C-DIAS PROCESSOR MODULE CCP 531
12.04.2017 Page 1
C-DIAS Processor Module CCP 531
The CCP 531 processor module runs the control program and
thereby represents an essential component of an automation
system. The internal DC/DC converter powers all modules on a
C-DIAS module carrier.
The CAN bus, an Ethernet interface or the USB device (Mini
USB) can be used as the online interface connection.
A 7-segment display and 2 status LEDs provide information on
the actual status of the CPU.
For program updates, the integrated USB Host interface can be
used (USB stick, keyboard). With help from the exchangeable
SD card, the entire control program can be easily exchanged.
The CCP 531 processor module is designed to be mounted in
the control cabinet.
Compatibility
Completely PC-compatible. The CCP 531 works with standard PC BIOS and therefore no
SIGMATEK-specific BIOS is needed; the LASAL operating system in provided.
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Technical Data
Performance data
Processor
EDGE-Technology X86 compatible
16-bit data bus
Clock frequency
500 MHz
Addressable I/O/P modules
CAN bus: 32
C-DIAS bus: 8
Internal I/O
No
Internal cache
32-kbyte L1 Cache
256-kbyte L2 Cache
BIOS
AMI
Internal program and data memory
(DDR2 RAM)
64 Mbytes
Internal remnant data memory
512 Kbytes
(1)
Internal storage device
512 Mbytes microSD card (12-104-531)
1-Gbyte microSD card (12-104-531-1)
Interface connections
1 x USB Host 2.0 (full speed 12 MBit/s)
1 x USB Device 1.1
1 x Ethernet
1 x CAN
1 x C-DIAS
Data buffer
Yes
Status display
Yes
Status LEDs
Yes
Real-time clock
Yes (buffering approximately 10 days)
(1)
See chapter “Note on SRAM Behavior”
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Electrical requirements
Supply voltage
+18 – 30 V DC
Supply voltage (UL)
18 – 30 V DC (Class 2)
Current consumption of (+24 V)
power supply
Typically 150 mA
Maximum 500 mA
Current consumption of (+24 V)
power supply (UL)
Maximum 500 mA
Starting current
For a very short time (~20 ms) : 30 A
Power supply on the C-DIAS bus
Supplied by the CCP 531
Current load on C-DIAS bus
(power supply for I/O/P modules).
Maximum 1.2 A
Only US and Canada:
Use class 2 power supply only!
Seulement Etats-Unis et Canada:
Utilisez alimentation de la classe 2 uniquement!
Standard configuration
Ethernet 1
IP: 10.10.150.1
Subnet-Mask: 255.0.0.0
CAN bus
Station: 00
Baudrate: 01 = 500 kBaud
Problems can arise if a control is connected to an IP network, which contains mod-
ules that do not run a SIGMATEK operating system. With such devices, Ethernet
packets could be sent to the control with such a high frequency (i.e. broadcasts),
that the high interrupt load could cause a real-time runtime error or runtime error. By
configuring the packet filter (Firewall or Router) accordingly however, it is possible
to connect a network with SIGMATEK hardware to a third party network without trig-
gering the error mentioned above.
Des problèmes peuvent survenir si un automate est connecté à un réseau IP con-
tenant des modules qui ne fonctionnent pas sous un système d'exploitation
SIGMATEK. Avec de tels dispositifs, les paquets Ethernet peuvent être envoyés à
l’automate avec une fréquence tellement élevée (càd. diffusion), que les interrup-
tions ainsi générées peuvent provoquer une erreur d'exécution. En configurant
d’une façon appropriée le filtre de paquets (pare-feu ou un routeur) il est toutefois
possible de connecter un réseau avec le matériel SIGMATEK à un réseau tiers sans
déclencher l'erreur mentionnée ci-dessus.
