PLS 210 Single-Channel High-speed Programmable Limit Switch Module User s Guide

Transcription

1 Seventh Street, Suite 200, Pittsburgh, PA (412) PLS 210 Single-Channel High-speed Programmable Limit Switch Module User s Guide ( ) Revision /14/02

2 221 Seventh Street, Suite 200 Pittsburgh, PA Phone (412) Fax (412) WEB:

3 User s Guide PLS 210 CONTENTS 1. Chapter 1 OVERVIEW Important User Information Product Warranty Return Policy Technical Support Assumptions Contents of This Manual Chapter 2 INTRODUCTION Product Description Product Features Resolution Information Throughput Tracking Rate Recommended Resolver Discrete Inputs Discrete Outputs Analog Outputs Parameter Storage Power Consumption Environmental Conditions Chapter 3 INSTALLATION Inspect the Shipment Typical System Components Installation Precautions Electrical Noise Heat & Humidity Panel Layout System Wiring Resolver & Power Connections (J1 Top Connector) Output Connections (J2 Middle Connector) Input Connections (J3 Bottom Connector) Resolver Mounting Resolver Connections External ±24Vdc Supply Chapter 4 SETUP SOFTWARE Installing the Software Running the Software Windows 95/98/NT/2000 Startup i

4 PLS 210 CONTENTS User s Guide 4.3. Configuring the Module Communications Pull-down Menu Connect Disconnect File Pull-down Menu Get Data from Module Set Data to Module Upload Firmware Download Firmware Verify Firmware Upload Settings Download Settings Save Settings to Flash Exit Setup Pull-down Menu (Global Parameter Setup) General [F2] Limit Switch [F3] Input Latch [F4] Set Position Tools Pull-down Menu Fault Status [F5] Output Control [F6] Command Log [F7] Help Pull-down Menu Firmware Information About PLS Chapter 5 PLC PROGRAMMING PLC Programming I/O Mapping the Module Peer-Copping the Module I/O Map Register Description I/O Mapped Registers Limit Switch & Output Register Bits PLS 210 to PLC Communication Test PLC Communication Test Example PLC Programming Example (Get Position & Speed) PLC Programming Example (Clear Module Faults) PLC Programming Example (Set Current Position in UU) PLC Programming Example (Setup Speed Monitoring) Chapter 6 TROUBLESHOOTING Troubleshooting Procedure Diagnostic LEDs Green Module Status LEDs Top Row Module Heartbeat [LED 1] Serial Communication Active [LED 2] PLC Communications Active [LED 3] Resolver Active [LED 4] ii

5 User s Guide PLS 210 CONTENTS Global Enable Active [LED 5] Red Module Fault LEDs Bottom Row Code Checksum Fault [LED 6] Serial Communication Fault [LED 7] PLC Command Fault [LED 8] Resolver Fault Latch [LED 9] Setup NOT Saved to FLASH [LED 10] PLC Diagnostics PLS 210 Status/Faults & Resolver Status Registers PLS 210 Setup Software Diagnostics Screen A Appendix A DRAWINGS... A-1 A.1. Module & Power Supply Dimensions... A-1 A.2. Connection and Wiring Diagrams... A-3 B Appendix B PLS 210 I/O MAP & COMMANDS... B-1 B.1. PLS 210 I/O Map Register Description...B-1 B.1.1. I/O Mapped Registers...B-1 B.1.2. PLS 210 Command Reference...B-2 iii

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7 PLS 210 OVERVIEW Chapter 1 In this Chapter you will learn about: Important User Information Product Warranty Return Policy Technical Support Assumptions 1. Chapter 1 OVERVIEW Contents of This User s Guide 1.1. Important User Information To ensure safe and satisfactory operation of the equipment described in this user s guide, as well as the equipment connected to and used with your PLS 210, all applicable local and national codes that apply to installing and operating the equipment must be followed. WARNING! Failure to comply with applicable local and national codes and standards can result in damage to equipment and/or serious injury to personnel. Personnel responsible for the installation and/or operation of the equipment should study this user s guide and all referenced documentation prior to installation or operation of the equipment. In no event is the provider of the equipment liable for any incidental, consequential or special damages of any kind or nature whatsoever, including but not limited to lost profits arising from or in any way connected with the use of this user s guide or the equipment. The PLS 210 is designed to provide solutions for one channel high-speed PLS resolver feedback to monitor position, speed, and outputs. Therefore, it is the end user s responsibility to determine the acceptability of any products used in any application. The equipment provider assumes no responsibility for the User s misapplication of the PLS 210. Since I 2 T constantly strives to improve its products, we reserve the right to change this user s guide and any equipment mentioned herein at any time without notice Product Warranty I 2 T warrants that all equipment they manufacture will be free from defects in materials and workman-ship for a period of one (1) year from the date of invoice. Within this warranty period, I 2 T shall, at its option, repair or replace free of charge, any equipment covered by this warranty. This warranty does not cover any equipment damaged by improper installation, accident, alteration or misuse. In no event shall I 2 T be liable for incidental or consequential damages or for delay in performance of this warranty. 1-1

