Rockwell Automation D64046.5.1 U MNL WIN DDMC User Manual

Allen-Bradley

Distributed Diagnostics and Machine Control

(Cat. No. 6404-DDMC)

User Manual

Important User Information

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:

FIX, Factory Link, and RSView code/screens PLC (ladder) functions PanelView screens

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.

Distributed Diagnostics and Machine Control

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able of Contents

Using

This Manual

Understanding How a DDMC32 System Works

Installing DDMC32 Hardware Components

Preface

Manual Objectives P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Audience P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What this Manual Contains P-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATTENTION and Important Notes P-3. . . . . . . . . . . . . . . . . . . . . . .

Terms and Conventions P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Publications P-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1

What this Chapter Contains 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How the DDMC32 System Works 1-1. . . . . . . . . . . . . . . . . . . . . . .

Understanding the SDS Instruction 1-3. . . . . . . . . . . . . . . . . . . . . . .

Understanding the DFA Instruction 1-7. . . . . . . . . . . . . . . . . . . . . . .

Implementing DDMC32 Instruction in Levels 1-8. . . . . . . . . . . . . .

DDMC32 System Components 1-8. . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2

What this Chapter Contains 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware Configurations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing DDMC32 Components 2-3. . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing DDMC32 Software

Configuring SDS Instructions

Chapter 3

What this Chapter Contains 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Up Your Operator Interface Terminal 3-1. . . . . . . . . . . . . . .

Installing and Configuring the Software 3-1. . . . . . . . . . . . . . . . . . .

Installing DDMC32 Software 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Completing the DDMC32 Software Installation 3-8. . . . . . . . . . . . .

What to Do Next 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4

What this Chapter Contains 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Smart Directed Sequencer Overview 4-2. . . . . . . . . . . . . . . . . . . . .

Programming the SDS Instruction 4-5. . . . . . . . . . . . . . . . . . . . . . . .

Documenting the SDS Instruction 4-18. . . . . . . . . . . . . . . . . . . . . . . .

Configuring the SDS Instruction 4-22. . . . . . . . . . . . . . . . . . . . . . . . .

Exiting the SDS Instruction 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Editing and Copying SDS Instructions 4-34. . . . . . . . . . . . . . . . . . . .

What to Do Next 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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able of Contents

Configuring DFA Instructions

Creating and Updating the Message Database

Configuring Diagnostic Message

Chapter 5

What this Chapter Contains 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Fault Annunciator Overview 5-2. . . . . . . . . . . . . . . . . . .

Programming the DFA Instruction 5-2. . . . . . . . . . . . . . . . . . . . . . .

Documenting the DFA Instruction 5-12. . . . . . . . . . . . . . . . . . . . . . .

Configuring Messages for the DFA Instruction 5-16. . . . . . . . . . . . .

Exiting the DFA Instruction 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6

What this Chapter Contains 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Importing the SDS and DFA Documentation 6-1. . . . . . . . . . . . . . .

Message Database Options 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7

What this Chapter Contains 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Parts of a Diagnostic Message 7-1. . . . . . . . . . .

Diagnostic Message Types 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessing the Message Template Editor Functions 7-5. . . . . . . . . .

Message Template Editor Function 7-6. . . . . . . . . . . . . . . . . . . . . . .

Configuring Diagnostic Messages 7-8. . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Debugging Your DDMC32 System

ii

Chapter 8

What this Chapter Contains 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Correcting Step Configuration Errors 8-1. . . . . . . . . . . . . . . . . . . . .

Locating Sequencing and Timing Errors 8-5. . . . . . . . . . . . . . . . . . .

Troubleshooting Problems in Your Operator Interface 8-12. . . . . . . .

What to Do Next 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Configuration and Operation of the DDMC32 System

Using the Report Generator Software

Chapter 9

What this Chapter Contains 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring Output Devices 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring the Clock/Creep Option 9-2. . . . . . . . . . . . . . . . . . . . .

Selecting Instruction Type(s) to Use 9-5. . . . . . . . . . . . . . . . . . . . . .

Auto-Starting DDMC32 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto-Hiding the Banner 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto-Purging the Current Database 9-6. . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping DDMC32 Software 9-6. . . . . . . . . . . . . . . . .

Monitoring the Fault Log 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clearing the Fault Log 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 10

What this Chapter Contains 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Becoming Familiar with the Report Generation Options 10-1. . . . . .

Menu Selections 10-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring Reports 10-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generating Reports 10-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduling Reports 10-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Miscellaneous Operations 10-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 10-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Information

Appendix A

Appendix Overview A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reference Information for the SDS Instruction A-1. . . . . . . . . . . . .

