modify information in the Input Definition screen, follow the
procedure below.
1.If you want to change the Operator Interface Station Address:
a.Press
[F1]
- Station Address
b.Type the number of the Data Highway Plus node ( 0-778) where
you want the diagnostic message sent, for example
press
[ENTER].
77, and
Important: If you want to send diagnostic messages to other operator
interface stations, use the Message Instruction in 6200 Series software.
For procedures on sending messages with the Message Instruction, refer to
PLC-5 Programming Software Documentation Set (publication
9399-PL5MAN) or the PLC-5/250 Programming Software Documentation
Set (publication 9313-5250).
2.If you have a PLC-5/250 and you want to change the port number,
your screen has an additional option:
a.Press
[F3]
- Port.
b.Enter the port number. The following table shows the port
number to enter for the specific link type.
Port
Number Entries
For this link:Enter this port number:
ASCII, DF1, Master, and Slave1
port 2A, 2B for DH and DH+2
port 3 for DH and DH+3
5-10
Chapter 5
A
Configuring DF
Instructions
3.If you want to alter an existing address or enter a new address in a list
of inputs:
a.Press
[F7]
- Modify Inputs.
The system prompts you for an
address.
b.Type in your input address and press
[ENTER].
Valid entries include any logical address specified to the bit
level, with the exception of indirect addresses.
4.After entering or modifying an input address, cursor to the next field
and repeat this step until you have completed all entries or changes.
5.After entering all your addresses, press
Definition screen function keys, and then press
[ESC] to display the Input
[ENTER].
The system returns to the DFA instruction.
6.Press
[ENTER].
The system displays the Edit Rung screenseen below.
Edit
Rung Screen
I +DFA–––––––––––––––––––––––––+ I
I––––––––––––––––––––––––––––––––––––––––––+DIAGNOSTIC FAULT ANNUNCIATOR+–(EN)–I
I |Control File N10:0| I
I |No. of I/O 8+–(ER) I
I |Program File No. 1CAR0| I
I +––––––––––––––––––––––––––––+ I
| |
+––––––––––––––––––––––––––––––––[END OF FILE]–––––––––––––––––––––––––––––––––+
| |
Press a function key for desired editing function, or type a mnemonic.
1STEP0:0>
Program Forces:Disabled Edits:None Rung:Insert PLC–5/25 Addr 5
Branch Append Insert Modify Delete Undel Accept
* Instr Instr Instr Instr Instr Rung
F1 F3 F4 F5 F6 F7 F10
7.Press [F10]
- Accept Rung.
Important: You must accept the rung to save the information you entered
into the DFA instruction.
5-11
Chapter 5
Configuring DF
A
Instructions
Documenting the DFA
Instruction
The DFA instruction provides a documentation function that lets you
describe the instruction and its associated addresses. The documentation
function also lets you assign symbols to addresses.
To document your DFA instruction, press
[F5]
- Documnt
from the Input
Definition screen.
The system displays the DFA Instruction Documentation screen (next
page).
Press a function key.
>
Program Forces:Disabled Edits:None Addr:Decimal PLC–5/25 Addr 5
Instr Address Modify Remove Display Save &
Comment Comment Symbol Symbol Symbol Contnue
F2 F3 F6 F7 F9 F10
5-12
Chapter 5
A
Configuring DF
Instructions
From this screen you can perform the following documentation tasks:
If you want to:Press this key:
Activate the cursor in the instruction
comment window and display the Instruction
Comment Editor.
Activate the cursor in the address comment
window and display the Address Comment
Editor.
Assign a symbol to an address or change
and existing symbol.
Remove the symbol from the current
address.
Switch between address comment, symbolic
name, or logical address of input. The
function key always displays the next format;
for example, if address comments are being
displayed, then [F2] reads Display Symbol.
Save your work in the database. If you are
editing off line, the archive file is updated and
the comment and symbol files are saved. If
you are editing on line, only the comment
and symbol files are saved.
