HORNERAPGHORNERAPG HORNERAPGHORNERAPG 20 Years of Innovation Operator Control Station Workshop Operator Control Station “All in One” Integrated.

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APG

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APG

www.heapg.com20 Years of Innovation

Operator Control Station Workshop

OperatorOperatorControlControlStationStation“All in One”Integrated Control Solution

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Logic Controller Basics - 101

Programmable Controller• A set of coded instructions that enables a machine, especially a

computer, to perform a desired sequence of operations. • To provide (a machine) with a set of coded working instructions. • To train to perform automatically in a desired way.

• To prepare an instructional sequence

I/O (Inputs / Outputs)• Input and Output communication between a controller and its

"peripherals".

Program (RLL)• Relay Ladder Logic. Similar to a one line electric diagram.

Operator Interface• A device to let an operator monitor and adjust parameters on a

machine or process through the controller.

Networking• Interconnecting Controllers, Operator Interfaces and I/O to allow

them all to communicate as one system.

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INPUTTABLE

Basic Controller SCAN - Block Diagram

Programming Device

USERPROGRAM

OUTPUT TABLE

DATASTORAGE

InputDevices

Input/Output Modules

OutputDevices

Central Processing Unit(CPU)

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Controller Sweep ComponentsInput Update

CommunicationandDiagnostics

1 0 1 0

0 1 0 0

1 1 1 0

0 0 1 1

Input Image Table

1 0 1 0

0 1 0 0

1 1 1 0

0 0 1 1

Output Image Table

( )

Output Update

Logic Execution

BannerProx

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Data Types : by the numbers

1248163264128256512102420484096819216384

BIT

NIBBLE

BYTE

WORD

0 = 00001 = 00012 = 00103 = 00114 = 01005 = 01016 = 01107 = 01118 = 10009 = 1001A = 1010B = 1011C = 1100D = 1101E = 1110F = 1111

HE

X

BC

D

BINARY

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Bits - Bytes - and Words

A Bit is One Decimal It is either a 1 or a 0. On or Off, In Alarm or Not in Alarm

A Byte is 8 Bits. +127 to -128

A Word Is 2 Bytes or 16 Bits +32767 to -32768 ex. 00000000 00100101 = +37 (used for Analog and Register values) (sign bit) 16384 8192 4096 2048 1024 512 256 128 64 32 16 8 4 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Bit ValueBit Place

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Bit type References

%I# Field Discrete Input to OCS. The # is the unique reference address.

%Q# Field Discrete Output from OCS. The # is the unique reference address.

%M# Internal Coils in OCS. The # is the unique reference address.

%T# Internal Coils in OCS. Non-Retentive. The #is the reference that can be repeated.

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Continued bit type References

%S# Internal Diagnostic Contacts. The # is unique foreach function.

%IG# Global Data Input bits used to share data between multiple OCS’s over the CAN network.

%QG#Global Data Output bits used to share data between multiple OCS’s over the CAN network.

%K# Function Key Contacts. The # is unique foreach function key.

%D# Display bits used to turn on screens and for logical compares. The # is unique for each display screen.

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Word type References

%R# Internal 16 bit Registers used to store user datainformation. The # is the unique reference address.

%AI# Field varying signal input to OCS. The # is the unique reference address.

%AQ# Field varying signal output from OCS. The # isthen unique reference address.

%SR# Internal system values like Time/Date/Year/displaynumber, LED’s and more.

%AIG# - Global Analog Input used to read Network CAN data from other OCS’s.

%AQG# - Global Analog Output used to Send Network CAN data to other OCS’s.

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Relay Ladder Logic (Contacts & Coils)

A Contact is used to monitor the state of a reference address. A reference is ON if its state is 1; it is OFF if its state is 0.

Normally Open Contact

Contact passes Power to right whenreference is on.

Normally Closed Contact

Contact passes Power to right whenreference is off.

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Relay Ladder Logic (Contacts & Coils)

Coils are used to control discrete references. Conditionallogic is used to control the flow of power to a coil. Coilscause action directly; and are located at the rightmostposition of the rung.

-( )-Normally Open Coil

Power to coil is on,reference is on.Power to coil is off,reference is off.

-( )-Power to coil is on,reference is off.Power to coil is off,reference is on.

Normally Closed Coil

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Sample Ladder Program

( )

Left Power Rail Right PowerRail

%I1 %I2 %Q1

%Q1 Instruction

Reference Address

Power Flow

Start_PB Stop_PB Motor

MotorNick Name

Branch

2

1

1

3

4

5

Line Number

Rung Number

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( )

%I1 %I2 %Q1

%Q1

Series = AND Logic

( )

%I1 %I2 %Q1

%Q1

Parallel = OR Logic

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Left Power Rail Right PowerRail

IF (%I1 is on OR %Q1is on) AND

(%I2 is off) TURN on %Q1

Rung Logic

( )

%I1 %I2 %Q1

%Q1

%I1%I1


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LAB TIMELAB TIME

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Timers and Counters

On Delay Timer

Note: Only the On Delay Timer is retentive (when power flow is removed from the element -it does not clear the elapsed time).

When power is supplied to the TON the output becomes inactive and the TON counts up to the preset value at a rate determined by the configured timebase. When the internal accumulator reaches the Preset Value, the output becomes active and counting stops.

When power is removed from the element, the TON resets to zero. The timebase is user definable in 10mS or 100mS "ticks". When power is applied to the element, counting proceeds using this timebase.

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Timers and Counters

Retentive On Delay Timer

A Retentive On Delay Timer is a special case of the "standard" On Delay Timer, but differs from the standard timer in that the Retentive Timer does not reset when the input is brought inactive (off). The Retentive Timer requires that a reset signal be applied to the element in order for the timer to be reset.

Note: Resetting the Retentive Timer requires the use of a contact under software control of the controller. Since the Retentive Timer is retentive, any value appearing in registers assigned to the element can be invalid immediately after a down load. One approach is to reset the timer in combination with the First Scan bit:

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Timers and Counters

Off Delay Timer

Note: Only the On Delay Timer may be retentive (when power flow is removed from the element it does not clear the elapsed time).

When power is applied to the TOF Timer, the output immediately becomes active. When power is removed from the TOF the output stays active, and the TOF counts up to the preset value at a rate determined by the configured timebase. When the internal accumulator reaches the Preset Value, the output becomes inactive and counting stops.

When power is supplied to the element, the TOF resets to zero.

The timebase is user definable in 10mS or 100mS ticks. When power is applied to the element, counting proceeds at this timebase.

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Timers and Counters

Counter Operation Counter Address - Type in the Register Type and Offset to be used by this timer. Each counter requires two (2) consecutive addresses. PV (Setpoint) - This is the preset value for the counter. When the counter reaches this value, its output becomes TRUE, thus passing power to any other elements on this rung. Up Counter/Down Counter - This determines the direction of count - UP or DOWN. Reset Input Address - This determines which point is used to reset the timer. This should be a Boolean point. In this box, select the Register `Type and Offset. Reset Input Name - If the point used to reset the timer has already been named (highly recommended) one can select it by name rather than by Type and Offset. NOTE: The Reset Input must be configured even if it is not used.

The counter counts inactive-to-active transitions of it's input power. When the count reaches some preset value, the output becomes active, but the counter continues to count input pulses. The Counter can be reset at any time by applying power to the Reset input. Note: Resetting the Counter requires the use of a contact under software control of the controller.

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LAB TIMELAB TIME

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Move Functions

%R11 = 101

%R11 = 0

%R1 = 101

%R2 = 102

%R3 = 103

%R11 = 101

%R12 = 102

%R13 = 103

MO

VB

MV

%R1 = 101

OR

0

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Move Functions

%R1 = 101

OR

500

%R11 = 101

%R12 = 101

%R13 = 101

%R11 = 500

%R12 = 500

%R13 = 500

FIL

L

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Move Functions

1

2

3

%R11 = 1

%R12 = 2

%R13 = 3CS

T

MO

V

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Indirect Moves

Indirect Moves allow the user to specify a variable pointer for an address instead of a fixed address.

When specifying an Indirect Move, address pointer looks to the %R register with the pointer’s number.

Example: %R1 contains a value of 501. If used in an indirect move, data is addressed to and from %R501 instead of %R1.

Indirect Moves allow the user to specify a variable pointer for an address instead of a fixed address.

When specifying an Indirect Move, address pointer looks to the %R register with the pointer’s number.