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Miscellaneous
Article number
12-104-531 (512 Mbytes microSD card)
12-104-531-1 (1-Gbyte microSD card)
Hardware version
1.x
Project back-up
Internally on the microSD card
Standard
UL508 (E247993)
Environmental conditions
Storage temperature
-10 ... +85 °C
Operating temperature
0 ... +60 °C
Humidity
10 – 90 %, uncondensed
EMV stability
According to EN 61000-6-2 (industrial area)
Shock resistance
EN 60068-2-27
150 m/s²
Protection Type
EN 60529
IP20
Protection Type (UL)
open type device
Pollution degree
2
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C-DIAS PROCESSOR MODULE CCP 531
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Mechanical Dimensions
104.10 (dimensioning incl. covers)
24.90
129
109.2
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Connector Layout
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X1: USB Device 1.1
n.c. = do not use
X2: USB Host 2.0
It should be noted that many of the USB devices on the market do not comply with
USB specifications; this can lead to device malfunctions. It is also possible that
these devices will not be detected at the USB port or function correctly. Therefore, it
is recommended that every USB stick be tested before actual use.
Il faut souligner que la plupart des périphériques USB sur le marché ne sont pas
conformes aux spécifications USB, ce qui peut entraîner des dysfonctionnements de
l'appareil. Il est également possible que ces dispositifs ne seront pas détectés par le
port USB ou qu’ils ne fonctionnent pas correctement. Par conséquent, il est recom-
mandé que chaque clé USB soit testée avant l'utilisation sur l’automate.
X3: Ethernet
Pin
Function
1
+5 V 2 D- 3 D+ 4 n.c. 5 GND
Pin
Function
1
+5 V 2 D- 3 D+ 4 GND
Pin
Function
1
TX+ 2 TX- 3 RX+
4 - 5
n.c. 6 RX-
7 - 8
-
a
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X4: CAN-Bus
X5: Power plug
X6: microSD Card
It is recommended that only storage media provided by SIGMATEK
(CompactFlash cards, microSD cards etc.) be used.
Order number for the 512-Mbyte EDGE microSD card: 12-630-051
Order number for the 1-Gbyte EDGE microSD card: 12-630-101
The number of read and write actions have a significant influence on the
lifespan of the storage media.
Il est recommandé de n’utiliser que les supports de stockage approuvés par SIG-
MATEK (compact flash, microSD, etc.).
Numéro de commande pour la carte microSD 512 Mo Edge est le: 12-630-051
Numéro de commande pour la carte microSD 1 Go Edge est le: 12-630-101
Le nombre de cycles de lecture et d'écriture a l’influence notable sur la durée de
vie des supports de stockage.
Pin
Function
1
CAN A (CAN LOW)
2
CAN B (High)
3
CAN A (CAN LOW)
4
CAN B (High)
5
GND 6 n.c.
Pin
Function
1
+24 V supply
2
GND
Pin
Function
1
DAT2
2
CD/DAT3
3
CMD 4 +3V3 5 Clk 6 GND 7 DAT0 8 DAT1
1
1 2
65
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Exchanging the microSD card
The microSD card is located under the LED cover.
To exchange the microSD card, carefully lift the LED cover.
The microSD card is located on the left side and can be
disengaged by lightly pressing on the card itself.
Remove the microSD card.
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Connector
Type
Wire Size
Max. drive torque
X1
USB Type Mini-B
- - X2
USB Type A
- - X3
RJ 45 - -
X4
B2L 3.5/6
0.13 - 1.0 mm2
28 - 18 AWG (UL/CSA)
Cage Clamp
X5
FK-MCP 1.5/ 2-ST-3.5
0.14 - 1.5 mm2
28 - 16 AWG (UL/cUL)
Cage Clamp
MC 1.5/ 2-ST-3.5
0.13 - 1.0 mm2,
30 - 16 AWG (UL),
28 - 16 AWG (CSA)
0.22 - 0.25 Nm
Applicable connectors
USB Device: 5-pin, type Mini-B
USB Host: 4-pin, type A
Ethernet: 8-pin, RJ45
CAN Bus: 6-pin Weidmüller plug, B2L3,5/6
Supply: 2-pin Phoenix plug with screw terminal technology MC 1.5/ 2-ST-3.5
2-pin Phoenix plug with spring terminal FK-MCP 1.5/ 2-ST-3.5
The complete C-DIAS CKL 017 connector set with spring terminals is available from
Sigmatek under the article number 12-600-017.
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Status Displays
Ethernet
LED
Color
Description
Active
Yellow
Lights when data is exchanged over Ethernet
Link
Green
Lights when the connection between the two PHYs is established
Control
LED
Color
Description
ERROR
Red
Lights when an error occurs (defective USV)
DCOK
Green
Lights when the power supply is OK
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Display
The CCP 531 processor module has a 2-digit decimal display (7 segment display) for the
following functions:
- When configuring the processor module, the parameters are shown in the display.
- If an error occurs while running the program or no valid user program is found, the dis-
play shows an error message. Thereby, "Er" (error) and the error code are displayed alternatingly. The same error code is also shown in the LASAL status line.
- While running the program, the display can be used to show digits using the system
variable _cpuDisplay. Valid values are 0 to 255; values over 99, however, are not shown
and the display remains dark.
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CAN Bus Setup
This section explains how to configure a CAN bus correctly. The following parameters must
first be set: Station number and data transfer rate.
CAN bus station number
Each CAN bus station is assigned its own station number. With this station number, data
can be exchanged with other stations connected to the bus. Up to 31 stations can be installed in a CAN bus system. However, each station number can only be assigned once.
CAN bus data transfer rate
The data transfer rate (baud rate) for the CAN bus can be set. However, the longer the
length of the bus, the smaller the transfer rate that must be selected.
Value
Baud rate
Maximum length
00
615 kBit/s
60 m
01
500 kbit/s
80 m
02
250 kBit/s
160 m
03
125 kBit/s
320 m
04
100 kBit/s
400 m
05
50 kBit/s
800 m
06
20 kBit/s
1200 m
07
1 Mbit / s
30 m
These values are valid for the following cable: 120 , Twisted Pair.
NOTE: the following is valid for the CAN bus protocol: 1 kBit/s = 1 kBaud.
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Configuration of the Process Module
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To enter the mode for setting changes, press and hold the SET button while the C-IPC is
booting.
When the following appears in the display:
the SET button can be released.
After releasing the SET button, the first menu appears in the display.
With several short presses of the SET button, it is possible to switch through the various
menu points. By pressing the SET button for approximately 1.5 s, the menu is accessed
and the setting can be changed with short presses.
Once the desired changes are made, press the SET button for about 5 seconds to end the
process. If the changes are to be discarded, press the RESET button to restart the C-IPC.
The settings for the IP address, subnet mask and gateway are hexadecimal, whereas in
the left and right digits, 0 - F must be entered separately. The switch occurs when the SET
button is pressed for about 1.5 s.
The values from AUTOEXEC.LSL are used as the standard settings; changes are written
back to this file. Before this, the original content of the file is written to AUTOEXEC.BAK.
a
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C1 ... CAN PLC station
00 – 30 ... Station number
C2 ... CAN PLC baud rate
00 ... 615.000
01 … 500.000
02 … 250.000
03 … 125.000
04 … 100.000
05 … 50.000
06 … 20.000
07 … 1.000.000
I1, I2, I3, I4 IP address I1.I2.I3.I4,
Hexadecimal
00 – FF respectively
S1,S2,S3,S4 Subnet Mask S1.S2.S3.S4, hexadecimal
00 – FF respectively
G1,G2,G3,G4 Gateway G1,G2.G3.G4, hexadecimal
00 – FF respectively
a
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CAN Bus Termination
In a CAN bus system, both end modules must be terminated. This is necessary to avoid
transmission errors caused by reflections in the line.
Device 1 Device 2 Device 3 Device n
e.g. CPU
DCP 080
e.g. Terminal
ET 081
CAN-Bus-Connections
CAN-Bustermination on
terminal module
D-SUB-plug
with terminating
resistors
e.g. Terminal
ET 805
If the CCP 531 processor module is an end module, it can be terminated by placing a 150Ohm resistor between CAN-A (Low) and CAN-B (High).
1 x 150-Ohm resistor
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Wiring and Mounting Instructions
Earth Connection
The CCP 531 must be connected to earth over the mounting on the back wall of the control
cabinet or over the earth terminal provided (C-DIAS module carrier). It is important to create a low-ohm earth connection, only then can error-free operation be guaranteed. The
earth connection should have the maximum cross section and the largest electrical surface
possible.