[F2] - Instr Comment
[F3] - Address Comment
[F6] - Modify Symbol
[F7] - Remove Symbol
[F9] - Display Comment/Symbol/Log Adr
[F10] - Save & Contnue
Editing Instruction and Address Comments
To activate the cursor in the instruction comment window, press
[F2]
- Instr Comment
from the DFA Instruction Documentation screen.
5-13
Chapter 5
Configuring DF
A
Instructions
The system displays the Instruction Comment Editor screen:
Enter instruction comment for : SDS,1N10:0
>
Program Edit mode:Insert Col:7 Line:3 PLC–5/25 Addr 5
Delete Undel Delete Undel Delete Undel Accept/
Comment Comment Line Line Word Word Exit
F1 F2 F3 F4 F5 F6 F8
To activate the cursor in the address comment window, press
[F3]
- Address Comment
from the DFA Instruction Documentation
screen.
The system displays the Address Comment Editor screen:
Enter address comment for : I:001/16
>
Program Edit mode:Insert Col:2 Line:2 PLC–5/25 Addr 5
Delete Undel Delete Undel Delete Undel Accept/ Next Prev
Comment Comment Line Line Word Word Exit Address Address
F1 F2 F3 F4 F5 F6 F8 F9 F10
5-14
Chapter 5
A
Configuring DF
Instructions
The function keys for both Editor screens are the same, except that the
Address Comment Editor screen has soft function keys for moving the
cursor to the next or previous address:
If you want to:Press this key:
Delete the current comment.[F1] - Delete Comment
Re-insert the last deleted comment where
the cursor is.
Delete the line the cursor is on from the
current comment.
Re-insert the last deleted line from a
comment.
Delete the word the cursor is on from the
current comment.
Re-insert the last deleted word from a
comment.
Save the current comment and return to the
Input Definition screen.
For Address Comments Only:
[F2] - Undel Comment
[F3] - Delete Line
[F4] - Undel Line
[F5] - Delete Word
[F6] - Undel Word
[F8] - Accept Edits
[F9] - Next Address
Save the current comment and/or move the
cursor to the next address.
Save the current comment and/or move the
cursor to the previous address.
[F10] - Prev Address
5-15
Chapter 5
Configuring DF
A
Instructions
Configuring
Messages for
the DFA Instruction
The DFA instruction provides a feature which lets you enter the equivalent
of pre-stored text messages to relate to your inputs. When an input or
inputs change to the defined state (ON or OFF), the DDMC32 software
automatically generates the message on the operator interface terminal.
To enter your messages, follow the procedure below:
1.Start on the Ladder Editing screen.
2.Cursor to the DFA instruction and press
3.Press [F2]
- I/O Edit.
[F10]
- Edit.
The system displays the DFA Message screen:
DFA
Message Screen
DFA for DFA 1 AT N9:0
No Input ID Input Message State
0 C4:01/ON TOOL CHANGE REQUIRED
1 I:000/02 LUBE FAULT
2 I:000/01 LUBE LEVEL LOW
3 I:000/06 NO PARTS PRESENT
4 I:B3/03 LOAD PARTS IN STA.5
5 I:000/04 PLACE MACHINE IN AUTO MODE
6 O:000/05 TIME TO CALL MAINTENANCE
7 T5:1/ON MACHINE OVER CYCLE
Press a function key or enter input number.
>
Rem Prog 5/25 Addr 5 DB_TEST
Change Display Exit Input Edit Input Accept
Mode Symbol Monitor Message State Edits
F1 F2 F3 F5 F7 F8 F10
5-16
Chapter 5
A
Configuring DF
Instructions
You can perform the following tasks from the DFA Message screen:
If you want to:Press this key:
Switch between program mode, test mode, and run
[F1] - Change Mode
mode.
Switch between address comment, symbolic name,
[F2] - Display Comment/Symbol/Log Adr
or logical address of input. The function key always
displays the next format; for example, if address
comments are being displayed, then [F2] reads
Display Symbol.
Exit the configuration utility.[F3] - Exit
Display the Input Monitor screen. (Refer to the
[F5] - Input Monitor
chapter entitled “Debugging Your DDMC32 System”
for information on the Input Monitor screen.)