8 Chapter 1 PLS 210 OVERVIEW 1.3. Return Policy Any equipment returned as new must be in the original, unopened shipping carton and is subject to a 30% restocking fee. NOTE that No equipment can be returned after a period of 60 days. All equipment returned to I 2 T for repair or replacement, regardless of warranty status, must have return authorization. To receive return authorization, call the I 2 T technical assistance number with the following product information: Product Part Number Serial Number Description of Problem I 2 T issues a Return Material Authorization (RMA) number. You must ship the product to I 2 T with shipping charges prepaid and the RMA clearly marked on the outside of the shipping container. Title and risk of loss or damage remains with the customer until shipment is received by I 2 T. All equipment returned for warranty repair must be in the original shipping container or additional handling charges apply. In special cases, I 2 T will provide emergency replacement of defective equipment. For special cases, the customer must provide a Purchase Order number in the amount of a product being shipped plus any applicable taxes and shipping charges. In the event that the defective equipment is not returned within seven (7) days, I 2 T bills the customer for the replacement equipment Technical Support All I 2 T products are sold through authorized Schneider Electric high-tech distributors. The customer should attempt to resolve any problems through their local distributor before contacting I 2 T directly. Should your local distributor be unavailable or unable to solve a problem, contact I 2 T Technical Support at (412) Setup Software and Firmware updates are available via our WEB site at Assumptions To effectively use the PLS 210 User s Guide to install, develop and maintain your system, you should have a fundamental understanding of the following: Electronic concepts such as voltage, current, switches, etc. Ladder Logic programming skills Contents of this PLS 210 User s Guide. 1-2

9 PLS 210 OVERVIEW Chapter Contents of This Manual Each chapter provides a different level of help to get your system set up and ready to go. Below is a summary of each chapter s purpose. Chapter / Appendix Purpose 1 Overview Provides an overview of the items to be covered in this PLS 210 User s Guide. 2 Introduction Describes the PLS 210 and provides a brief overview of its features and design. 3 Installation Provides instructions for configuring, mounting, and wiring the module. 4 PLS 210 Setup Software Allows the User to configure and test the module in a Windows environment. 5 PLC Programming Describes the PLS 210 functions in detail and shows how to implement them into your application. 6 Troubleshooting Describes methods for isolating and resolving hardware and software problems. Describes the Diagnostics LEDs and the fault registers returned to the PLC. A Drawings B I/O Map & Commands Provides drawings showing module/field interconnections and mechanical drawings. Provides supplemental information about the product. This appendix also covers the PLC Low-level Command Set. 1-3

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11 PLS 210 INTRODUCTION Chapter 2 In this Chapter you will learn about: Product Description Product Features 2.1. Product Description 2. Chapter 2 INTRODUCTION The PLS 210 high-speed programmable limit switch is a Momentum module manufactured by Integrated Industrial Technologies for the Schneider Electric TSX Momentum open architecture system. The PLS 210 monitors the position of a single-turn resolver, which is used to set the state of 16 ultra high-speed outputs. The on/off positions for each output is set by either a TSX Momentum processor adapter mounted to the PLS 210 for a remote PLC or PC field bus connected to the PLS 210 with a communication adapter. The user may also program the on/off positions from the Windows PLS Setup Software via the on-board serial port, allowing the PLS 210 to be a stand-alone controller. The PLS 210 mode of operation is a One-channel, High-speed PLS Resolver Feedback intended to monitor position and speed, and to turn on outputs to control a machine a true programmable limit switch. This module suits many applications including press control, assembly and packaging machinery, food processing, packaging and labeling, paper product production, glue or material applicators, pharmaceuticals among many other applications. The PLS 210 module can be configured by using the PLS Windows Setup Software that is supplied with the module. Monitoring and diagnostics are also possible with the PLS software. This software package runs on any IBM compatible computer running Windows 95, 98, NT and The module configuration data is entered via the PC and downloaded to the module via the programming port on the front of the module. The configuration data is stored in Flash memory in the PLS 210 Module so that data is maintained during a power loss. To program the PLS 210 module, the user can send low-level commands to the PLS 210 module from the PLC. Chapter 5 provides detailed information on PLC programming pertaining to the PLS Product Features The PLS 210 Module is a single resolver, high-speed limit switch module that is compatible with the Momentum PLC. The PLS 210 incorporates many features that are described below Resolution The resolver-to-digital converter is 16-bit. The PLS 210 module has a resolution of 65,535 counts per revolution. 2-1