Reference Information for the DFA Instruction A-7. . . . . . . . . . . . .

iii

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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 components 2 — 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:

Publication Title Publication Number

DDMC32 User Manual 6401–6.5.1

PLC-5 Processors

1785 PLC-5 Family Programmable Controllers Installation Manual 1785-6.6.1 1785 PLC-5 Programmable Controller Design Manual 1785-6.2.1 Pyramid Integrator Design Manual PLC-5 Programming Software Documentation Set 9399-PLC5MAN PLC-5/250 Programming Software Documentation Set

Communications

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 Works 1-1 Understanding the SDS Instruction 1-3 Understanding the DFA Instruction 1-7 Implementing DDMC32 Instructions in Levels 1-8 DDMC32 System Components 1-8 What to do Next 1-12

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

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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.

Smart

Directed Sequencer Instruction Terminal Display (PLC-5

processor)

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

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

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Chapter 1

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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 INPUTS STEP 2 EXPECTED INPUTS

OFF OFF OFF ON

––> ON ––> ON

––> ON ––> OFF

OFF ON OFF ON

––> 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.)

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Chapter 1

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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 step are set as defined in that step step 0 reset to off initialization step stay 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.

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Chapter 1

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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 level Uses this

1 DFA ladder logic ladder logic DFA 2 SDS and DFA ladder logic SDS SDS and DFA 3 SDS and DFA SDS and ladder logic SDS SDS 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 Configurations 2-1 Installing DDMC32 Components 2-3 What to do Next 2–4

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 Computer DDMC32 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/O PLC-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 Manual 6160-6.5.1

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 Terminal 3-1 Installing and Configuring the Software 3-1 Installing DDMC32 Software 3-2 Completing the DDMC32 Software Installation 3-8 What to do Next 3-8

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 Overview 4-2 Programming the SDS Instruction 4-5 Documenting the SDS Instruction 4-18 Configuring the SDS Instruction 4-22 Exiting the SDS Instruction 4-31 Editing and Copying SDS Instructions 4-34 What to do Next 4-37

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).

Online

Program Directory (PLC-5)

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).

File

Directory W

+= PROGRAM DIRECTORY FOR PROCESSOR: += C:\IPDS\ARCH\PLC5\*.CAR ===========+=+ | File Name Type | Name Size Date Time | | |–––––––––––––––––––––––––––––––––––|––––––––––––––––––––––––––––––––––––––––|–| | 0 | SDS5 5672 5–04–90 12:50p | | | 1 | | | | 2 | | | | 3 | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | +===================================+========================================+=+

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.

SDS

Instruction (PLC-5)

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-5 Nfff:eee

PLC-5/250 Nffff:eeee ffff = 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-5 Nfff:eee

PLC-5/250 Nffff:eeee ffff = 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

8 68 58 16 68 58 32 68 58

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:

8 76 250 16 45 250 32 23 232

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.)

Modify

I/O Definition Screen (PLC-5/250)

Smart Directed Sequencer I/O Input Defines Output Defines Definition for Control Block 0: I:001/16 0: O:000/04 N10:0 1: I:001/15 1: O:000/01 2: I:001/14 2: O:000/02 3: IS:003/02 3: +=Ins Cmt==+ +=Adr Cmt==+ 4: IS:003/03 4: |DRILL | |RETURNED L| 5: 5: |MACHINE | |S | 6: 6: |HEAD 1 | | | 7: 7: | | | | | | | | +==========+ +==========+

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

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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:

PLC-5/20 PLC-5/30 PLC-5/40 PLC-5/11 PLC-5/40L PLC-5/60 PLC-5/60L PLC–5/80

Chapter 4

Configuring SDS Instructions

Port

Number Entries

For this link: Enter this port number:

ASCII, DF1, Master, and Slave 1

port 2A, 2B for DH and DH+ 2

port 3 for DH and DH+ 3

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)

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.

SDS

Instruction Documentation Screen (PLC-5)

Smart Directed Sequencer I/O Input Defines Output Defines Definition for Control Block 0: I:001/16 0: O:000/04 N10:0 1: I:001/15 1: O:000/01 2: I:001/14 2: O:000/02 3: B3/2 3: +=Ins Cmt==+ +=Adr Cmt==+ 4: B3/3 4: |DRILL | |RETURNED L| 5: 5: |MACHINE | |S | 6: 6: |HEAD 1 | | | 7: 7: | | | | | | | | +==========+ +==========+

Operator Interface Station Addr : 77

Timebase for Step Timer : 0.01

Press a function key.

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

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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

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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.

Instruction

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

Comment Editor Screen (PLC-5)

4-20

Chapter 4

Configuring SDS Instructions

Address

Comment Editor Screen (PLC-5)

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

.

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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.

2. Press

3. Press [F2]

[F10]

– Edit

- I/O Edit.

.

The system displays the Step Directory.

Step

Directory (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 | | 1 LOADING | | 2 | | 3 | | 4 | | 5 | | 6 | | 7 | | 8 | | 9 | | 10 | +==============================================================================+

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

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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

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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 equations 4-25 Configure or edit combinatorial equations 4-27

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 PART LIMIT SWITCH 1 is ON while WAITING FOR PART MOVING PART ON CONVEYOR LIMIT 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:

INIT Outputs 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 0 All 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.

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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:

outputs off type of step normal step destination step timer destination step timer 0.00 (disabled) messaging off

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.