Display the Edit Message screen for the cursored
[F7] - Edit Message
message so that the message can be edited.
Define/change the input state for the selected input.[F8] - Input State
Accept all entries/edits. The system prompts you to
[F10] - Accept Edits
confirm your decision.
4.To enter your messages, press
[F7] - Edit Message.
The system displays the Edit Message screen:
Edit
Message Screen
DFA for DFA 1 AT N9:0
No Input ID Input Message State
0 C4:01/ON TOOL CHANGE REQUIRED
1 I:000/02 LUBE FAULT
2 I:000/01 LUBE LEVEL LOW
3 I:000/06 NO PARTS PRESENT
4 I:B3/03 LOAD PARTS IN STA.5
5 I:000/04 PLACE MACHINE IN AUTO MODE
6 O:000/05 TIME TO CALL MAINTENANCE
7 T5:1/ON MACHINE OVER CYCLE
Enter the desired comment. Press <CR> to accept the comment, <ESC> to return
TOOL CHANGE REQUIRED
Rem Prog 5/25 Addr 5 DB_TEST
5.Cursor to the message you wish to edit or to the number of the input
where you wish to enter a new message and type the new message.
Any message you enter may have a total length of up to 50
characters.
5-17
Chapter 5
Configuring DF
A
Instructions
6.Once you have completed your changes, press [ENTER] to accept the
comment.
Exiting the DFA Instruction
7.Press
[ESC]
to return to the DFA Message screen.
8.Cursor to the state column of the desired input and press
[F8]
- Input State.
[F8] is a toggle key which allows you to choose from OFF, ON, or
NONE (if you select NONE, a message is never sent) for the state in
which you want your message to be sent. Continue to press this key
until you reach the state in which you want your message to be sent.
Once you have configured your diagnostic messages, you can exit the DFA
instruction.
To exit the DFA instruction:
1.Press
[ESC].
The system displays the DFA Message screen.
2.Press
[F10]
- Accept Edits
.
The system prompts you to confirm your decision.
What to Do Next
5-18
3.Press
4.Press [F3]
[F8]
- Yes
- Exit
.
. Once you’ve entered and documented all of your
input information, the system asks if you want to save your work.
5.Press
[F8]
- Yes
.
The system displays the Ladder Editor main menu. If you have other
DFA instructions to configure or edit, you can do so as described in
the “Enter or Modify DFA Instructions” section in this chapter. If
not, you may exit the program as described in the next chapter.
Chapter 6 describes how to create a message database with the
documentation imported from the DFA instruction.
Chapter
Creating and Updating the
Message Database
6
What this Chapter Contains
Importing the SDS and DFA
Documentation
Read this chapter to learn how to import the documentation from the SDS
instruction(s) and the DFA instruction(s) into the message database so it
can be used by the DDMC32 software.
This chapter contains the following sections:
Section:Page:
Importing the SDS and DFA Documentation6-1
Message Database Options6–3
What to do Next6-5
When you are done configuring your ladder program or making changes in
the Ladder Editor, you are ready to exit the program. If you want the
DDMC32 software to reflect any of the documentation changes or
additions made to the program, you must import the information into the
DDMC32 message database. (At this point, all SDS and/or DFA
documentation has been written to an ASCII file.)
To import SDS and/or DFA instruction information to the DDMC32
message database, follow the procedure on the following pages.
6-1
Chapter 6
Creating and Updating the Message Database
1.From the Database menu, choose the appropriate command for the
type of instruction information you want to import into the database.
For DFA Instruction Information:
Select Import 6200.DFA File. The Import 6200.DFA File screen
appears.
For SDS Instruction Information:
Select Import 6200.SDS File. The Import 6200.SDS File screen
appears.
2.Enter the import path file, or click on Browse... to locate the file to
import.
3.Click on OK.
6-2
The Import Progress bar will show you the progress of the file import
process. Repeat this process for each .SDS and/or .DFA file you
want to import.
4.Click on Done when complete.
Chapter 6
Creating and Updating the Message Database
Message Database Options
You may select, create, or Copy a DDMC32 database by clicking on the
desired option from the menu. The following screens are displayed
according to the option you have chosen.