Example: %R1 contains a value of 501. If used in an indirect move, data is addressed to and from %R501 instead of %R1.

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Indirect Moves

Gets data from %R100 if Gets data from %R100 if the value in %R1 = ‘100’.the value in %R1 = ‘100’.

Gets data straight from Gets data straight from %R1.%R1.

Gets data from %R100 if Gets data from %R100 if the value in %R1 is ‘100’.the value in %R1 is ‘100’.

Puts data straight into Puts data straight into %R2.%R2.

Puts data into %R200 if Puts data into %R200 if %R2 = ‘200’.%R2 = ‘200’.

Puts data into %R200 if Puts data into %R200 if %R2 = ‘200’.%R2 = ‘200’.

If IN is checked as Indirect:If IN is checked as Indirect:

If Q is checked as Indirect:If Q is checked as Indirect:

If both IN and Q are checked as If both IN and Q are checked as Indirect:Indirect:

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LAB TIMELAB TIME

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CsCAN - Overview

Cscape Control Area NetworkCsCAN Wiring conforms to most any other

CAN standardVisit http://www.odva.org and look for DeviceNet specs

CsCAN is a “Daisy-Chain” layout… No “Star” or “Ring” layouts allowed!

1500 feet or 64 Nodes between repeaters

3 repeaters max for 6000 feet or 253 nodes

Cscape Control Area NetworkCsCAN Wiring conforms to most any other

CAN standardVisit http://www.odva.org and look for DeviceNet specs

CsCAN is a “Daisy-Chain” layout… No “Star” or “Ring” layouts allowed!

1500 feet or 64 Nodes between repeaters

3 repeaters max for 6000 feet or 253 nodes

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CsCAN – Network Layout

Trunk Line

24VDC, 75mA per

node

Terminating Resistor

121Ohm ±1% is spec

120Ohm ±5% can work

Drops: 20ft or LESS in length!

Drops add to your total network length, too!!


121Ohm ±1% is spec

120Ohm ±5% can work

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CsCAN – Alternate Layout

To cut down on wiring accessory cost or for short networks:To cut down on wiring accessory cost or for short networks:

OCSOCS OCSOCS OCSOCS OCSOCS



Don’t forget to power the network Don’t forget to power the network somewhere!somewhere!

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CsCAN - Wiring

•Wiring consists of two shielded, twisted pairs of wireBelden 3082A for Thick (Trunk) wire, Belden 3084A for Thin (Drop) Wire

•Red/Black = 24VDC and Ground (V+ and V-)Must be applied to the network from an external source

•White/Blue = Communications (CAN_H and CAN_L)Terminating Resistor goes between CAN_H and CAN_L

•DeviceNet wiring accessories on the market work for CsCAN, too!

•Wiring consists of two shielded, twisted pairs of wireBelden 3082A for Thick (Trunk) wire, Belden 3084A for Thin (Drop) Wire

•Red/Black = 24VDC and Ground (V+ and V-)Must be applied to the network from an external source

•White/Blue = Communications (CAN_H and CAN_L)Terminating Resistor goes between CAN_H and CAN_L

•DeviceNet wiring accessories on the market work for CsCAN, too!

V+

CAN_H

Shield

CAN_L

V-

V+

CAN_H

Shield

CAN_L

V-

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CsCAN – Alternate Wiring

Multiple Power Supplies may be used, but the “V-” connection MUST still be common to all nodes!!!

Multiple Power Supplies may be used, but the “V-” connection MUST still be common to all nodes!!!

V+

CAN_H

Shield

CAN_L

V-

V+

CAN_H

Shield

CAN_L

V-

24VD24VDCC

24VD24VDCC

24VD24VDCC

24VD24VDCC

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CsCAN - Shielding

Shields should be connected at ONE END ONLY of any given length of CAN wire.


No No Connection!Connection!

To Earth To Earth GroundGround

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CsCAN - Shielding



No No Connection!Connection!

To Earth To Earth GroundGround

OCSOCS

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LAB TIMELAB TIME

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Display Edit Icon

Graphical Displays

OR

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Graphical Displays

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LAB TIMELAB TIME

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OCS A Fully Integrated Control Solution

Thank You

HORNERAPGHORNERAPG HORNERAPGHORNERAPG 20 Years of Innovation Operator Control Station Workshop Operator Control Station “All in One” Integrated.

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