Any noise signals that reach the CCP 531 over external cables must be filtered out over
the earth connection. With a large (electrical) surface, high frequency noise can also be
well dissipated.
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Shielding
The wiring for the CAN bus and Ethernet must be shielded. The low-ohm shielding is either
connected at the entry to the control cabinet or directly before the CCP 531 processor
module over a large surface (cable grommets, grounding clamps)!
Noise signals can therefore be prohibited from reaching the electronics and affecting the
function.
ESD Protection
Before any device is connected to or disconnected from the CCP 531, the potential with
ground should be equalized (by touching the control cabinet or earth terminal). Static electricity (from clothing, footwear) can therefore be reduced.
Working with and on the CCP 531
Valid operating and safety guidelines for personal safety must always be observed.
With installation /initial start-up / product maintenance, the relevant measures for ESD
protection must be taken.
(For example: the employees must ground themselves before they start working with and on the
product.
a
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Process Diagram
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System Boot Checkpoints
The checkpoints are shown on the 7-segment display before the LASAL CLASS software
status and error messages. Since this involves checkpoints, it should be interpreted as
errors when the system stops at a checkpoint.
Number
Meaning
Cause/solution
88
Display during system start.
If the status does not change, the oper-
ating system or application cannot be
started. This may be for different
reasons.
- The operating system is not fully booted
- Check operating system/boot medium
- Boot medium not inserted
- Boot medium defective
- No operating system on the boot medium
- BIOS self-test error
- RAM, CPU, BIOS, etc.
Unlisted messages are an indication of a hardware defect.
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Status and Error Messages
Status and error messages are shown in the status test of the LASAL CLASS software. If
the CPU has a status display, the status or error number is also show here as well.
POINTER or CHKSUM messages can also be shown on the terminal screen.
Number
Message
Definition
Cause/solution
00
RUN RAM
The user program is currently running in RAM.
The display is not affected.
01
RUN ROM
The user program in the program memory
module was loaded into the RAM and is
currently being run.
The display is not affected.
02
RUNTIME
The total duration of all cyclic objects exceeds
the maximum time; the time can be configured
using 2 system variables:
-Runtime: time remaining
-SWRuntime: pre-selected value for the
runtime counter
03
POINTER
Incorrect program pointers were detected
before running the user program
Possible Causes:
- The program memory module is miss-
ing, not programmed or defect.
- The program in the user program
memory (RAM) is not executable.
- The user program is overwriting a
software error
Solution:
- Reprogram the memory module, if the
error reoccurs exchange the module.
- Correct programming error
04
CHKSUM
An invalid checksum was detected before
running the user program.
Cause/solution: s. POINTER
C-DIAS PROCESSOR MODULE CCP 531
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05
Watchdog
The program was interrupted through the
watchdog logic.
Possible Causes:
- User program interrupts blocked
over a longer period of time (STI
command forgotten)
- Programming error in a hardware
interrupt.
- INB, OUTB, INW, OUTW instruc-
tions used incorrectly.
- The processor is defect.
Solution:
- Correct programming error.
- Exchange CPU.
06
GENERAL
ERROR
General error
07
PROM DEFECT
An error has occurred while programming
the memory module.
Cause:
- The program memory module is
defect.
- The user program is too large.
- The program memory module is
missing.
Solution:
- Exchange the program memory
module
08
Reset
The CPU has received the reset signal
and is waiting for further instructions.
The user program is not processed.
09
WD DEFEKT
The hardware monitoring circuit (watchdog logic) is defect.
After power-up, the CPU checks the
watchdog logic function. If an error
occurs during this test, the CPU deliberately enters an infinite loop from which no
further instructions are accepted.
Solution: Exchange CPU.
10
STOP
11
PROG BUSYS
12
PROGRAM
LENGTH
13
PROG END
The memory module was successfully
completed.
14
PROG MEMO
The CPU is currently programming the
memory module.
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15
STOP BRKPT
The CPU was stopped by a breakpoint in
the program.
16
CPU STOP
The CPU was stopped by the PG software (F6 HALT in status test).
17
INT ERROR
The CPU has triggered a false interrupt
and stopped the user program or has
encountered an unknown instruction
while running the program.
Cause:
- A nonexistent operating system was
used.
- Stack error (uneven number of PUSH
and POP instructions).
- The user program was interrupted by
a software error.
Solution:
18
SINGLE
STEP
The CPU is in single step mode and is
waiting for further instructions.
19
Ready
A module or project has been sent to the
CPU and it is ready to run the program.
20
LOAD
The program has stopped and is receiving a module or project.
21
UNZUL.
Modul
The CPU has received a module, which
does not belong to the project.
22
MEMORY
FULL
The operating system memory /Heap) is
too small. No more memory could be
reserved, when an internal or interface
function was called from the application.
23
NOT LINKED
When starting the CPU, a missing
module or a module that does not belong
to the project was detected.
24
DIV BY 0
A division error has occurred.
Possible Causes:
- Division by 0.
- The result of a division does not fit in
the result register.
Solution:
- Correct programming error.
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25
DIAS ERROR
An error has occurred while
accessing a DIAS module.
Possible Causes:
- An attempt is made to access
a nonexistent DIAS module.
- DIAS bus error.
Solution:
- Check the DIAS bus
- Check the termination resis-
tors.
26
WAIT
The CPU is busy.
27
OP PROG
The operating system is currently
being reprogrammed.
28
OP INSTALLED
The operating system has been
reinstalled.
29
OS TOO LONG
The operating system cannot be
loaded; too little memory.
30
NO OPERATING SYSTEM
Boot loader message.
No operating system found in
RAM.
31
SEARCH FOR OS
The boot loader is searching for
the operating system in RAM.
32
NO DEVICE
33
UNUSED CODE
34
MEM ERROR
The operating system loaded does
not match the hardware configuration.
35
MAX IO
36
MODULE LOAD ERROR
The LASAL Module or project
cannot be loaded.
37
GENERELLER BS-FEHLER
A general error has occurred while
loading the operating system.
38
APPLMEM ERROR
An error has occurred in the
application memory (user heap).
39
OFFLINE
40
APPL LOAD
41
APPL SAVE
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46
APPL-LOAD-ERROR
An error has occurred while
loading the application.
47
APPL-SAVE-ERROR
An error has occurred while
attempting to save the application.
50
ACCESS-EXCEPTIONERROR
Read or write access of a restricted memory area. (I.e. writing to the
NULL pointer).
51
BOUND EXCEEDED
An exception error caused by
exceeding the memory limits
52
PRIVILEDGED INSTRUCTION
An unauthorized instruction for the
current CPU level was given. For
example, setting the segment
register.
53
FLOATING POINT ERROR
An error has occurred during a
floating-point operation.
60
DIAS-RISC-ERROR
Error from the Intelligent DIASMaster.
64
INTERNAL ERROR
An internal error has occurred, all
applications are stopped.
Restart; report error to Sigmatek.
65
FILE ERROR
An error has occurred during a file
operation.
66
DEBUG ASSERTION
FAILED
Internal error.
Restart; report error to Sigmatek.
67
REALTIME RUNTIME
The total duration of all real-time
objects exceeds the maximum
time; the time cannot be configured.
2 ms for 386 CPUs
1 ms for all other CPUs
Starting from Version 1.1.7
68
BACKGROUND RUNTIME
The total time for all background
objects exceed the maximum time;
the time can be configured using
two system variables:
-BTRuntime: time remaining
-SWBTRuntime: pre-selected
value for the runtime counter
70
C-DIAS ERROR
An error occurred in connection
with a C-DIAS module.
Cause:
- The reason for this error is
documented in the log file
Solution:
- Depends on the cause
a
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75
SRAM ERROR
Only EDGE CPUs
An error occurred while initializing,
reading or writing SRAM data.
Possible causes:
- - SRAM configured incorrect-
ly
- - SD card formatted incor-
rectly
- - SD card removed
Solution:
- - evaluate log file
(Event00.log)
- - check configuration
- - format SD card as EDGE
medium with Lasal Class 2
- check SD card
95
USER DEFINED 0
User-definable code.
96
USER DEFINED 1
User-definable code.
97
USER DEFINED 2
User-definable code.
98
USER DEFINED 3
User-definable code.
99
USER DEFINED 4
User-definable code.
100
C_INIT
Initialization start; the configuration is
run.
101
C_RUNRAM
The LASAL project was successfully
started from RAM.
102
C_RUNROM
The LASAL project was successfully
started from ROM.
103
C_RUNTIME
104
C_READY
The CPU is ready for operation.
105
C_OK
The CPU is ready for operation.
106
C_UNKNOWN_CID
An unknown class from a stand-along or
embedded object: unknown base class.
107
C_UNKNOWN_CONSTR
The operating system class cannot be
created; the operating system is probably wrong.
108
C_UNKNOWN_OBJECT
Reference to an unknown object in an
interpreter program, creation of more
than one DCC080 object.
109
C_UNKNOWN_CHNL
The hardware module number is greater
than 60.
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110
C_WRONG_CONNECT
No connection to the required channels.
111
C_WRONG_ATTR
Wrong server attribute.
112
C_SYNTAX_ERROR
No specific error, recompile all and
reload project components.
113
C_NO_FILE_OPEN
An attempt was made to open an
unknown table.
114
C_OUTOF_NEAR
Memory allocation error
115
C_OUT OF_FAR
Memory allocation error
116
C_INCOMAPTIBLE
An object with the same name exists
but has another class.
117
C_COMPATIBLE
An object with the same name and
class exists but must be updated.
224
LINKING
The application is currently linking.
225
LINKING ERROR
An error has occurred while linking. An
error messaged is generated in the
LASAL status window.
226
LINKING DONE
Linking is complete.
230
OP BURN
The operating system is currently
being burned into the Flash memory.
231
OP BURN FAIL
An error has occurred while burning
the operating system.
232
OP INSTALL
The operating system is currently
being installed.
240
USV-WAIT
The power supply was disconnected;
the UPS is active.
241
Reboot
The operating system is restarted.
242
LSL SAVE
243
LSL LOAD
252
CONTINUE
253
PRERUN
The application is started.
254
PRERESET
The application is ended.
255
CONNECTION BREAK
For unlisted error messages, please contact SIGMATEK.
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Application exceptions
SRAM and IRQ routines
Writing remnant data during interrupt routines is not allowed and leads to a system crash.
SRAM and consistency of changed data
If more than 32 different sectors are changed (512 bytes each) shortly before shutting
down the voltage supply while the user program is writing to the microSD card, this can
sometimes lead to partial loss of remnant data.
The file system does not support safe writing through SRAM
If files are stored, modified or written on the microSD card from the user program, these
files must always be stored with a fixed maximum size. Since changes in size and the simultaneous shutdown of the voltage supply can corrupt the file system, a later change in the
file size is not allowed.
Data Breakpoint
This CPU does not support the data breakpoint is a feature.
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Note on SRAM Behavior
Because the SRAM (remnant memory) is emulated via the microSD card, there are two
different mechanisms for saving SRAM data to the microSD card:
1. Cyclic writing when data is changed (default)
2. Writing only in the event of PowerFail with a backup time buffered through the
hardware (starting with version 01.02.195)
The advantage of cyclic writing is that in the event of a severe system crash, it's possible to
reference an image of the SRAM data that with the standard settings, is a maximum of 1
minute older than the last change. With extensive use, the amount and frequency of SRAM
data changes from the user program can have a massive effect on the microSD card
lifespan.
Detailed information regarding the SRAM behavior and the corresponding settings can be
found in the LASAL OS documentation, in the chapter “SRAM”.
In the LASAL CLASS project, seldom changed value settings in retentive servers as well
as RamEx and StringRam objects, can be converted to file storage. Should existing objects
be converted from SRAM to File, the loader version 02.02.140 or higher and the RamEx
and StringRam classes of the Tools library version 01.02.033 or higher must be used.
If the user program runs cyclic writing processes in files, the tool “Flash Media Lifetime
Calculation” included in LASAL CLASS can be used to determine the effects of the opera-
tions mentioned above on the flash media. This allows the lifespan of the media to be calculated for different, configurable writing scenarios.
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