Select
Database
Create Database
Copy Database
6-3
Chapter 6
Creating and Updating the Message Database
When you select a database, you can also choose how many days of fault
log data to keep. If you have Auto-Purging enabled, fault log data will
automatically be purged, based on the value entered.
For all of the above screens, you can type in the database name or click on
Browse... to find the required database.
Click on OK when complete and continue with your next function.
Deleting a Message Database
1.To delete a message database, select Delete Message Database from
the Database menu.
The Delete Database Selection screen appears.
Delete
Database Selection Screen
6-4
2.Type in the database path or click on Browse... to find the file and
click on OK.
The Verify Delete screen appears, prompting you to confirm that you
want to delete the database.
Verify
File Delete
Chapter 6
Creating and Updating the Message Database
3.Click on Yes to verify, or No to abort the delete.
Important: Once you click on Yes to verify the delete there is no way to
abort the process. Ensure that the selected database is the correct file.
If you click on Yes to verify that you want to delete the database, the
file is deleted and the File Delete Complete screen appears.
File
Delete Complete
What to Do Next
4.Click on OK to close this window.
Now that you have completed creating and/or updating your message
database, you can configure the Diagnostic Message Utility. Chapter 7
describes the procedures for Configuring Diagnostic Messages.
6-5
Chapter 6
Creating and Updating the Message Database
Notes:
6-6
Chapter
7
Configuring Diagnostic Messages
What this Chapter Contains
Understanding the Parts of a
Diagnostic Message
Read this chapter to learn about diagnostic messages provided in the
DDMC32 system and procedures to configure the format for diagnostic
messages. To configure diagnostic messages, you:
build the message out of fragments and link the text with your own
words
select options for message display
This chapter contains the following sections:
Section:Page:
Understanding the Parts of a Diagnostic Message7-1
Diagnostic Message Types7-3
Accessing the Message Template Editor Functions7-5
Configuring Diagnostic Messages7-8
What to do Next7-11
The DDMC32 software contains a routine that generates messages as faults
occur. When a fault is detected by the SDS or DFA instruction the
operator interface terminal automatically displays a message in a window
reserved for messages (if configured by the user). That same message can
also be broadcast to annunciator panels in the plant such as a Dataliner
Message Display (bulletin number 2706, series DL10).
7-1
Chapter 7
Configuring Diagnostic Messages
Diagnostic Message Fragments
To create a diagnostic message, you can select from several different
fragments and string them together, with connector words you define, to
form a sentence. In other words, you tell the software how to configure the
message by selecting message fragments and linking them with your own
words.
Because you enter the fragments to form the diagnostic sentence when you
configure the SDS and DFA instructions, it is very important that you
assign clear names to steps, inputs, and outputs (for example,
RETURNING, ADVANCING) so that your message makes sense.
An example of a clear statement constructed from fragments (shown in
italics) and linking text might be:
Proc1 was Advancing when Sta3 ADVANCE Request turned off
Important: Fragment options for the SDS and DFA instruction messages
are different. The options for each type of instruction are listed below.
Items accompanied by (src) refer to source steps; items accompanied by
(dest) refer to destination steps.
SDS Message Fragment Options
This Message Fragment :Is the:
processoreight character name of the processor where the SDS
instruction resides, for example, Proc1 or xferline
instruction commentname of the SDS instruction, for example,
Drill Station #1, Station 32R, or ProbeSta
step comment (src)step where the error occurred, for example, Advancing,
Returning, or Loading
logical address (src)data type, file number, offset, and bit number of the bit which
changed to cause the message, for example, N10:000/2,I:020/05, or O:001/12
symbolic address (src)10 character symbolic string, entered in the PLC programming
software, which represents the bit which changed to cause the
message, for example, SW103
short address comment
(src)
long address comment (src) description of up to 50 characters of the bit address which
20 character or less portion of the address comment that was
delimited by asterisks (*) when the comment was entered in
the PLC programming software, for example, Switch 1,or
AdvancedL.S.
changed to cause the message, for example, “Tool change
required”
7-2
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