Automation Direct OP-620-M Owner's Manual

OP--620
Operator Panel
Manual Number OP--620--M
WARNING
Thank you for purchasing automation equipment from PLCDirect. We want your new DirectLOGIC automation
equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and any other
relevant publications) before installing or operating the equipment.
To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate
the installation and operation of your equipment. These codes vary from area to area and usually change with time. It is
your responsibility to determine which codes should be followed, and to verify that the equipment, installation, and
operation is in compliance with the latest revision of these codes.
At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the
codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or government
offices that can also help determine which codes and standards are necessary for safe installation and operation.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and
standards. We do not guarantee the products described in this publication are suitable for your particular application,
nor do we assume any responsibility for your product design, installation, or operation.
If you have any questions concerning the installation or operation of this equipment, or if you need additional
information, please call us at 1–800–633–0405.
This publication is based on information that was available at the time it was printed. At PLCDirect we constantly
strive to improve our products and services, so we reserve the right to make changes to the products and/or
publications at any time without notice and without any obligation. This publication may also discuss features that may
not be available in certain revisions of the product.
Trademarks
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company names may be trademarked and are the sole property of their respective owners. PLCDirect disclaims any
proprietary interest in the marks and names of others.
Stage is a trademark of Koyo Electronics Industries Co., LTD. Texas Instruments is a registered trademark of Texas
Instruments, Inc. TI, TIWAY, Series 305, Series 405, TI305, and TI405 are trademarks of Texas Instruments, Inc.
Siemens and SIMATIC are registered trademarks of Siemens, AG. GE is a registered trademark of General Electric
Corporation. Series One is a registered trademark of GE Fanuc Automation North America, Inc. MODBUS is a
registered trademark of Gould, Inc. IBM is a registered trademark of International Business Machines. MS-DOS and
Microsoft are registered trademarks of Microsoft Corporation. Windows is a trademark of Microsoft Corporation.
OPTOMUX and PAMUX are trademarks of OPTO 22.
Copyright 1998, PLCDirect Incorporated
All Rights Reserved
No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written consent of
PLCDirect Incorporated. PLCDirect retains the exclusive rights to all information included in this document.
1
Manual Revisions
If you contact us in reference to this manual, be sure and include the revision number.
Title: OP–620 Operator Panel User Manual
Manual Number: OP–620–M
Issue
Date
Original
8/97
Rev A
6/98
Effective Pages
Cover/Copyright
Contents
Description of Changes
Original Issue
Made minor revisions before reprinting
1
Table of Contents
i
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OP-620 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Stand Alone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Multi Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use With A PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Register Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Messages on the LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing Numeric Data in the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Data with a Decimal Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Fixed Point Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying BCD and Binary Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying “Double Numbers” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Floating Point Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Numeric Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Entry/Adjustment with the Arrow Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of Arrow Adjustment of Numeric Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Tree Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examples of Use with A PLCDirect PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Register Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Messages on the LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Long BCD Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Floating Point Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrow Adjustment of Setpoint Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Menu Tree Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examples of Use with an Allen-Bradley PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interfacing to A-B Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Floating Point Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Messages on the LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Long BCD Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrow Adjustment of Setpoint Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Menu Tree Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup and Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Legending the Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents
Connections to a Computer or PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Connection to OP-9001 Communications Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Module PLC Based Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi Module PLC Applications (Uses Communications Master) . . . . . . . . . . . . . . . . . . . . . . . . . .
Creating Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label and Message Definition Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A, Example Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Example Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Steps to Using the Example Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1: Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1A: Multi-Panel Power Supply Connections (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Selecting Configuration Mode: Setting the OP-Panel DIP Switches . . . . . . . . . . . . . . . .
Step 3: Selecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choosing Your Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Cable Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Connecting Configuration Cable OP–ACBL–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 5: Installing Example Programs on Your Personal Computer Hard Drive . . . . . . . . . . . . . .
Step 6: Loading OP-WINEDIT Example Program into the OP-Panel . . . . . . . . . . . . . . . . . . . . . .
Step 7: Setting the OP-Panel DIP Switch Positions for Program/Run Mode . . . . . . . . . . . . . . . .
Step 8: Loading DirectSOFT Example Program into the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 9: Connecting the OP-Panel to the PLC and Running the Program . . . . . . . . . . . . . . . . . .
Running the OP-620 Example Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kiln Demo Example Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example Message Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example Menu Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OP-620 Application Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OP-620 Message Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OP-620 Menu Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OP-9001 Multi-Panel Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B, Troubleshooting the OP-620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the OP-620 Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Configuration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel to PLC Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allen-Bradley Panel to PLC Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1
A-2
A-2
A-3
A-3
A-4
A-5
A-5
A-6
A-7
A-8
A-8
A-9
A-10
A-10
A-10
A-11
A-16
A-17
A-18
A-19
A-20
A-21
A-22
B-1
B-2
B-2
B-2
B-3
B-4
1
EU Information
This product is manufactured in compliance with European Union (EU) Directives and carries the CE
mark. The following information is provided to comply with EU documentation requirements.
NOTE: Products with CE marks perform their required functions safely and adhere
to relevant standards as specified by EC directives provided they are used
according to their intended purpose and that the instructions in this manual are
adhered to. The protection provided by the equipment may be impaired if this
equipment is used in a manner not specified in this manual. Only replacement parts
supplied by PLCDirect or its agents should be used. A listing of international affiliates
is available at our Web site
http://www.plcdirect.com
Technical Support
If you need technical assistance, please call the technical support group at
PLCDirect (3505 Hutchinson Rd., Cumming, GA 30040, U.S.A.) at 800--633--0405.
They are available Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern
Standard Time. Their Web Site address is
http://www.plcdirect.com
SELV Circuits
All electrical circuits connected to the communications port receptacle are rated as
Safety Extra Low Voltage (SELV).
Environmental
Specifications
Operating Temperature . . . . . . . . . . . . . . . . . . . . . 0° to 50° C
Storage Temperature . . . . . . . . . . . . . . . . . . . . . . --20° to 70° C
Operating Humidity . . . . . . . . . . . . . . . . . . . . . . . . 95% (non-condensing)
Air Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . No corrosive gases permitted
Preventative
Maintenance and
Cleaning
No preventative maintenance is required. To clean the exterior of the panel
disconnect the input power and carefully wipe the panel with a cloth moistened with
plain water.
External Fuse
Protection
for Input Power
There are no internal fuses for the input power circuits, so external circuit protection
is needed to ensure the safety of service personnel and the safe operation of the
equipment itself. To comply with EU specifications, the input power must be fused.
Use a fuse rated at twice the input current rating of the panel. For example, if the
panel has an input current rating of 0.5 amperes, use a fuse rated for 1 ampere.
Installing and Using the Example Programs
The Purpose of
this Manual
This User Manual provides user information on panel installation, panel
configuration, and programming the OP-620. The purpose of this manual is to teach
programming techniques which may be applied while implementing the OptiMater
panels. After reading the manual completely, load and run the example programs
which are on the supplied diskette using the directions in Appendix A.
Contents of the
Manual
Inside this manual you will learn about
planning, implementing, and utilizing the
OptiMate OP-620 panel. Also included
are application examples to improve the
learning process and working knowledge
of the OptiMate units.
How to
Use the
OP-620
The OPĆ1500 and OPĆ1510
Operator panels may be
reconfigured to exchange data
with
your
programmable
controller.
Supplemental
Manuals
Reference the appropriate PLC/CPU
User Manuals for the commands and
address references required for your
system. If you are using a DirectLOGIC
PLC product, you will want to keep the
DirectSOFT User Manual handy while
programming your system. For other
PLC brands you must reference their
User manuals to properly program the
ladder logic required to operate the
OP-panels.
For Multi-Panel applications utilizing the
OP-9001
Communications
Master
please refer to the OPĆ9001 User Manual
(Part Number OP–9001–M).
Technical
Assistance
After completely reading this manual, including Appendix B, Troubleshooting the
OP-620, if you are not successful with implementing the OP-620, you may call
PLCDirect at (800) 633-0405, Monday through Friday from 9:00 A.M. to 6:00 P.M.
Eastern Standard Time. Our technical support group will work with you in answering
your application questions. If you have a comment or question about our products,
services, or manuals which we provide, please fill out and return the suggestions
card included with this manual.
Appendix B
ASCII to HEX Cross Ref.
Introduction
Appendix A
Example Programs
1A
Installing and Using the Example Programs
Appendix B
ASCII to HEX Cross Ref.
Understanding the One of the best ways to learn how to use the OP-panel is to load the example
Example Programs programs which are on the supplied diskette, and run the program for your PLC. A
Cement Kiln System is used to demonstrate the ladder logic required to support the
various OP-panel features. The program provides ladder logic which demonstrates
controlling pushbuttons, lamps, messages and menu operations. Use an
understanding of this example program to help develop programs for your own
applications.
Follow the instructions in this chapter for installing and running the example
programs.
Software
Requirements
The example programs require that you have two software packages loaded on your
personal computer:
S DirectSOFT programming software, and
S OP-WINEDIT (OptiMate Editor) configuration software.
If you do not have these software packages, obtain and install them on your personal
computer using the instructions in their user manuals.
Once you have both programs installed on your personal computer you are ready to
use the following step-by-step instructions for installing and using the example
programs.
Page A–2
Installing and Using the Example Programs
9 Steps to Using the Example Programs
SOFT
OPĆWINEDIT
Pushbuttons...
Memory Requirements...
Process Data.....
Fault messages....
CLEAR/
ABORT
MENU
ENTER
Example Programs
Step 1: Power
Supply Connections
An external power supply should be used to power the Optimation unit. The power
supply must supply a voltage of 8 to 30 VDC. Connect the power supply using the
supplied terminal block connector. The connector is keyed to prevent reversing the
polarity. Pin 1 is the positive connection (8 to 30VDC), while pin 2 is the common
(0VDC) or ground connection.
Use 18–24 AWG conductor wire and connect the
power supply to the supplied connector block as
follows: Connect the positive (+8 to 30 VDC) lead to
terminal 1, and connect the common ground (0V)
lead to terminal 2.
Receptacle
Terminal 2
1
Terminal 1
Ground
+24VDC
Plug the terminal block connector
into Power receptacle located on
the back side of the panel.
Page A–3
2
Installing and Using the Example Programs
Step 1A:
Multi-Panel Power
Supply
Connections
(Optional)
In multi-panel applications, if using separate power supplies, make sure the
electrical ground commons do not have a great potential difference. When using a
single power supply in a multi-panel application, the power supply must maintain the
specified voltage and current consumption for each of the individual units under all
conditions (including power-up). See individual panel power requirements.
(Communications to PLC)
+
OP-9001
Power
Supply
J1
J2
(RS-422)
Panel 1
Power
Supply
Page A–4
Panel 3
Panel 2
Power
Supply
Power
Supply
Installing and Using the Example Programs
Step 2: Setting the
OP-Panel
PGM/RUN DIP
Switch to PGM
You may generate your OP-panel configuration off-line. To download your
configuration, the PGM/RUN DIP switch located on the back of the OP-panel must
be set to PGM (ON). The TERM switch should remain off.
NOTE: You must cycle power to the panel (turn power off, set DIP switch, and turn power
back on) to activate the new switch settings.
RUN
Step 3: Selecting
Cables
1
2
ON
PGM
TERM
Set to PGM
For multi-panel configurations, see the section titled OP-9001 Multi-Panel
Configurations towards the end of this chapter.
Depending on which PLC you are using, you may require as many as three cables to
use the example programs:
S
S
S
An OP–ACBL–1 configuration cable to connect your personal computer
to the OP-panel to load the configuration program into the panel. All
panels use the OP–ACBL–1 for the configuration cable. This cable is
also used to connect an OP-panel to an Allen-Bradley SLC 500 CPU.
A cable to connect your personal computer to the PLC to load the
DirectSOFT example ladder programs into your PLC. See the
DirectSOFT user manual for help in selecting the proper cable to use
with your PLC.
A cable to connect the OP-panel to the PLC. Use the information on the
next two pages to select the proper cable to use with your PLC.
Page A–5
Installing and Using the Example Programs
Choosing Your
Connecting Cables
Depending on which PLC you are
using, you may require as many as
two cables. Here are the
requirements:
D
OP-ACBL-1: all units require
this cable for configuration. This
is a 9-pin female to 15-pin male
cable that connects your
personal computer to the
OP-panel. This cable is also
used to connect an OP-panel to
the Allen-Bradley SLC 500
CPUs listed.
D CPU Cables: You will also need
the appropriate cable to connect
your CPU to the OP-panel. Use
the chart shown to the right to
choose
the
correct
communications cable.
OP-9001 Cable Connectors
OptiMate Cables
Family
CPU
(or other device)
D
D
D
OP-CMCON–1 — pack of 4
ribbon cable connectors.
OP-CMCON–2 — pack of 4
solder-type connectors.
OP-CMCON–3 — pack of 2
D–shell connectors with screw
terminals for use with OPĆ9001
& multiple OP-panels.
OP-PSCON — pack of 4 power
supply block connectors.
For electrically noisy environments,
we recommend an individually paired
and shielded cable, such as Belden
9729 or equivalent. This type of
cable requires the solder-type or
D-shell
with
screw
terminal
connectors. For distance of 30 feet or
less, you can use ribbon cable. For
ribbon cable, we recommend
Belden 9L28015 or 3M 3365/15.
* — requires RS232 Data Communications Unit (D3–232–DCU)
**– also DC versions
Cable
DirectLOGICt
DL105
DL130
Only port
OP–2CBL
DirectLOGICt
DL205
DL230
Only port
OP–2CBL
DL240
Top port
OP–2CBL
Bottom port
OP–2CBL
Top port
OP–2CBL
Bottom port
OP–2CBL–1
D2–DCM (module)
Only port
OP-4CBL–2
DL330
Requires DCU*
OP–4CBL–2
DL330P
Requires DCU*
OP-4CBL–2
DL340
Top port
OP-3CBL
Bottom port
OP-3CBL
Top port
OP-2CBL
Bottom port
OP-4CBL-2
Top port (15-pin)
OP-4CBL–1
Bottom port (25-pin)
OP-4CBL–2
Top port
OP-4CBL–1
Bottom port
OP-4CBL–2
Phone Jack
OP-2CBL
Top port (15-pin)
OP-4CBL–1
DL250
DirectLOGICt
DL305
DL350
DirectLOGICt
DL405
DL430
If you’re planning to use multiple
panels and an OP-9001, then you
will need to build your own custom
cables. Since the proper cable
choice really depends on your
application, we offer the following
connectors.
D
Port
DL440**
DL450
GE
Series 1
Bottom port (25-pin)
OP-4CBL–2
D4–DCM (module)
Only port
OP-4CBL–2
Slice I/O panels
Only port
OP-4CBL–1
IC610CPU105/106
Requires DCU*
OP-4CBL–2
GE Seriest 90/30
All Models (311–351)
RS232, RS422
Serial Port
OP-GCBL–1
GE Fanuct
Series 90 Micro
All Models
RS232, RS422
Serial Port
OP-GCBL–1
MODICON
ModBus
RJ45 port
OP-MCBL–1
TI305t /
SIMATIC TI305t
325–07, PPX:325–07
Requires DCU*
OP-4CBL–2
330–37, PPX:330–37
Requires DCU*
OP-4CBL–2
325S–07 (or 325 w/ Stage Kt)
Requires DCU*
OP-4CBL–2
330S–37, PPX:330S–37
Requires DCU*
OP-4CBL–2
335–37, PPX:335–37
Phone Jacks
OP-3CBL
TI405t /
SIMATIC TI405t
If DCU is used*
OP-4CBL–2
425–CPU, PPX:425–CPU **
Only port
OP-4CBL–1
PPX:430–CPU
Top port (15-pin)
OP-4CBL–1
Bottom port (25-pin)
OP-4CBL–2
Top port (15-pin)
OP-4CBL–1
435–CPU, PPX:435–CPU **
Bottom port (25-pin)
OP-4CBL–2
Smart Slicet I/O panels
Only port
OP-4CBL–1
A–B SLC 500
5/03, 5/04
Bottom port
OP-ACBL–1
A-B
MicroLogix
Only port
OP-ACBL–2
Page A–6
Installing and Using the Example Programs
Connecting Cable Details
Connecting Cable
RJ12 (PLC)
4
3
1
DB15
3
2
5
RJ11 (PLC)
2
1
4
DB15
3
2
5
DB15 (PLC)
2
3
4
13
14
15
1
7
8
DB15
3
2
5
DB25 (PLC)
2
3
7
4
5
DB15
3
2
5
8 Pin Mini DIN DB15
7
3
4
2
2
5
The OP–620 connecting cable may vary depending on which CPU you use. Refer to
the previous page to select the proper cable for connecting to your PLC.
1= 0V
2= not used
3= Din
4= Dout
5= not used
6= not used
RJ12
(6P6C)
RJ12
12 3 456
8= YOM
7= CTS
6= not used
5= not used
4= On-line
3= Din
2= Dout
1= YOP
13= not used
12= not used
11= not used
10= not used
9= not used
8= not used
7= 0V
6= not used
5= CTS
4= RTS
3= Din
2= Dout
1= not used
15= tied (0V)
14= tied (0V)
13= tied (0V)
12= not used
11= not used
10= not used
9= not used
4
DB15
12
DB15
DB25
Mini–DIN
5
DB15
DB15
3= Din
2= Dout
5 =0V
RS-422 Pinout
PLC
Din +
Din –
Dout +
Dout –
0V
DB15
25= not used
24= not used
23= not used
22= not used
21= not used
20= not used
19= not used
18= not used
17= not used
16= not used
15= not used
14= not used
6 7 8
DB15
RJ11
(4P4C)
1= Din
RJ11
2= Dout
3= not used
4= 0V
1 234
3
Panel
11 = Dout+
12 = Dout –
9 = Din +
10 = Din–
5 =0V
9= not used
10= not used
11= not used
12= not used
13= not used
14= not used
15= not used
RTS+
CTS+
RTS–
CTS–
Page A–7
1= not used
2= Dout
3= Din
4= not used
5= 0V
6= not used
7= not used
8= not used
Installing and Using the Example Programs
Step 4: Connecting Once the example programs are loaded in your personal computer, the first step will
be to load the configuration program from the computer into the OP-panel, so make
Configuration
Cable OP–ACBL–1 this cable connection first. Connect the configuration cable between the serial port of
the OP-panel and the serial port of the personal computer when configuring panels
using the OP-WINEDIT software. The OP-WINEDIT software requires you to select
the serial port number (com1, com2) being used for configuration. The figure below
shows programming cable connectors and wiring specifications. Wiring diagrams
refer to the cable connectors, not the communication ports.
Appendix B
ASCII to HEX Cross Ref.
(
1
Female
DB9
3
2
5
7
8
9
5= 0V
4= not used
3= Dout
2= Din
1= not used
9=not used
8= CTS
7= RTS
6=not used
1
Male
DB15
3
2
5
9= not used
10= not used
11= not used
12= not used
13= not used
14= not used
15= not used
1= not used
2= Dout
3= Din
4= not used
5= 0V
6= not used
7= not used
8= not used
Step 5: Installing
It is possible to load the examples from the diskette; however, we recommend
copying them to the hard drive in your computer and keeping the original diskette in a
the Example
Programs on Your safe place.
Personal Computer
Hard Drive
a:\filename.prj
To install the example programs if using Windows 3.1, follow these steps:
1. Call up the DOS Prompt. Make a new directory on the hard drive in your
computer. For example,
if the hard drive is drive C and you are using an OP-620 panel, type:
MD C:\OP–620
2. Copy all the files from the example program disk to the new directory. For
example, if the diskette is in drive A: and the hard drive is drive C:, type:
COPY A:\*.* C:\OP–620\*.*
Page A–8
Installing and Using the Example Programs
To install the example programs if using WIN 95, follow these steps:
1. Select the Explorer icon and open. If the hard drive is drive C, select the
(C:) icon.
2. Make a new directory in the hard drive of your computer. For example, if
you are using an OP-620 panel, Select the File menu, then select New and
then Folder. Notice the New Folder icon that appears. Select the folder
and name it “OP-620” by selecting the File menu and selecting Rename.
Type in the new name.
3. Copy all the contents of the example program disk. Insert the diskette in
drive A, and select and open the 3 1/2 Floppy (A) icon. Notice the disk has
numerous files of example programs. Select all the programs by opening
the Edit menu and selecting Select All. Open the Edit menu again and
select Copy.
4. Paste the program disk contents into the new C drive “OP–620” directory.
Open the “OP–620” directory, open the Edit menu and select Paste.
The example programs are now loaded onto the hard drive of your computer.
Remove the diskette from drive A.
Step 6: Loading the The next step is to load the configuration program into the OP-panel as follows:
OP–WINEDIT
Example Program
1. Open the OP-WINEDIT (also called OPEditor) software.
into the OP–Panel
2. When the initial screen appears, select Existing System.
3. A File Open window appears. Open the example program file that you just
loaded on your hard drive (“OP-620”). A list of files appears, all having “.ocf”
after the file name. These are all configuration programs.
4. Select the configuration program for the OP-panel and PLC you are using.
For example, if you are using an OP-620 panel with a DL205 PLC, select
and open the file titled “620_205.ocf”.
5. A screen appears having all the configuration parameters for running the
example program using an OP-620 with a DL205 PLC. Make sure your
OP–ACBL–1 cable is connected between your personal computer and the
OP-panel, that the DIP switch slides are set to ON, and that the OP-panel
power supply is on. Select Configure Panel.
6. When the next window appears, select Write to Panel. This loads the
program into the OP-panel.
7. After the program is loaded, close the open windows and select Exit
Software. This closes out the OP-WINEDIT software.
The OP-panel is now configured, and the OP-ACBL-1 cable can be disconnected.
Page A–9
Installing and Using the Example Programs
Step 7: Setting the To run the example programs, set the RUN/PRG DIP switch to RUN.
OP-Panel PRG/RUN
DIP Switch to RUN
NOTE: You must cycle power to the panel (turn power off, set DIP switch, and turn
power back on) to activate new switch settings.
Set to RUN
RUN
1
2
ON
PGM
TERM
Step 8: Loading the The next step is to load the DirectSOFT example program into the PLC as follows:
DirectSOFT
Example Program
1. Connect the communications cable from your personal computer
into the PLC
communications port to your PLC’s programming port on the CPU.
2. Start DirectSOFT on your personal computer.
3. Select Open Document.
4. A dialog box appears. Open the example program file that you just loaded
on your hard drive (”OP-620”). A list of files appears, all having “.prj” after
the file name. These are the example program files. Notice that the
program files are named for the OP-panel and PLC being used and end
with “.prj”.
5. Select the example program for the OP-panel and PLC you are using. For
example, if you are using an OP-620 panel with a DL205 PLC, select and
open the file titled “620_205.prj”. When the program opens, its ladder rungs
will appear on the monitor screen.
6. Select the PLC menu, then Connect, then select the link to use. All the
program examples are saved without PLC link information, so you have to
re-connect to your particular CPU. If a message appears which asks you to
select the source of program to view, select Disk.
7. Make sure the CPU is in Program mode. Then download the program to the
CPU. One method is to select the File menu, Write Program..., then select
To PLC.
8. When the program download is complete, put the CPU in Run Mode. Select
the PLC menu, PLC Modes..., then select Run. The program is now
running.
Step 9: Connecting The next step is to connect the OP-panel to the PLC using the cable you selected
the OP-Panel to the earlier. Once the OP-panel is connected to the PLC you can run the program. Read
PLC and Running through the following section, Running The OP-620 Example Program, while at the
same time doing the setup and actually running the program on your OP-panel. It
the Program
would be helpful to print a hardcopy of the example program and study the ladder
logic to see how the program operates. In addition, see the Kiln Demo Worksheets at
the end of this chapter to help understand the program. There are also blank
worksheets to use for your own applications.
Page A–10
Installing and Using the Example Programs
Running the
OP-620 Example
Program
In this example program a Cement Kiln System is used to demonstrate the ladder
logic required to support the various OP-panel features. The program provides
ladder logic which demonstrates controlling pushbuttons, lamps, messages and
menu operations.
Items listed in the figure below, such as Hopper Selection, Kiln Speed,
Start/Stop/Run controls, and Kiln Zone Temperatures are monitored and controlled
by the OP-panel example program.
There are two parts to the program: 1. Using the “MENU” function to enter the setup
parameters, and 2. Starting and stopping the program. We will discuss setup first.
Use your imagination to picture the operation of the kiln system shown. The first
thing we must do is the program setup. There are two main categories of setup
parameters, “Raw Meal Control” and “Temperature Control”. We will discuss “Raw
Meal Control” first.
There are two parameters which must be setup for “Raw Meal Control”:
S
“Hopper Selection”: This parameter selects which hopper is going to
provide the material for the kiln system. The choices are Hopper 1,
Hopper 2 or Hopper 3.
S
“Kiln Speed”: This parameter selects the speed that the material will
travel through the kiln system. The speed is specified as a percentage
of the maximum possible speed and can be set for any speed between
1% (lowest speed) and 100% (highest speed).
Page A–11
Installing and Using the Example Programs
CLEAR/
ABORT
MENU
ENTER
There are three parameters which must be setup for “Temperature Control”:
S
S
S
“Setpoint Zone1 Temp.”: This parameter selects the temperature that
the material will be exposed to while traveling through Temperature
Zone 1. The temperature can be set to any setting from 1 to 2,000, with
1 being the lowest temperature setting and 2,000 being the highest.
“Setpoint Zone2 Temp.”: This parameter selects the temperature that
the material will be exposed to while traveling through Temperature
Zone 2 and can be set from 1 to 2,000.
“Setpoint Zone3 Temp.”: This parameter selects the temperature that
the material will be exposed to while traveling through Temperature
Zone 3 and can be set from 1 to 2,000.
Once all five parameters are setup, we are ready to run the program. This is done by
pressing the F1 pushbutton. To stop the program, press F2.
This is a simple program, but it shows how a program can be developed for a
practical application for the OP-panel. Follow these step-by-step directions to setup
the parameters and run the example program:
1. After starting the DirectSoft example program, the initial OP-panel display
is:
OPĆ620 KILN DEMO
MENU: Setup
F1: Start
The first thing we want to do is setup the parameters, so press the Menu
pushbutton to get the following screen:
Raw Meal Control
Enter/Arrow/Clear
Page A–12
Installing and Using the Example Programs
Press either of the up/down arrow pushbuttons (YorB) to get the following
screen:
Temperature Control
Enter/Arrow/Clear
Notice that pressing either YB pushbutton toggles the display between
these two screens. These are the two main categories of setup
parameters. In the second line of each screen are three choices of
pushbutton selections we can make at this point:
S Enter: Press this to setup the parameter currently shown.
S Arrow: Press either YB pushbutton to toggle between the two
screens.
S Clear/Abort: Press this pushbutton to return to the initial screen.
2. Let’s setup the Raw Meal Control first, so press either YB pushbutton to
get to that screen, and press Enter. The following screen appears:
Hopper Selection
Enter/Arrow/Clear
Press Enter. The following screen appears:
Meal Hopper (1Ć3): 2
Arrow UP/DOWN = 1
Select Hopper 1, 2 or 3 by using the YB pushbuttons, and pressing Enter.
For example, the “2” on the top line indicates that Hopper 2 is currently
selected. If we wish to change our selection to Hopper 1, press YB
pushbuttons until a “1” is displayed on the bottom line, and press Enter. A
“1” replaces the “2” on the top line and the display returns to the previous
“Hopper Selection” screen.
Pressing Clear/Abort cancels any changes made and returns the display
to the initial screen.
3. Next we need to set the kiln speed. With the “Hopper Selection” screen
displayed, press YB pushbuttons to get the following screen:
Kiln Speed Control
Enter/Arrow/Clear
Page A–13
Installing and Using the Example Programs
4. Press Enter. The following screen appears:
Kiln Speed (%) :
25
New Kiln Speed =
50
Select kiln speed by using the YB pushbuttons, and pressing Enter. For
example, the “25” on the top line indicates that a speed of 25% of maximum
speed is currently selected. If we wish to change our selection to 50% of
maximum speed, press the Y pushbutton until a “50” is displayed on the
bottom line, and press Enter. A “50” replaces the “25” on the top line and the
display returns to the previous “Kiln Speed Control” screen.
Both Raw Meal Control parameters are now set. Next we need to set the
three Temperature Control parameters.
5. Press Menu and use the YB pushbuttons to select the following
Temperature Control screen:
Temperature Control
Enter/Arrow/Clear
Press Enter to get the following screen:
Setpoint Zone1 Temp.
Enter/Arrow/Clear
First we will set the Zone 1 temperature. Press Enter to get the following
screen:
Zone1 Temp. SP:
100
Enter New Temp= 200
Select Zone1 temperature by using the YB pushbuttons, and pressing
Enter. For example, the “100” on the top line indicates the current Zone1
temperature setting. If we wish to change our selection to “200”, press the
Y pushbutton until a “200” is displayed on the bottom line, and press
Enter. A “200” replaces the “100” on the top line. The Zone1 temperature is
now set and the display returns to the following screen:
Setpoint Zone1 Temp.
Enter/Arrow/Clear
Page A–14
Installing and Using the Example Programs
6. We now need to set the Zone 2 and Zone 3 temperatures in the same
manner. To set the Zone 2 temperature, press the YB pushbuttons until
the “Zone1” portion of the display changes to “Zone2” as follows:
Setpoint Zone2 Temp.
Enter/Arrow/Clear
Press Enter, and set the Zone 2 temperature the same way that you set the
Zone 1 temperature. Repeat the same procedure for the Zone 3
temperature.
All setup parameters are now set, and you are ready to run the program.
7. After the last setup parameter is entered, press Clear/Abort to return to the
following initial screen:
OPĆ620 KILN DEMO
MENU: Setup F1: Start
To start the program, press the F1 pushbutton. Notice that the F1 indicator
light momentarily lights and the screen quickly changes to the following:
KILN STARTING
Press F2 to Stop
The above screen only appears momentarily before changing to the
following:
SYSTEM RUNNING
Press F2 to Stop
The program is now running using the parameters we preset. If you wish to
stop the program, press F2. The program stops, the F2 indicator light goes
on, and following screen appears:
KILN SYSTEM STOPPED
Press F2 to Continue
Press F2 to resume running the program. You have now run through the
entire example program.
Print a hardcopy of the example program and study the ladder logic to see how the
program operates. Hopefully this example will help you utilize the OP-panel for your
own applications.
Page A–15
Installing and Using the Example Programs
DESCRIPTION :
System Type
Panel Type
PUSHBUTTONS / LAMPS :
A M (Alternate/Momentary)
F1
Start
x
Stop
F2 x
PLC Base Register Addr
Appendix B
ASCII to HEX Cross Ref.
F3
F4
PLC CONFIGURATION :
PLC Family
CPU Model
F5
Protocol
PLC Address
PLC Timout
Baud Rate
Parity
Data/Stop Bits
Green
Lamp1
System Running
Yellow
Lamp2
System Starting
Red
Lamp3
System Stopped
MESSAGE:
Text
No. 1
No. 5
O P _ 6 2 0
K I
Action: N/A
Data Type/Format:
Text Message
M E N U : S E T U P
Action: N/A
Data Type/Format:
Text Message
K I L N
S T A R T
Action: N/A
Data Type/Format:
Text Message
P R E S S
F 2
T
Action: N/A
Data Type/Format:
Text Message
S Y S T E M
R U N
No. 6
Action: N/A
Data Type/Format: N/A
Text Message
P R E S S
F 2
T O
N/A
No. 7
Action: N/A
Data Type/Format:
Text Message
K I L N
S Y S T E
N/A
No. 8
Action: N/A
Data Type/Format:
Text Message
P R E S S
F 2
T
No. 9
Action: N/A
Data Type/Format:
Text Message
M E A L
H O P P E
No. 2
No. 3
No. 4
No. 10
L N
N/A
F
D
1
:
N/A
I
Range: N/A
O
S
T
N
G
N/A
M
O
I
O P
Range: N/A
Range: N/A
S
T
O P
Range: N/A
S
T
O P
P
E D
Range: N/A
C
O N
T
I
N U
E
Range: N/A
N/A
R
S T A R T
Range: N/A
N G
N/A
N
E M O
Range: N/A
(
)
:
Action: N/A
Data Type/Format: INTEGER/BCD Range:
Text Message
A R R O W
U P / D O W N
= ^ ^
Action: Arrow
Data Type/Format: BCD
Range:
^
Page A–16
1
–
3
1–3
^
Installing and Using the Example Programs
MESSAGE:
Text
No. 11
No. 12
No.13
No.14
No. 15
No.16
No.17
No. 18
Text Message
K I L N
S P E E D
( % )
Action: N/A
Data Type/Format: BCD
Text Message
N E W
K I L N
S P E E D
Action: Keypad Data Type/Format: BCD
Z O N E 1
T E M P
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P :
E N T E R
N E W
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P :
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N E W
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Action: N/A
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P
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Page A–17
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Installing and Using the Example Programs
MENU:
Text
No. Menu Level
Appendix B
ASCII to HEX Cross Ref.
No. 1
2
2
4
Menu Level 1
No. Menu Level 1
No. Menu Level 1
No. Menu Level 1
No. 4
Menu Level 1
No. 3
M E
Menu Level 1
2
3
3
L
Function No.
E R
S
E
S
P E E
C
Z O
N E
Z O
Z O
P
O
2
4
Function No. 3
P
O
2
4
Function No. 4
O
I
I
I
N
N
N
T
T
T
T
2
3
4
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2
3
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No.
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No.
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No.
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No.
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No.
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No.
Menu Level 1
I O N
U R E
Function No.
P
L
T
R O
L
Function No. 2
4
C T
E
C O N
2
3
L
R O
D
E R A
3
N T
P
3
C O
Function No. 1
N
4
A
Page A–18
T
R O
1
T
E M P
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N E
2
T
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N E
3
T
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.
O N
L
Installing and Using the Example Programs
PUSHBUTTONS / LAMPS :
A M (Alternate/Momentary)
DESCRIPTION :
F1
System Type
Panel Type
F2
PLC Base Register Addr
F3
F4
PLC CONFIGURATION :
PLC Family
CPU Model
Protocol
PLC Address
F5
Green
Lamp1
PLC Timout
Yellow
Lamp2
Baud Rate
Parity
Red
Lamp3
Data/Stop Bits
MESSAGE:
Text Message
No.
Action:
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Page A–19
Installing and Using the Example Programs
MESSAGE:
Text Message
No.
Action:
Data Type/Format:
Range:
Action:
Data Type/Format:
Range:
Action:
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Range:
Action:
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Appendix B
ASCII to HEX Cross Ref.
No.
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Page A–20
Installing and Using the Example Programs
MENU:
Text Message
No.
Menu Level 1
2
3
4
Function No.
2
3
4
Function No.
2
3
4
Function No.
2
3
4
Function No.
2
3
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Page A–21
Installing and Using the Example Programs
OP-9001 Multi-Panel Configurations
If you are connecting more than one OptiMate panel to a single CPU this is referred
to as multi-panel configuration. MultiĆpanel configurations require the OP-9001
Communications Master, which the CPU communicates to for obtaining data from
the connected OP-panels. The OP-9001 Communications Master looks for an
address within the range of 0 to 30 for each panel connected. Each panel connected
in a RS-422 link must have a unique address. A more detailed description of multiple
panel configuration and installation is given in the OP–9001-M User Manual.
The Termination
Resistor
The last panel must be terminated when using a RS-422 communications link by
setting DIP switch 2 to the TERM (ON) position. Operator panels communicatiing
more than 50 feet distance must use RS-422 and also be properly terminated.
NOTE: Only the last panel of each RS-422 link should have the termination DIP
switch 2 set to the TERM position. All other panels should have the DIP switch set to
the off (left) position. After changing the DIP switch settings, remember to cycle
power on panel to activate the new switch settings.
Page A–22
Appendix B
Troubleshooting the
OP-620
1A
Maintenance and Troubleshooting
Troubleshooting the OP–620 Panel
Appendix B
ASCII to HEX Cross Ref.
Troubleshooting
In this section, we explain how to isolate potential problems which may occur while
using the OPĆ620. If you are unable to troubleshoot and correct your problem using
these procedures, please contact our technical product support team between the
hours of 9:00 AM and 6:00 PM (EST) Monday through Friday. Call 1–800–633–0405
or fax (770) 889–7876.
We have organized the troubleshooting section into two categories:
S
S
Panel Configuration
Problems
Panel configuration problems
Panel and PLC communications failures
We explained in previous sections that the OP–WINEDIT configuration software is
used to create OP-panel applications and to download and upload your OP-panel
programs. If you are online with the panel and communications fails, the following
error message is displayed:
“Could not communicate with panel”
(OP–WINEDIT )
If this occurs, check the following in the order given:
1. Check the rear panel RX/TX LEDs while attempting the Upload or Download operation. Both LEDs should be giving slow alternating flash signals, indicating the PC and OP–panel are connected. If only the TX (transmitter) LED
is flashing, or if the TX/RX LEDs are not alternating between flashes, check
that the OP–panel is set to the configuration mode by setting the RUN/PGM
DIP switch to the PGM position.
2. Check to make sure the configuration cable (OP–ACBL–1) is properly connected. For cable details, refer to the Appendix A, Connecting the Configuration Cable OP–ACBL–1 section.
3. Make sure the correct communications port is selected with the software,
such as COM1, COM2, COM3, COM4.
4. Check the 24VDC power source and connections.
5. After checking the above items, repeat the online panel Download or
Upload procedure.
Rear Panel View
OPĆACBLĆ1
?
RX/TX LEDs
Check cable connections.
RUN
1
2
ON
PGM
TERM
Page B–2
RUN/PGM DIP Switch
Place the PGM/RUN switch in the PGM
position when configuring the panel.
TERM switch stays in the off position.
Maintenance and Troubleshooting
Panel to PLC
Communications
Problems
If you experience communications difficulties between the OP-panel and PLC for a
period of twelve seconds, the LEDs in the corners of the five pushbuttons will flash
rapidly.
In this case, you should check the following items:
1. Observe the TX and RX LEDs on the rear of the panel. Both LEDs should be a
steady flash or glow (depending on baud rate). If not, check and make sure you
are using the proper communications cable and that it is securely connected.
2. Examine the PGM/RUN DIP switch to
make sure it is placed in the RUN position
to load and run the ladder program. You
must cycle OP-panel power for address
switch changes to take effect.
RUN
1
2
ON
PGM
TERM
Place the PGM/RUN switch in the RUN
position when running the program.
3. Examine the communications information for the proper PLC type, protocol
type, baud rate, parity, stop bit, address number. Use the user manual for the
PLC product you are using to determine the proper settings.
4. If you are using an OP cable, verify cable pinout. For RS422 connections
use a Belden 9729 or equivalent cable.
5. Check 24VDC power source and connections.
Direct
LOGIC
PLC
DirectLOGIC PLCs : If you are using the secondary communications port such as
DirectLOGIC PLC port 2, ensure the communications port address and protocol
setting match.
Page B–3
Maintenance and Troubleshooting
PLC Model
Port/Baud Rates
DL105/230/240
9600
Top
Parity
Odd
1
Bottom Bottom (DL240 only)
9600/19.2k
DL250
Top 9600
Odd/None
Odd/None
1
Appendix B
ASCII to HEX Cross Ref.
Bottom 9600/19.2K
DL330
DCU only 4800/9600/19.2k
Odd/None
1
DL340
Bottom &Top 4800/9600/19.2k
Odd/None
1
DL350
Top 9600
Odd
1
Bottom 4800/9600/19.2K
DL430/440
Top Top
9600
Bottom 9600/19.2k
DL450
Allen-Bradley
Panel to PLC
Communications
Problems
OTHER
PLC
Stop
Bit
DB15 9600
Odd
Odd/None
1
Odd
DB25 9600/19.2k
Odd/None
RJ12 9600/19.2k
Odd/None
1
For Allen-Bradley, you may connect to Channel 0 (bottom serial port), using DF1 in
full duplex mode. Additionally, the Allen-Bradley software allows the bottom port to a
unique PLC address. The Allen-Bradley software default is PLC address one. You
must ensure the OP-panel configuration address matches the PLC address you
have assigned. The Allen-Bradley port only communicates using either 4800 or
9600 baud. No other baud rates are supported between the OP-panel and
Allen-Bradley PLC. For example, on Allen-Bradley PLC’s the serial port baud rate
defaults to 1200 baud and must be changed. The baud rate for channel 0 must be set
to 4800 or 9600 baud to match the OP–WINEDIT configuration. Also the base
memory area must be expanded to include the full range of registers such as N7:0
through N7:7.
OTHER PLCs : Regardless of which PLC brand you are implementing, the
communications parameters should be reviewed and properly configured. Please
check the appropriate manual for your PLC product to ensure proper
communications port and panel type settings.
Page B–4