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Chapter 9: Maintenance and Troubleshooting
Machine Startup and Program Troubleshooting
The DL06 Micro PLCs provide several features that can help you debug your program before
and during machine startup. This section discusses the following topics which can be very
helpful.
• Program Syntax Check
• Duplicate Reference Check
• Special Instructions
• Run Time Edits
• Forcing I/O Points
Syntax Check
Even though the Handheld Programmer and DirectSOFT32 provide error checking during
program entry, you may want to check a program that has been modified. Both programming
devices offer a way to check the program syntax. For example, you can use AUX 21, CHECK
PROGRAM to check the program syntax from a Handheld Programmer, or you can use the
PLC Diagnostics menu option within DirectSOFT32. This check will find a wide variety of
programming errors. The following example shows how to use the syntax check with a
Handheld Programmer.
Use AUX 21 to perform syntax check
CLR
C
B
2
1
AUX
ENT
AUX 21 CHECK PRO
1:SYN 2:DUP REF
Select syntax check (default selection)
ENT
(You may not get the busy display
if the program is not very long.)
BUSY
One of two displays will appear
Error Display (example)
$00050 E401
MISSING END
(shows location in question)
Syntax OK display
NO SYNTAX ERROR
?
See the Error Codes Section for a complete listing of programming error codes. If you get an
error, just press CLR and the Handheld will display the instruction where the error occurred.
Correct the problem and continue running the Syntax check until the NO SYNTAX ERROR
message appears.
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Chapter 9: Maintenance and Troubleshooting
Special Instructions
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There are several instructions that can be used to help you debug your program during
machine startup operations.
• END
• PAUSE
• STOP
END Instruction: If you need a way to quickly disable part of the program, just insert an
END statement prior to the portion that should be disabled. When the CPU encounters the
END statement, it assumes that is the end of the program. The following diagram shows an
example.
New END disables X10 and Y1
Normal Program
X0
X2
X1
X3
Y0
X4
X0
X2
X1
X3
Y0
X4
Y1
X10
END
Y1
X10
END
END
PAUSE Instruction: This instruction provides a quick way to allow the inputs (or other logic)
to operate while disabling selected outputs. The output image register is still updated, but the
output circuits are not. For example, you could make this conditional by adding an input
contact or CR to control the instruction with a switch or a programming device. Or, you
could just add the instruction without any conditions so the selected outputs would be
disabled at all times.
PAUSE disables Y0 and Y1
Normal Program
X0
X2
X1
X3
Y0
Y0 – Y1
PAUSE
X10
X4
Y1
X0
X2
X1
X3
X10
Y0
X4
Y1
END
END
STOP Instruction: Sometimes during machine startup you need a way to quickly turn off all
the outputs and return to Program Mode. You can use the STOP instruction. When this
instruction is executed the CPU automatically exits Run Mode and enters Program Mode.
Remember, all outputs are turned off during Program Mode. The following diagram shows an
example of a condition that returns the CPU to Program Mode.
DL06 Micro PLC User Manual; 2nd Ed., 3/04
Chapter 9: Maintenance and Troubleshooting
STOP puts CPU in Program Mode
Normal Program
X0
X2
X1
X3
Y0
X7
ST OP
X4
Y1
X5
X0
X2
X1
X3
Y0
X4
X5
Y1
END
END
In the example shown above, you could trigger X7 which would execute the STOP
instruction. The CPU would enter Program Mode and all outputs would be turned off.
Duplicate Reference Check
You can also check for multiple uses of the same output coil. Both programming devices offer
a way to check for this condition.. For example, you can AUX 21, CHECK PROGRAM to
check for duplicate references from a Handheld Programmer, or you can use the PLC
Diagnostics menu option within DirectSOFT32. The following example shows how to
perform the duplicate reference check with a Handheld Programmer.
Use AUX 21 to perform syntax check
CLR
C
B
2
1
AUX
ENT
AUX 21 CHECK PRO
1:SYN 2:DUP REF
Select duplicate reference check
ENT
(You may not get the busy
display if the program is not
very long.)
BUSY
One of two displays will appear
Error Display (example)
(shows location in question)
Syntax OK display
$00024 E471
DUP COIL REF
NO DUP REFS
?
If you get an error, just press CLR and the Handheld will display the instruction where the
error occurred. Correct the problem and continue running the Duplicate Reference check
until no duplicate references are found.
NOTE: You can use the same coil in more than one location, especially in programs containing Stage
instructions and / or OROUT instructions. The Duplicate Reference check will find occurrences, even
though they are acceptable.