12 Chapter 2 PLS 210 INTRODUCTION Information Throughput The PLS 210 reads position and digital inputs and sets digital and analog outputs every 50μ seconds. New data is presented to the PLC on every scan Tracking Rate The tracking rate of the Resolver-to-Digital converter is variable with a maximum tracking rate of 27 revolutions per second 6-bit accuracy. At faster rates, the module switches to 14-bit mode. At 14-bits the maximum is 100 revs/sec Recommended Resolver The User may select any transmit type resolver. The tested transformation range is 0.47 to 1:1. Although it is the responsibility of the purchaser to ultimately choose which type of resolver to use, we recommend an I 2 T brushless resolver to ensure the best possible performance. The auto voltage referencing circuit allows for the use of different resolvers with varying cable lengths and transformation ratios on each channel Discrete Inputs Eight Vdc inputs for position latching or global enable functions Discrete Outputs Eight 24 Vdc sinking outputs at 250 ma, and eight 24 Vdc sourcing outputs at 1 Amp Analog Outputs Two ±10 Vdc, 16-bit analog outputs Parameter Storage On-board FLASH memory for module setup and Firmware storage Power Consumption Maximum 24Vdc Minimum 0.3A (typical 0.4A) Actual current is determined by the top hat used. Readings do not include the current necessary for 24Vdc sourcing outputs Environmental Conditions Operating Temperature: 0 to 60 C Relative Humidity: 5 to 95 % (non-condensing) Storage Temperature: -40 to 85 C 2-2

13 PLS 210 INSTALLATION Chapter 3 In this Chapter you will learn about: Inspecting the Shipment Typical System Components Installation Precautions Panel Layout System Wiring Resolver Mounting Resolver Connections 3. Chapter 3 INSTALLATION 3.1. Inspect the Shipment Check your PLS 210 packages, upon receipt, for obvious damage that may have occurred during shipment. Report any damage to the shipping company immediately. I 2 T cannot be held responsible for damage incurred during shipment. Along with your PLS 210 One-Channel High-Speed Programmable Limit Switch Module (P/N: ), the following parts should be included: PLS 210 HMI Windows Setup Software (P/N: ) The following parts may also be included in your shipment, depending on your order, and must also be inspected for damage as they are received. 24 Vdc Module Power Supply (P/N: ) Heavy-duty Industrial Brushless Resolver (P/N: , ) RJ45 Module-to-Computer Programming Cable (P/N: ) Module-to-Resolver Cable 25/50/100 ft. (P/N: 4000-xxx) Retain all shipping containers in case you need to return the PLS 210 or related products for any reason. Any damage incurred due to improper packing is the responsibility of the shipper and will further delay the repair or replacement of your parts. NOTE " Resolvers, resolver cables, and programming cables are typically shipped in separate containers. 3-1

14 Chapter 3 PLS 210 INSTALLATION 3.2. Typical System Components Figure 3-1 shows the parts necessary to setup and operate a typical PLS 210 control system. Figure 3-1: Typical Control System 3.3. Installation Precautions Before installing the PLS 210, there are several precautions to take. If for any reason, you are unsure about the system design, call your distributor or I 2 T technical assistance ( ) before completing your design Electrical Noise By observing the following installation precautions, you can prevent electrical noise problems. CAUTION! Do not route high-voltage wires and low-level signals in the same conduit. Always run the resolver cables in their own conduit or with other low-level signals. Ensure that all components are properly grounded. Ensure that all wiring is properly shielded and that all shields are tied to a good earth ground. 3-2

15 PLS 210 INSTALLATION Chapter 3 CAUTION! Always use twisted-pair shielded cables when running signals. Always use isolated circuits for remote signals. Use isolated analog and digital signals when possible. Never cut the resolver cables to land on a terminal strip. Always run the resolver cables from the resolver directly to the module. This will keep the shielding scheme intact and minimize the possibility of creating ground loops. Put surge suppression components on all electrical coils: Resistor/Capacitor filters, MOVs, Zener, and clamping diodes Heat & Humidity All PLC equipment should be housed in an enclosure that will prevent exposure to dirt, dust, liquids, and harsh environments. To ensure personal safety and long life of the PLS 210 module, pay special attention to the following environmental conditions. NOTE " Always operate the PLS 210 at an ambient temperature between 0 and 60 C. Always store the PLS 210 at an ambient temperature between -40 and 85 C. Maintain a relative humidity below 95% (non-condensing) Panel Layout The PLS 210 should be installed in an enclosure that will protect it from atmospheric contaminants such as oil, metallic particles, moisture, and dirt. The National Electrical Manufacturers Association (NEMA) established standards that define the degree of protection that electrical enclosures provide. The enclosure that you use for PLC equipment should, as a minimum, conform to a NEMA 12 standard. The PLS 210 is din-rail mounted. The PLS 210 module communicates with the Momentum processor directly through a communication top hat, so no external wiring between the module and the processor is required. When performing your panel layout, locate the PLS 210 module in area that will best avoid noise problems. 3-3

16 Chapter 3 PLS 210 INSTALLATION NOTE " Due to EMI generated by power switching devices, any devices mounted in the same control panel as the PLS 210 should be located as far away as possible from PLC equipment and should have surgesuppressing devices installed on their terminals. This includes motor contactors, motor starters, and relays Standard (Analog/Vdc I/O) - Two-tiered ass'y dim's (note: secondary dim's in (brackets) are in inches) Figure 1- PLS 210 Module Dimensions 3-4

17 PLS 210 INSTALLATION Chapter System Wiring The following sections explain how to wire your PLS 210 to either an I²T or third-party resolver, among other hardware devices. The following (in order of the terminal block pins displayed on the front of the module) identifies the connections on the PLS 210 module. Top Hat (optional) RJ 45 Connector (for Setup & Configuration) RJ45 Status & Fault LEDs (2 Rows of 10) see Chapter 6 J1 Power & Resolver J2 Output J3 Input Resolver & Power Connections (J1 Top Connector) The resolver is connected to terminals 1 through 7 on the top connector. Connect the shield of the resolver to terminal 7. Make sure that terminal 7 is connected to cabinet ground, which is connected to your building ground. Scaled analog outputs can be connected to terminals 8 and 11 for Analog Output 1 or terminals 9 and 11 for Analog Output 2. A machine fault can be connected to terminals 15 and 16. Connect Amps, (recommend I²T, 24Vdc Power Supply P/N ) to terminals 17 and 18. Pin No. Signal Name Description Pin No. Signal Name Description 1 REF+ Resolver Reference + 10 NC No Connection 2 REF - Resolver Reference - 11 ANA GND Analog Common 3 SIN + Resolver Sine + 12 EARTH GND Earth Ground 4 SIN - Resolver Sine - 13 NC No Connection 5 COS+ Resolver Cosine + 14 SIG COM Signal Common 6 COS- Resolver Cosine - 15 NC No Connection 7 EARTH GND Earth Ground 16 NC No Connection 8 ANA1+ Analog Output VDC + 24 Vdc Power Connection 9 ANA2+ Analog Output 2 18 SIG COM 24 Vdc Power Supply Connection Common Table 3-1: Resolver and Power Connections (J1 Top Connector) 3-5