Equation

Editor Screen (PLC-5)

STEP 4 CLAMPING +========================+ Eq# |Equation | 1 I:000/01 | 1 0&4 | 2 I:000/02 | 2 | | 3 | | | | | | | | | | | | | | | | | | +========================+

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 inputs 1. 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 input 1. Combine the inputs as shown above.

2. Place the cursor on the input you wish to negate and press [F6] - NOT.

[F1]-Select

Input

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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.

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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.

processor name.

SDS

disk drive

:\IPDS\ARCH\PLC5\

processor name

.SDS /S/M

and press [ENTER].

For example:

\IPDS\ARCH\PLC5\PROC1.SDS A:\IPDS\ARCH\PLC5\PROC1.SDS /S/M

and press

[ENTER].

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

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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)

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.

:\IPDS\ARCH\PLC5\

name of file

.SLS

disk drive

:\IPDS\ARCH\PLC5\

name of file

.SLS

and press

[ENTER].

For example,

copy

C:\IPDS\ARCH\PLC5\DRILL.SLS A:\IPDS\ARCH\PLC5\DRILL.SLS

and press [ENTER].

If you want to copy all of the files, you can replace

name of file

an asterisk (*).

4. Insert the disk into the system to which you are transferring the

configuration.

with

4-35

Chapter 4

Configuring SDS Instructions

copy

5. Type:

disk drive

copy

The system now copies the SDS configuration file to your disk.

Copying an Existing SDS Configuration from a File

:\IPDS\ARCH\PLC5\

name of file

.SLS

hard drive

:\IPDS\ARCH\PLC5\

and press [ENTER].

For example,

A:\IPDS\ARCH\PLC5\DRILL.SLS C:\IPDS\ARCH\PLC5\DRILL.SLS

and press [ENTER].

name of file

.SLS

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

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.

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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 Overview 5-2 Programming the DFA Instruction 5-2 Documenting the DFA Instruction 5-12 Configuring Messages for the DFA Instruction 5-16 Exiting the DFA Instruction 5-18 What to do Next 5-18

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

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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

2. Press

Software Main Menu (PLC-5)

[F1] - Online Program.

The system displays the online program directory:

Program

Directory (online PLC-5)

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

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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).

File

Directory W

+= PROGRAM DIRECTORY FOR PROCESSOR: += D:\IPDS\ARCH\PLC5\*.CAR ==============+=+ | File Name | Name Size Date Time | | |–––––––––––––––––––––––––––––––––––|––––––––––––––––––––––––––––––––––––––––|–| | 0 | DFA5 936 9–06–91 10:11a | | | 1 | SDS5 5672 9–06–91 10:10a | | | 2 | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | +===================================+========================================+=+

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).

DFA

Instruction

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-5 Nfff:eee

PLC-5/250 Nffff:eeee ffff = 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

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Chapter 5

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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 Slave 1

port 2A, 2B for DH and DH+ 2

port 3 for DH and DH+ 3

5-10

Chapter 5

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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).

DFA

Instruction Documentation Screen

Diagnostic Fault Annunciator Input Defines Definition for Control Block 0: I:001/16 N10:0 1: I:001/15 2: I:001/14 3: IS:003/02 +=Ins Cmt==+ +=Adr Cmt==+ 4: IS:003/03 |DRILL | |RETURNED L| 5: |MACHINE | |S | 6: |HEAD 1 | | | 7: | | | | | | | | +==========+ +==========+

Operator Interface Station Addr : 77

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

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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:

Instruction

Comment Editor Screen

Diagnostic Fault Annunciator Input Defines Definition for Control Block 0: I:001/16 N10:0 1: I:001/15 2: I:001/14 3: IS:003/02 +=Ins Cmt==+ +=Adr Cmt==+ 4: IS:003/03 |DRILL | |RETURNED L| 5: |MACHINE | |S | 6: |HEAD 1 | | | 7: | | | | | | | | +==========+ +==========+

Operator Interface Station Addr : 77

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:

Address

Comment Editor Screen

Diagnostic Fault Annunciator Input Defines Definition for Control Block 0: I:001/16 N10:0 1: I:001/15 2: I:001/14 3: IS:003/02 +=Ins Cmt==+ +=Adr Cmt==+ 4: IS:003/03 |DRILL | |RETURNED L| 5: |MACHINE | |S | 6: |HEAD 1 | | | 7: | | | | | | | | +==========+ +==========+

Operator Interface Station Addr : 77

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

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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

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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.

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Chapter 5

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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 Documentation 6-1 Message Database Options 6–3 What to do Next 6-5

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

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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

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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.

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Chapter 6

Creating and Updating the Message Database

Notes:

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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 Message 7-1 Diagnostic Message Types 7-3 Accessing the Message Template Editor Functions 7-5 Configuring Diagnostic Messages 7-8 What to do Next 7-11

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).

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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: processor eight character name of the processor where the SDS

instruction resides, for example, Proc1 or xferline

instruction comment name 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”

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Rockwell Automation D64046.5.1 U MNL WIN DDMC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual