advertisement
D3--HSC
High Speed Counter
Manual Number D3--HSC-M
WARNING
Thank you for purchasing automation equipment from PLCDirectä. We want your new DirectLOGICä 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 PLCDirectä 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
This publication may contain references to products produced and/or offered by other companies. The product and company names may be trademarked and are the sole property of their respective owners. PLCDirectä 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 1997, PLCDirectä Incorporated
All Rights Reserved
No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written consent of
PLCDirectä Incorporated. PLCDirectä retains the exclusive rights to all information included in this document.
Manual Revisions
If you contact us in reference to this manual, please include the revision number.
1
Title: DL--305 High Speed Counter
Manual Number: D3--HSC--M
Issue
Original
Rev. A
Date
7/95
6/98
Effective Pages
Cover/Copyright
Contents 1--22
Back Cover
Entire Manual
Manual Revisions
Description of Changes
Original Issue
Downsize to spiral
Rev. A
1
Table of Contents
Getting Started
Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction to High Speed Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is a High Speed Counter?
Types of Counting
Using Presets and Current Count
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Who Needs a High Speed Counter?
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is a Preset and Current Count?
Positive Value Requirement
The HSC Outputs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using an Offset Value for Current Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Outputs OUTPUT1 and OUTPUT2
Two Modes of Controlling Outputs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Logic Control
Status Flags (I/O Points)
Counter Reset
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Count Outputs in BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two Response Rates
General Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Steps For Setting Up and Using the D3-HSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Wiring
Installing the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Slot for the HSC Module
Selecting the Response Rate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the Module in the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soldering the Wires to the Connector Block
Wiring for UP/ DOWN Counting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Wiring Diagram
Output Wiring Diagram
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BCD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
11
10
10
10
10
12
13
14
15
16
4
5
4
4
3
4
3
3
2
3
5
5
5
5
6
7
8
9
7
7
ii
Table of Contents
Writing the Program
Writing the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Enter Your Program:
Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Diagram of SetupLogic
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Up the Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Conventions
Preset and Current Count
Relationship Between Preset and Current Count
What Happens After the Counter Reaches the Upper Limit?
Overflow
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Up the Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Control The Outputs:
Flow Diagram of SetupLogic
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 1: Status of Mode and Logic Controls in the Automatic Mode
Setting Mode and Output Logic Control
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Putting It All Together -- Examples
Example 1: Activating both Outputs Automatically
Example 2: Mixing Modes of Operation for Outputs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 3: Changing Presets On the Fly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
23
24
20
20
20
20
21
18
18
18
19
19
19
17
17
17
17
D3--HSC
High-Speed Counter
In This Manual. . . .
— Getting Started
— Installation and Wiring
— Writing the Program
— Putting It All Together -- Examples
2
Getting Started
Overview
The Purpose of this Manual
This manual is designed to allow you to setup and install your D3--HSC High-Speed Counter
(HSC).
Supplemental
Manuals
Here are two additional manuals that you may find necessary or helpful:
User Manuals
D
DL305 User Manual
D
DirectSoft Programming Software part number part number
D3--USER--M
DA--DSOFT--M
Who Should Read this Manual
Quality Technical
Manuals and
Technical Support
If you need a High-Speed Counter for your DL305 PLC and you understand the basics of installing and programming PLCs, this is the right manual for you.
We strive to make our manuals the best in the industry, and we rely on your feedback to let us know if we are reaching our goal. If you cannot find the solution to your particular application, or, if for any reason you need additional assistance, please call us at 800--633--0405. Our technical support group is glad to work with you in answering your questions. They are available weekdays from 9:00 a.m. to 6:00
p.m. Eastern Time. You can also contact us on the worldwide web at:
http://www.plcdirect.com
(PLCDirect Web site for general info/file transfers)
You can also find a variety of support solutions at our 24--hour per day BBS at:
770--844--4209
If you find a problem with any of our products, services, or manuals, please fill out and return the ’Suggestions’ card that came with this manual.
Getting Started
3
Introduction to High Speed Counters
What is a High
Speed Counter?
Who Needs a High
Speed Counter?
Types of Counting
Literally, high speed counters count fast! The DL305 High Speed Counter (D3-HSC) has its own microprocessor that asynchronously counts and accumulates the high speed pulses. The D3-HSC will count pulses from sensors, encoders, switches, and so on, at two different response modes. You can use its10 kHz mode when measuring the fast pulses ( 500 Hz to 10kHz), or you can use the 500 Hz mode when measuring pulses being transmitted at a much slower frequency (below 500 Hz).
Both frequencies require 50% duty cycle.
If you are using a DL305 system and have an application that needs to count pulses rapidly, then you are a prime candidate for an HSC. In most applications, the HSC counts pulses being sent from encoders.
DL305 System
2 outputs:
OUTPUT1
OUTPUT2
Encoders are used to emit pulses in relation to a turning motor shaft. The encoders emit a certain number of pluses with each shaft rotation. By counting the pulses, you can easily determine the position of things being controlled by the motors. The pulses are counted at high speed, and are then compared to a preset that you define in your program. The results of this comparison control the built-in HSC outputs or can be used to perform operations within your RLL program.
HSC
Encoder
An example application could be as follows: An encoder could be connected to a motor shaft that is moving boards into position for cutting. An output (OUTPUT1) could control the OFF and ON signal to a motor that advances the boards. Since the same current count and preset can be setup to affect both outputs, you could use
OUTPUT2 to control the cutting blade.
The D3-HSC can do standard UP and DOWN counting. It cannot do quadrature
counting, and therefore cannot be used with a quadrature encoder. The UP/DOWN input signals can come from standard 1--channel encoders. One channel is used for
UP counting and the other channel is used for DOWN counting.
Using 1 Encoder for UP Counting
UP
INA
Using 1 Encoder for DOWN Counting
INB
DWN
3 3
4
Getting Started
Using Presets and Current Count
What is a Preset and Current Count?
High speed counters allow you to enter a target pulse count value (called the Preset
) that you can use to make some event (or events) happen. The event could be turning on a lamp, starting a motor, tripping a switch--virtually anything. When the
HSC starts counting pulses the accumulated count is continuously being written to the HSC’s memory. This value is referred to as the Current Count. In most applications, when current count equals preset (C = P), the event or events will be triggered. The D3--HSC will turn ON or OFF up to two external outputs when C = P.
You determine whether the outputs are turned ON or OFF when you write your ladder logic. Actually with the D3--HSC you are given the option to automatically turn outputs ON or OFF when C = P, or you can turn the outputs on manually at any time regardless of the relationship between C and P. We’ll talk more about automatic and manual operation on the next page.
Normal place to trigger an event (C = P)
Preset Value
Pulse
Count
Using an Offset
Value for Current
Count
Positive Value
Requirement
Time
You do not have to start your current count at zero when starting your high speed counter. If you start at some number other than zero, this is called an “offset”. We’ll show you how to enter the offset when we explain the setup procedure in greater detail.
When setting up the preset or current count offset value, you must use a positive number between 0 and 9999. The D3--HSC does not understand negative numbers.
Getting Started
The HSC Outputs
External Outputs
OUTPUT1 and
OUTPUT2
In most applications, you need to take some type of action when the number of pulses (current count) received equals your preset target (C=P).There are two discrete external outputs (OUTPUT1 and OUTPUT2) for the D3--HSC. The outputs are triggered by a combination of your ladder logic and/or the pulses received on the count inputs of the HSC.
DL305 System
HSC
DL305
5 5
2 outputs:
OUTPUT1
OUTPUT2
INA--UP
Encoder A
Two Modes of
Controlling Outputs
You can control the two outputs of the D3-HSC by choosing one of two modes:
D
Automatic (Mode=1)----If you choose the automatic mode, then the current count alone will determine when an output will change status (ON or OFF).
D
Manual (Mode=0)----If you choose to operate the outputs manually, then the current count of the counter does not affect the outputs. Instead, you can use the outputs just like any normal output, which means you control them with your ladder logic program.
Output Logic Control
Current Count
Outputs in BCD
The relationship between current count and preset controls the outputs, when in automatic mode. However, there is an additional feature called Output Logic Control that lets you choose how the outputs operate. For example, in one application you may want the output to come on when current count equals preset (C=P). However, in another application, you may want the output to go off when current count equals preset (C=P). Fortunately, you can choose the method individually for each point.
Pages 18--19 explain this in more detail.
You cannot read the current count of the HSC by reading an internal register. This is different from the HSC modules offered in the DL205 and DL405 families. However, there are 16 outputs that can be connected to a display (or even an input module) to show the current count in BCD. We’ll talk about this in a later section.
Example Interface for BCD Output of Current Count Value to LED Display
User--Supplied
Display Circuit
6
Getting Started
Status Flags
(Internal Relays)
In addition to the two external outputs (OUTPUT1 and OUTPUT2) and the BCD outputs, the D3-HSC also will set several status flags (C < P, C = P, C > P and
Carry/Borrow) that are assigned to certain I/O points that you can use in your ladder logic. These I/O points are internal to the HSC and have no outside connecting points on the module connector.
Later, we’ll present a table that shows you what memory reference to use in your ladder logic in order for the CPU to read the status of these flags. The numbers referring to the status flag relays are uniquely determined by the base slot position that you choose for your HSC.
Below is a diagram showing the internal and external I/O of the HSC.
Current
Count
BCD
Output
Output1
Output2
Field Devices
HSC
C < P
C = P
C > P
Carry/Borrow
Base Backplane
CPU
Getting Started
Counter Reset
External Reset
Once the pulses have been counted you need a way to reset the counter. There are two options:
D
D
External Reset--You can reset the counter of the HSC externally via a device connected to pins 6A and 6B on the front of the module. The wiring diagram on Page 12 provides the electrical details. This can be a limit switch, proximity switch, photoswitch, or virtually any field device that will provide a logical high pulse (in the range of 3VDC to 7VDC) for a period of at least 100 milliseconds.
Internal Ladder Logic Reset-- You can also reset the counter by using the proper sequence of commands in your ladder logic. You do this by entering a new Current Count value, followed by entering a Preset Value in the same scan cycle. We’ll show you how to do this in the back part of this manual when we show you how to write logic for some specific applications.
Two Response Rates
There are two dip switches located on the circuit board of the HSC----the one marked SW2 (with the letters S and M marking the switch positions) is for matching up the responsiveness of the reset switch with the counting rate. SW1 is for setting the counting rate.
Consequently, when you set the counting rate on SW1 (either 500 Hz or 10 kHz), you will want to set SW2 so that it matches.
SW1
SW2
OPEN
Set response for counting inputs
1 2
S
M
Set response for external reset
Position M= 500 Hz and Position S =
10kHz.
7 7
8
Getting Started
General Specifications
Counter
Counter Speed
Counter Inputs
Reset
Count Value
Counter Preset
Outputs
(External Points)
Status Flags
(Internal Relays)
Item
Output Response
Base Power Requirement
Weight
Specification
UP/DOWN Counter
10 kHz maximum
Dip Switch Selectable Response Rates:
Either 10 kHz or 500 Hz (50% Duty Cycle)
1 Count UP Input
1 Count DOWN Input
External Reset Available
Non-Retentive Upon Power Cycle
Set by CPU Ladder Logic Program
16-Outputs for BCD Display
Output1
Output2
C < P Flag
C = P Flag
C > P Flag
Carry/Borrow Flag
0.01 ms, maximum
9V 70 mA, maximum
4.6 ounces (130 grams)
NOTE: The D3-HSC cannot perform quadrature counting. This module will not work with a quadrature type encoder.
Getting Started
3 Steps For Setting Up and Using the D3-HSC
Step 1: Set Response and Wire
Module
(See “Installation and Wiring”,
Pages 8 through 14)
The HSC has two response speeds--either 10kHz or 500Hz. These are selectable via two sets of dip switches on the side of the module. You should set these to your choice of response speeds. Then, solder the wires to the removable connector block, following the wiring diagram in this manual.
Step 2: Install the Module
(See “Installation and Wiring”,
Pages 8 through 9)
You will decide which slot to use for the
HSC. You have your choice of Slots 0, 1,
2, or 3. This will, in turn, determine the memory locations assigned to the HSC inputs and outputs.
DL305
Choose a slot for the HSC
OPEN
Set response for counting inputs
1 2
S
Removable
Connector
Block
M
Set response for external reset
9 9
Step 3: Write the Setup Program
(See “Writing the Program”,
Pages 15 through 19)
With a segment of ladder logic entered via DirectSOFT or a handheld programmer, you will write ladder logic that sets up the counter and optionally determines the logic and mode of control for the outputs. The setup sequence is as follows:
D
D
D
D
IO020
C160
C160
OUT RST
IO110
SET
IO111
SET
IO112
SET
Set up the current count and preset for the counter.
Select the mode--automatic or manual
If you choose the automatic mode, you must select the Output Logic
Control method (ON-to-OFF or
OFF-ON) for OUTPUT1 and
OUTPUT2
If you choose the manual mode, you must write the logic to control
OUTPUT1 and OUTPUT2 directly.
IO113
SET
Only the first bullet point in Step 3 is necessary if you plan to use no outputs.
10
Installation and Wiring
Installing the Module
Selecting a Slot for the HSC Module
The D3-HSC can occupy Slots 0,1, 2, or 3 of any DL305 base. The module will not
function in any other slots.The memory assignments for the HSC’s inputs and outputs (to be used in your ladder logic) are affected by the slot you choose. Pages
17 through 19 of this manual show you the specific memory assignments for inputs and outputs. For example, the following diagram is of a D3-08B 8-slot base. Notice that the CPU slot has no number.
CPU
Example with
HSC in Slot 1
Slot No.
6 5 4 3 2 1 0
DL305
Base
Power Supply
Selecting the
Response Rate
As mentioned earlier, the response rate for counting is dip switch selectable. Also the speed at which the reset input can be detected is selectable. These switches are on the component side of the module’s internal circuit board. SW1 is at the top and
SW2 at the bottom. Use the table below to select the rate. If the pulses are being sent at a rate higher than 500 Hz, then you need to choose the 10 kHz setting. Be aware
that the frequency response rate of SW1 must match that of SW2 if you plan to use the external reset.
SW1
OPEN
1 2
SW1
Counting Inputs:
Position 1
Position 2
10 kHz
OPEN
OPEN
500 Hz
CLOSED
CLOSED
SW2
S
M
SW2
External Reset
S
Position
M
Position
Inserting the Module in the Base
When inserting components into the base, align the PC board of the HSC module with the grooves on the top and bottom of the base. Push the module straight into the base until it is firmly seated in the backplane connector.
Align module to slots in base and slide in
WARNING: Never connect or install a module into the base while the power is applied. Failure to remove the power prior to the installation can result in damage to the module, other installed modules, the power supply and/or the
CPU itself.
Installation and Wiring
Wiring the Module
General
Considerations
Consider the following guidelines when connecting the field wiring to the D3-HSC.
Soldering the Wires to the Connector
Block
1.
2.
3.
4.
5.
There is a maximum size wire the module can accept. We recommend that you use wire that is no smaller than 22 AWG and no larger than 18 AWG.
Always use a continuous length of wire, do not combine wires to attain a desired length.
Use the shortest possible cable length.
Use wire trays for routing where possible
Avoid running wires near high energy wiring.
6.
7.
Avoid running input wiring in close proximity to output wiring where possible.
To minimize voltage drops when wires must run a long distance , consider using multiple wires for the return line.
8.
Avoid running DC wiring in close proximity to AC wiring where possible.
9. Avoid creating sharp bends in the wires.
The D3-HSC is shipped with the connector block and snap-together wire cover packaged separately. This block fits on the 32-pin male connector slot on the front of the module. Before you connect it to the HSC, you may find it easier to solder the wires that you will be connecting from the encoders, the external power supply, the optional BCD outputs, the external reset, and two discrete outputs (OUTPUT1 and
OUTPUT2). Refer to the wiring diagram on the next few pages for details.
Be careful not to create cold solder joints or place so much solder on a connecting pin that it shorts out against a neighboring pin. Make sure you refer to Page 13 for connecting the BCD outputs correctly. Note which bit of the 16-bit word goes with the each weighted position of the BCD value (4 bits per numeral). You don’t want to mix up the bits; otherwise, you will get a current count number that is incorrect.
Take care also to position the wires while soldering so that the cover can be snapped securely around the wires. The cover consists of two pieces. They are held together by small screws and hex nuts. Two long-shaft thumb screws attach the cover securely to the module as a final step.
WARNING: To minimize potential shock, turn off power to the I/O base and any modules installed in the base before inserting or removing a module. Failure to do so may result in potential injury to personnel or damage to the equipment.
Wiring for UP/ DOWN
Counting
On Page 10 of this manual you will be shown how to wire encoders for UP counting or for DOWN counting. Different connecting pins are used for each task.
IMPORTANT: When one channel is counting (either UP or DOWN), the other channel must be held high. If you are using only one encoder, tie the (+) connecting pin for the unused input to the high (positive) side of the encoder’s power supply ; and the (--) pin to the negative side.
12
Installation and Wiring
Encoder Wiring Diagram
10
9
8
7
6
5
4
3
B
16
A
15
14
13
12
11
2
1
B
A
Pin No.
HSC Connector
DOWN Counting
Jumper
2
Encoder
--
12VDC
+
1
B
A
Pin No.
Unused encoder input
1B wired to negative.
Unused encoder input
1A wired to positive.
NOTE: There are two pairs of encoder connecting pins. 1A and 1B are for UP counting and 2A and 2B are for DOWN counting. You must hook your encoder to one set of pins.
The unused set of pins must have the (A) pin connected to the positive side of the encoder supply, and the (B) pin connected to the negative side.
Unused encoder input
2B wired to negative.
UP Counting
Unused encoder input
2A wired to positive.
2
Jumper
12VDC
-+
1
B
A
Encoder
Pin No.
Internal Circuitry
optoisolator
+
Internal circuits on logic side of optoisolator
330 ohms
Internal circuit on field side of optoisolator
To output of encoder
--
Installation and Wiring
Output Wiring Diagram
10
9
8
7
6
5
4
3
B
16
A
15
14
13
12
11
HSC Connector
2
1
B
A
Pin No.
B
16
5
4
3
A
V1+
V1--
Load
Load
5 or 24 VDC
NOTE: Pins 3, 4 and 5 are internally connected. Any one of these pins can be used for the supply wiring.
Internal Circuitry
V1+
Optoisolator
Load
16A
Internal circuits on logic side of optoisolator
Internal circuit on field side of optoisolator
V1+
3A, 4A, or 5A
V1--
3B, 4B, or 5B
5 or 24 VDC
14
Installation and Wiring
Reset Wiring Diagram
10
9
8
7
6
5
4
3
B
16
A
15
14
13
12
11
HSC Connector
2
1
B
A
Pin No.
B
6
A
Internal Circuitry
optoisolator
Internal circuits on logic side of optoisolator
330 ohms
Internal circuit on field side of optoisolator
+
--
+
5 or 12 VDC
--
Installation and Wiring
BCD Outputs
The CPU cannot read the current count directly, but there are 16 BCD outputs for driving a BCD display or connecting to a DC input module to read the current count into the CPU. The 16-connecting points (7A&B thru 14A&B) are attached to the BCD input of the drivers for visually displaying the BCD value or you can wire them to an input module. Such a configuration is completely optional, and requires that you supply the external devices. You determine the voltage level of these 16 points through your choice of an external power supply with the positive side connected to points 3A, 4A, 5A, and negative side connected to 3B, 4B, and 5B.
Internal
Power
V1
Note:
Pins 3, 4 and 5 are internally connected.
B
16
A
15
14
13
Example Interface for BCD Output of Current Count Value to LED Display
HSC Connector
Bit No.
Drivers
Thousands
LEDs
15
14
13
12
8000
4000
2000
1000
12
11
Hundreds
10
9
11
10
9
8
800
400
200
100
8
Tens
7
6
5
4
7
6
5
4
80
40
20
10
3
2
1
B A
Pin No.
+
--
5 or 12 VDC
3
2
1
0
8
4
2
1
Units
User--Supplied Display Circuit
Negative
Logic
10K
BCD Output Circuit (For Interfacing Display Device or Input Module)
V1+
Sinking
Sourcing
V1+
10K
Load
Photocoupler
Photocoupler
Positive
Logic
Load
V1--
V1--
16
Installation and Wiring
I/O Specifications
Input Specifications
Minimum Input Pulse Width
Signal Direction
Power Source Voltage
ON Current
OFF Current
ON Voltage
OFF Voltage
Count Input
25 ms
Falling Edge
12 VDC 10%
10--25 mA
3 mA max.
7 V min.
3 V max.
Reset Input
100 ms
ON
12 VDC 10%
10--25 mA
3 mA max.
7 V min.
3 V max.
BCD Output Specifications
Current Consumption
Ripple
Output Current (source) (6.0 V)
5 V
¦
5%
10 mA max.
1% max.
0.1 mA
External Output Specifications
Output Type
Output Voltage
Output Current
Leakage Current
Rating
NPN Open Collector
5--24 VDC
0.3 A
0.05 mA max.
12V
¦
10%
25 mA max.
3% max.
0.4 mA
Writing the Program
Writing the Program
How to Enter Your
Program:
Setup Procedure
Flow Diagram of
SetupLogic
You can write your PLC program by using a computer with DirectSOFT programming software, or using a handheld programmer compatible with your particular model of
CPU.
Programming via
Computer
HSC
Handheld
Programmer
DL305
The HSC must be set up with your ladder logic in a specified manner. If you are using the counters only (and not the external outputs), then you only have to worry about setting up the counters:
D
Setup the Counters -- Your logic must setup a current count value (C) and a preset value (P) in the same scan cycle. The order of execution must be current count first and preset second. The values used for either C or P can be any integer between 0 and 9999. A value must be entered--there are no default values.
D
Setup the Outputs (Optional) -- If you plan to use the external outputs, you must setup something called Output Mode and Output Logic Control for each of the two outputs. These two settings will ultimately control the logic status (OFF or ON) and the method for triggering each output.
Start
Setup Current Count
Setup Preset
YES!
Stop!
No need to set
Mode or the
Logic Control
AUTOMATIC
(Mode=1)
YES!
Do you want counting only?
NO!
Do you want the counter to automatically control the output?
NO!
MANUAL
(Mode=0)
OFF!
What output status do you want when C< P?
Set Output
Logic=0
ON!
Set Output
Logic=1
Output=ON when C= P and C> P
Output=OFF when C= P and C> P
ON!
Set Output
Logic=1
Output=ON
Immediately
What output status do you want?
OFF!
Set Output
Logic=0
Output=OFF
Immediately
18
Writing Your Program
Setting Up the Counters
Programming
Conventions
Preset and Current
Count
As mentioned earlier, you can use either a handheld programmer or DirectSOFT to enter your ladder logic. The examples we will be giving in this section of the manual are specific to DirectSOFT. We will, however, where necessary point out some subtle differences for the handheld programmer. When setting up your counters, you will be using the following conventions:
D
D
Instructions -- You will not be using the normal counter box when setting up the
HSC. While in DirectSOFT, if you use hot key F7 and examine the list of boxes available, you will find that one of them is called HSC. This is the box that you use in your ladder logic for setting up the HSC. If you are using the handheld programmer for the DL305, you will use the conventional CNT key (followed by the appropriate counter number) in order to do the setup.
Registers or Constants -- In order to setup the current count and preset in your counters, you can either enter constant values directly (i.e. K125) or you can point to any user-register (i.e. R400 ) where the values are stored. This is entirely up to you. We have used the direct reference with a constant in all of our examples.
D
Activating the Setup -- the counter begins counting pulses as soon as the CPU enters the RUN mode and the setup logic is scanned. You can use any type of permissive contact to trigger the setup logic. The setup logic only has to be scanned one time to setup the preset and the current count starting point. Therefore, it is important to trigger the setup logic with a one--shot. (See the example below as to how this is done.) If you don’t use a one-shot, the current count and preset setup will be executed as long as the permissive contact is on. (It will look like the counter isn’t working properly, but in reality your program is simply loading a current count on every scan!)
Shown below is a table with the counter numbers that you will enter either in your
HSC box (when using DirectSOFT) or following your CTR command when using the handheld programmer. Notice that the counter used depends on the module location in the base.
Counter Setup
Current Count
Preset
Slot 0 Cntr Slot 1 Cntr Slot 2 Cntr Slot 3 Cntr
CT100 CT102 CT104 CT106
CT101 CT103 CT105 CT107
Example: The following ladder logic initializes an HSC in Slot 0 with a preset value of 125 and a current count of 0. Notice the OUT RST instruction. In the DL305 instruction set, the
OUT RST is a one-shot, similar to the PD (positive differential) instruction of the DL205 and
DL405 families.
Start Setup
IO120
C160
OUT RST
Setup One--Shot
C160
HSC
CT100
K0
Setup Current
Count
Load 0 into current count counter
HSC
CT101
K125
Setup Preset
Load 125 into preset counter
Writing the Program
Relationship
Between Preset and
Current Count
The relationship between current count and preset will change as your program runs and the HSC continues to count pulses. You can monitor the status of C<P, C=P, and
C>P by checking certain I/O points. Each of the three flags have I/O points assigned to them for storing the status of each. The addresses associated with these points changes according to which slot you have used for the HSC. You can use the I/O points for these flags to trigger events inside your RLL program.
Counter Status
C >P
C = P
C < P
Slot 0
IO000
IO001
IO002
Slot 1
IO010
IO011
IO012
Slot 2
IO020
IO021
IO022
Slot 3
IO030
IO031
IO032
Example: The following ladder logic will turn ON an indicataor lamp when C = P for an HSC in Slot2.
Setup of HSC precedes this section of code.
C = P
IO021
IO150
OUT
Turn ON indicator lamp.
What Happens After the Counter Reaches the Upper Limit?
The upper limit for the counter is 9999. If your ladder logic has been written so that the counter continues to count past C=P and eventually reach a current count of
9999, the counter will stop counting pulses when it reaches the upper limit. It does not wrap around to zero. It is instead in an “overflow” status.
Overflow
The I/O point assigned to the Overflow function (current count greater than 9999 range) of the HSC can also be monitored by your RLL to either report the status or trigger an event. The address associated with the I/O point changes according to
HSC slot position and is shown in the following table:
Counter Overflow
Count > 9999
Slot 0
IO003
Slot 1
IO013
Slot 2
IO023
Slot 3
IO033
Example: The following ladder logic will sound an alarm if the current count exceeds 9999. This example assumes the HSC is in Slot 0.
Setup of HSC precedes this section of code.
Overflow relay
IO003
IO140
OUT
Turn On Alarm connected at IO140
20
Writing Your Program
Setting Up the Outputs
How to Control The
Outputs:
You use your ladder logic to select the way that the HSC outputs operate. You will use your logic to turn ON or OFF certain internal I/O points that control what are called Output Mode and Output Logic Control. By controlling the mode and logic for Outputs1 and 2, we are able to determine when the outputs turn ON or OFF. The flow diagram shown below explains the thought process for setting the mode and logic control to determine the status of the outputs. For example, if you choose to operate OUTPUT1 in the automatic mode, and you want to have the output ON when current count is less thant preset (C < P), then you will want to set Output1
Mode = 1 and set Output1 Logic Control = 1.
Flow Diagram of
SetupLogic
AUTOMATIC
(Mode=1)
YES!
Do you want the counter to automatically control the output?
NO!
MANUAL
(Mode=0)
OFF!
What output status do you want when C< P?
Set Output
Logic=0
ON!
Set Output
Logic=1
ON!
What output status do you want?
OFF!
Set Output
Logic=1
Set Output
Logic=0
Output=ON when C= P
Output=OFF when C= P
Output=ON
Immediately
Output=OFF
Immediately
Table 1
Status of Mode and
Logic Controls in the
Automatic Mode
It may be also useful to look at the relationship between the Output Mode and Output
Logic control and the external outputs for C < P and C = P using a table.
Output 1 Mode Output 1 Logic
Control
1
1
1
1
0
1
Output 2 Mode
Output 2 Logic
Control
0
1
Output 1
C < P
OFF
ON
Output 2
C < P
OFF
ON
Output 1
C = P
ON
OFF
Output 2
C = P
ON
OFF
NOTE: When in the Automatic Mode (Output Mode = 1), the output will assume the state determined by the output logic control as soon as the CPU is placed into the
Run Mode.
Writing the Program
Setting Mode and
Output Logic Control
The table shown below will help you determine the appropriate internal I/O points for selecting the Mode and Output Logic Control associated with the two outputs of the
HSC. Remember the HSC can go into Slots 0, 1, 2 or 3. The numbers associated with the I/O points change depending on which slot you have selected.
CPU Output Reference
Output 1 Mode
Output 1 Logic Control
Output 2 Mode
Output 2 Logic Control
C160
Slot 0
IO100
IO101
IO102
IO103
Slot 1
IO110
IO111
IO112
IO113
Slot 2
IO120
IO121
IO122
IO123
Slot 3
IO130
IO131
IO132
IO133
Example: The following example shows how to set up an HSC installed in Slot 1 to automatically control the outputs. You want both outputs to be ON when the PLC is placed in RUN (C<P), but turn OFF when C=P. The table shows IO110--IO113 for
Slot1. If we follow the flow chart, we see that we need to turn ON IO110--IO113, which selects the automatic mode for both outputs and the C=P operation to go from ON to
OFF.
Start Setup
IO020
C160
OUT RST
Setup One--Shot
IO110
SET
IO111
SET
IO112
SET
IO113
SET
Output 1 Mode= 1 (Automatic)
Output 1 Logic Control = 1
Output 2 Mode= 1 (Automatic)
Output 2 Logic Control= 1
When using the automatic mode (as shown above), the state of Output 1 Logic
Control and Output 2 Logic Control determines the state of Output1 and Output2 until C = P. So in the above example, both outputs will turn ON as soon as the PLC enters RUN mode. These outputs will remain ON until enough pulses have been counted for current count to equal preset (C = P).
The example below, uses the RST command to set the Mode to manual and it uses the OUT command to control the Logic Controls for the two outputs IO21 and IO22.
Start Setup
IO020
C160
IO21
IO22
C160
OUT RST
IO110
RST
IO111
RST
IO112
OUT
IO113
OUT
Setup One--Shot
Output 1 Mode= 0 (Manual)
Output 2 Mode= 0 (Manual)
IO21 and IO22 are inputs from a disctrete input module installed in Slot 2.
Output1 will follow the status of IO21.
Output2 will follow the status of IO22.
22
Putting It All Together
Example 1:
Activating both Outputs Automatically
As you know from reading earlier pages, the HSC module can go in slots
0,1, 2, or 3. In this program, we are assuming that the HSC module has been placed in Slot 1. This means that the counters (HSC boxes) in your program would be designated as
CT102 and CT103 (See Page 16). The
Output Mode and Output Logic control are assigned I/O points 110 through
113 (See Page 19).
We are using IO0 and C160 as a one-shot to start this setup.The
one-shot enables the two HSC boxes,
CT102 and CT103 for one scan. This initializes the preset value to 20 and the current count to 0.
C160 also turns ON IO111 and IO113, enabling the Automatic Mode for both outputs. This means when each output will turn ON or OFF is solely dependent on the current count and preset. When
C = P, OUTPUT1 and OUTPUT2 will be activated. Whether this means either output turns ON or OFF, depends on how you have set the
Output Logic Control in each case.
Here you see that we have set the logic of both to 1. So, this means that the output will be ON when C < P and turn OFF when C = P.
Start Switch
IO0
One-Shot
C160
C160
C160
OUT RST
Setup One--Shot
HSC
CT102
K0
HSC
CT103
K20
Setup Current
Count
Load 0 into current count counter
Setup Preset
Load 20 into preset counter
IO111
SET
IO113
SET
IO110
SET
Set Output1 Mode=Automatic (1)
Set Output2 Mode=Automatic(1)
Set Output1 Logic = 1
IO112
SET
Set Output2 Logic = 1
The core of your program goes here.
END
Putting It All Together
Example 2:
Mixing Modes of Operation for Outputs
In this example, we are illustrating how you can use the manual and automatic modes for controlling outputs in the same program. We have decided to control OUTPUT1 automatically, and to control OUTPUT2 manually. This could be a cut-to-length application where OUTPUT1 advances a board toward a saw for a preset number of pulses recorded by the HSC. OUT-
PUT2 controls the cutting operation.
We will assume the HSC module is in
Slot 1.
When C = P, OUTPUT1 is turned OFF.
At the same time, relay C162 turns on a timer (T600). When T600 times out, we turn ON OUTPUT2 by setting
IO112. In our board cutting example, this could mean that a saw is activated by OUTPUT2. The point being made here is that manual control of an output or outputs operates independently from the status of preset and current count.
In the Manual Mode, the relationship of current count compared to preset does not automatically affect the output. In the example shown here, we have used an internal status flag relay
IO11 (C=P) to start a timer. When the timer times out(1 second), we turn ON
OUTPUT2 by setting IO112. This is done to insure the board has stopped moving before we start the cut.
Start Switch
IO0
C160
OUT RST
Setup One--Shot
HSC
CT102
K0
C160
C = P
IO11
Turns ON when C = P
C162
TMR
T600
K10
T600
HSC
CT103
K20
IO111
SET
IO113
RST
IO110
SET
C162
SET
IO112
SET
C162
RST
Setup Current
Count
Load 0 into current count counter
Setup Preset
Load 20 into preset counter
Set Output1 Mode = Automatic (1)
Set Output2 Mode=Manual (0)
Set Output1 Logic = 1
Set internal relay
C162 when current count equals preset.
cond.
When T600 times out, turn ON
OUTPUT2 and reset the timer.
IO112
RST
When cut is complete, turn OFF
OUTPUT2.
The core of your program goes here.
END
24
Putting It All Together
Example 3: Changing Presets On the Fly
WARNING: The application shown below changes the counter’s preset value while the program is executing. Under some conditions (explained in a moment), this causes OUTPUT1 and OUTPUT2 to turn ON for approximately 1 millisecond as soon as preset is changed. This condition occurs only if the external outputs are OFF when the change is initiated, and you are in the automatic mode of control. This could result in unsafe or unpredictable results if the field device connected to the outputs sees this momentary ON signal. To prevent this, include a segment in your ladder logic that switches the operating mode of the HSC to manual before the preset is changed. The example below illustrates how this is done.
In this example, we are illustrating how you can change the preset value “on the fly”. This means you are changing the preset while the program is still running.
Although we are only showing the logic for controlling OUTPUT1, the same method could be used to affect both outputs.
We have placed the HSC in Slot 1 for this example. It can, of course, go into any Slot
0 through 3. We will assume at the point in in your program where this logic starts, the process has been running with a Preset that had been entered in earlier ladder logic not shown here. At the point this ladder logic is executed, the counter has already been counting pulses and comparing them against the previous
Preset.
This part of the program uses an MCS and
MCR instruction to load a new Current
Count and Preset value. The logic between MCS and MCR will only execute when the MCS rung has power flow.
With this example, the process is started via IO002. When energized, C161 is latched in the ON state. C161 also enables the MCS. C161 resets IO111, putting the
HSC in Manual Mode. The only other rung that executes during this first scan is the rung that causes C161 to turn ON C162.
On the second scan through the logic inside the MCS/MCR, since C162 is now
ON, CT102 loads a new Current Count of
0 and CT103 writes a new Preset of 200.
C162 will one-shot C165, which puts the
HSC back into autmatic mode and resets
IO110. It also disables the MCS/MCR.
Load New Preset
IO002
Disable Load
C165
Configure HSC
C161
Configure HSC
C161
Configure HSC
C161
Load HSC Current Count
C162
Load HSC Preset
C162
C162
Configure HSC
C161
Disable Load
C165
C161
OUT
Configure HSC
MCS
IO111
RST
Set Output1 Mode =0 (manual)
HSC
CT102
K0
Current Count
Value Set to 0
HSC
CT103
K200
Preset Value Set to 200
C165
OUTRST
C162
OUT
Disable Load Using One-shot
Load HSC Current
Count and Preset
MCR
End logic under MCS and MCR Control
IO111
SET
Set Output1 Mode =1 (automatic)
IO110
RST
END
Output 1 Logic Control=0
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
Related manuals
advertisement