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Chapter 9: Maintenance and Troubleshooting
Run Time Edits
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The DL06 Micro PLC allows you to make changes to the application program during Run
Mode. These edits are not “bumpless.” Instead, CPU scan is momentarily interrupted (and
the outputs are maintained in their current state) until the program change is complete. This
means if the output is off, it will remain off until the program change is complete. If the
output is on, it will remain on.
WARNING: Only authorized personnel fully familiar with all aspects of the application should make
changes to the program. Changes during Run Mode become effective immediately. Make
sure you thoroughly consider the impact of any changes to minimize the risk of personal
injury or damage to equipment. There are some important operational changes during Run
Time Edits.
1. If there is a syntax error in the new instruction, the CPU will not enter the Run Mode.
2. If you delete an output coil reference and the output was on at the time, the output will
remain on until it is forced off with a programming device.
3. Input point changes are not acknowledged during Run Time Edits, so, if you’re using a
high-speed operation and a critical input comes on, the CPU may not see the change.
Not all instructions can be edited during a Run Time Edit session. The following list shows
the instructions that can be edited.
Mnemonic
TMR
TMRF
TMRA
TMRAF
CNT
UDC
SGCNT
STR, STRN
AND, ANDN
OR, ORN
STRE, STRNE
ANDE, ANDNE
ORE, ORNE
STR, STRN
AND, ANDN
9–14
Description
Timer
Fast timer
Accumulating timer
Accumulating fast timer
Counter
Up / Down counter
Stage counter
Store, Store not (Boolean)
And, And not (Boolean)
Or, Or not (Boolean)
Store equal, Store not equal
And equal, And not equal
Or equal, Or not equal
Store greater than or equal
Store less than (Comparative Boolean)
And greater than or equal
And less than (Comparative Boolean)
Mnemonic
OR, ORN
LD
LDD
ADDD
SUBD
MUL
DIV
CMPD
ANDD
ORD
XORD
LDF
OUTF
SHFR
SHFL
NCON
DL06 Micro PLC User Manual; 2nd Ed., 3/04
Description
Or greater than or equal or less than
(Comparative Boolean)
Load data (constant)
Load data double (constant)
Add data double (constant)
Subtract data double (constant)
Multiply (constant)
Divide (constant)
Compare accumulator (constant)
And accumulator (constant)
Or accumulator (constant)
Exclusive or accumulator (constant)
Load discrete points to accumulator
Output accumulator to discrete points
Shift accumulator right
Shift accumulator left
Numeric constant
Chapter 9: Maintenance and Troubleshooting
Run Time Edit Example
We’ll use the program logic shown to describe
how this process works. In the example, we’ll
change X0 to C10. Note, the example assumes
you have already placed the CPU in Run Mode.
Use the MODE key to select Run Time Edits
MODE
NEXT
NEXT
X0
X1
Y0
OUT
C0
*MODE CHANGE*
RUN TIME EDIT?
ENT
Press ENT to confirm the Run Time Edits
ENT
(Note, the RUN LED on the D2–HPP
Handheld starts flashing to indicate
Run T ime Edits are enabled.)
*MODE CHANGE*
RUNTIME EDITS
Find the instruction you want to change (X0)
SHFT
X
A
SET
0
SHFT
FD REF
FIND
$00000 STR X0
Press the arrow key to move to the X. Then enter the new contact (C10).
SHFT
C
B
2
A
1
0
ENT
RUNTIME EDIT?
STR C10
Press ENT to confirm the change.
ENT
(Note, once you press ENT , the next
address is displayed.
OR C0
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Chapter 9: Maintenance and Troubleshooting
Forcing I/O Points
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There are many times, especially during machine startup and troubleshooting, that you need
the capability to force an I/O point to be either on or off. Before you use a programming
device to force any data type, it is important to understand how the DL06 CPUs process the
forcing requests.
WARNING: Only authorized personnel fully familiar with all aspects of the application should make
changes to the program. Make sure you thoroughly consider the impact of any changes to minimize the
risk of personal injury or damage to equipment.
There are two types of forcing available with the DL06 CPUs. (Chapter 3 provides a detailed
description of how the CPU processes each type of forcing request).
• Regular Forcing: This type of forcing can temporarily change the status of a discrete bit. For
example, you may want to force an input on, even though it is really off.
This allows you to change the point status that was stored in the image
register. This value will be valid until the image register location is written
to during the next scan. This is primarily useful during testing situations
when you need to force a bit on to trigger another event.
• Bit Override : Bit override can be enabled on a point-by-point basis by using AUX 59 from
the Handheld Programmer or by a menu option in DirectSOFT. You can use
Bit Override with X, Y, C, T, CT, and S data types. Bit override basically
disables any changes to the discrete point by the CPU. For example, if you
enable bit override for X1, and X1 is off at the time, the CPU will not change
the state of X1. This means that even if X1 comes on, the CPU will not
acknowledge the change. Therefore, if you used X1 in the program, it would
always be evaluated as “off ” in this case. If X1 was on when the bit override
was enabled, then X1 would always be evaluated as “on”.
There is an advantage available when you use the Bit Override feature. The Regular Forcing is
not disabled because the Bit Override is enabled. For example, if you enabled the Bit
Override for Y0 and it was off at the time, the CPU would not change the state of Y0.
However, you can still use a programming device to change the status. If you use the
programming device to force Y0 on, it will remain on and the CPU will not change the state
of Y0. If you then force Y0 off, the CPU will maintain Y0 as off. The CPU will never update
the point with the results from the application program or from the I/O update until the Bit
Override is removed from the point.
DL06 Micro PLC User Manual; 2nd Ed., 3/04
Chapter 9: Maintenance and Troubleshooting
The following diagrams show how the bit override works for both input and output points.
The example uses a simple rung, but the concepts are similar for any type of bit memory.
Program Rung
X0
Override holds
previous state and disables
image register update by CPU
Y0
OUT
X0
override enabled
X0 at input
module
X0 in
image register
Y0 in
image register
The following diagram shows how the bit override works for an output point. Notice the bit
override maintains the output in the current state. If the output is on when the bit override is
enabled, then the output stays on. If it is off, then the output stays off.
Program Rung
X0
Override holds
previous state and disables
image register update by CPU
Y0
OUT
Y0
override enabled
X0 at
input mdoule
Y0 in
image register
Y0 at
output module
The following diagram shows how you can use a programming device in combination with
the bit override to change the status of the point. Remember, bit override only disables CPU
changes. You can still use a programming device to force the status of the point. Plus, since
bit override maintains the current status, this enables true forcing. The example shown is for
an output point, but you can also use the other bit data types.
Program Rung
X0
Y0
OUT
The force operation from the
programming device can still
change the point status.
Y0
override enabled
X0 at
input mdoule
Y0 force
from programmer
Y0 in
image register
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Chapter 9: Maintenance and Troubleshooting
The following diagrams show a brief example of how you
could use the DL06 Handheld Programmer to force an
I/O point. Remember, if you are using the Bit Override
feature, the CPU will retain the forced value until you
disable the Bit Override or until you remove the force. The
image register will not be updated with the status from the
input module. Also, the solution from the application
program will not be used to update the output image
register. The example assumes you have already placed the
CPU into Run Mode.
From a clear display, use the following keystrokes
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STAT
X0
Y0
OUT
C0
16P STATUS
BIT REF
X
ENT
Use the PREV or NEXT keys to select the Y data type. (Once the Y appears, press 0 to start
at Y0.)
NEXT
A
0
Y
ENT
10
Y
0
Y
0
Use arrow keys to select point, then use ON and OFF to change the status
Y2 is now on
Y
ON
INS
SHFT
10
Regular Forcing with Direct Access
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From a clear display, use the following keystrokes to force Y10 ON Solid fill indicates point is
on.
Solid fill indicates point is on.
SHFT
Y
MLS
B
A
1
0
SHFT
ON
INS
BIT FORCE
Y10
From a clear display, use the following keystrokes to force Y10 OFF No fill indicates point is
off.
No fill indicates point is off.
SHFT
Y
MLS
B
A
1
0
SHFT
OFF
DEL
DL06 Micro PLC User Manual; 2nd Ed., 3/04
BIT FORCE
Y10
Chapter 9: Maintenance and Troubleshooting
Bit Override Forcing
From a clear display, use the following keystrokes to turn on the override bit for Y10.
Solid fill indicates point is on.
X
SET
A
B
1
0
SHFT
ON
INS
BIT FORCE
SET Y 10
Small box indicates override bit is on.
Note, at this point you can use the PREV and NEXT keys to move to adjacent memory
locations and use the SHFT ON keys to set the override bit on.
From a clear display, use the following keystrokes to turn off the override bit for Y10. Solid
fill indicates point is on.
Solid fill indicates point is on.
for Y10.
S
RST
A
B
1
0
SHFT
ON
INS
BIT FORCE
RST Y 10
Small box is not present when override bit is off.
Like the example above, you can use the PREV and NEXT keys to move to adjacent memory
locations and use the SHFT OFF keys to set the override bit off.
Bit Override Indicators
Override bit indicators are also shown on the handheld programmer status display. Below are
the keystrokes to call the status display for Y10 – Y20.
From a clear display, use the following keystrokes to display the status of Y10 – Y20.
STAT
ENT
NEXT
B
A
1
0
ENT
Y
20
Y
10
Override bit is on
Point is on
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