18 Chapter 3 PLS 210 INSTALLATION Output Connections (J2 Middle Connector) There are two groups of outputs: Sinking and Sourcing. There are eight sourcing outputs (connections 1-8 on the middle connector) that can source 24 Vdc at 1 Amp to a load. There are eight sinking outputs (connections on the middle connector) capable of sinking 250mA each. Pin No. Signal Name Description Pin No. Signal Name Description 1 OUT 1 Sourcing Output 1 10 SNK 1 Sinking Output 1 2 OUT 2 Sourcing Output 2 11 SNK 2 Sinking Output 2 3 OUT 3 Sourcing Output 3 12 SNK 3 Sinking Output 3 4 OUT 4 Sourcing Output 4 13 SNK 4 Sinking Output 4 5 OUT 5 Sourcing Output 5 14 SNK 5 Sinking Output 5 6 OUT 6 Sourcing Output 6 15 SNK 6 Sinking Output 6 7 OUT 7 Sourcing Output 7 16 SNK 7 Sinking Output 7 8 OUT 8 Sourcing Output 8 17 SNK 8 Sinking Output 8 9 COMMON Output Group Common 18 COMMON Output Group Common Table 3-2: Output Connections (J2 Middle Connector) Input Connections (J3 Bottom Connector) There are eight User Inputs that can accept a Vdc input voltage. Pin No. Signal Name Description Pin No. Signal Name Description 1 INPUT 1 Input 1 10 INCOM Input Common 2 INPUT 2 Input 2 11 NC No Connection 3 INPUT 3 Input 3 12 NC No Connection 4 INPUT 4 Input 4 13 NC No Connection 5 INPUT 5 Input 5 14 NC No Connection 6 INPUT 6 Input 6 15 NC No Connection 7 INPUT 7 Input 7 16 NC No Connection 8 INPUT 8 Input 8 17 NC No Connection 9 INCOM Input Common 18 NC No Connection Table 3-3: Input Connections (J3 Bottom Connector) 3.6. Resolver Mounting Resolvers available from I 2 T are flange mount. When controlling a piece of equipment, your mechanical system should be as stiff as possible. Ideally, the resolver shaft should be mounted directly to the part of the machine to be monitored. If you should need to interface the resolver through a gearbox, use an anti-backlash gearbox to minimize the amount of error introduced. To minimize introduced noise, run resolver cables in a separate conduit away from high power cables. I²T resolver cables are available in 25, 50, and 100-foot lengths. To build a resolver cable, you must use Belden 9730 (or exact equivalent) cable and the shields must be terminated to a ground pin. Do not terminate shields at the resolver end of the cable. Resolver cable lengths should not exceed 100 feet. The resolver cable connects to the resolver using a military-style connector (P/N MS-3106A16S-1S). To avoid problems, wire the resolver cable exactly as shown in the drawing. 3-6

19 PLS 210 INSTALLATION Chapter Resolver Connections Pin No. Signal Name Pin No. Signal Name 1 REF+ 5 COS+ 2 REF- 6 COS- 3 SIN+ 7 Earth Ground 4 SIN- Table 3-4: Resolver Connections The PLS 210 accepts a transmit-type resolver. To minimize position errors, I 2 T recommends the use of their resolvers. The PLS 210 sends a 5 khz sinusoidal reference signal to the resolver which generates a sine and cosine signal that is then returned to the PLS 210 module. The cosine signals vary with the position of the resolver shaft. A tracking Resolver-to-Digital (R-to-D) converter on the module converts the sine and cosine signals to a 16-bit position value. To read accurate, jitter-free position values from the PLS 210 module, the resolver sine, cosine, and reference signals must be kept clear of electrical noise. This is done by running the resolver wiring away from high-voltage signals and by using shielded twisted-pair cable for resolver signals. I 2 T has designed the PLS 210 module with balanced inputs for the resolver signals. This method requires more wires going to the resolver, but it also provides better noise immunity than single-ended designs. To avoid potential noise problems, resolver shields must be tied to the earth ground pin on the PLS 210 module. NOTE " Do not tie the shields to the power supply common. If the electrical environment is extremely noisy, it may be necessary to bypass the resolver signals at the connector. Do this by placing 0.1µF / 25V capacitors directly across the ref, sine, and cosine signal pairs of the resolver experiencing noise problems External ±24Vdc Supply Table 3-5 provides a list of the external 24Vdc (J1) supply signals. Pin No. Signal Name J1, Pin 17 24V J1, Pin 18 24V COM Table 3-5: External ± 24Vdc Supply An external 0.5A (or greater) power supply must be supplied to the module (available from I 2 T as P/N ). The power supply voltage is isolated from the PLC backplane and is used to generate the resolver signals and field I/O signals. If an application does not require any analog or digital I/O, the minimum power supply is adequate. Current requirements for external I/O services such as relays or lamps should be added to the minimum power supply requirements to determine the size of the supply suitable for the application. 3-7

20 Chapter 3 PLS 210 INSTALLATION 3-8

21 PLS 210 SETUP SOFTWARE Chapter 4 In this Chapter you will learn about: Installing the Software Running the Software Configuring the Module 4. Chapter 4 SETUP SOFTWARE 4.1. Installing the Software Before attempting to install the HMI Windows Setup Software on your computer, verify that your system meets the following requirements. Recommended Requirements (Installs a 32-bit Version) Pentium 90 or higher Microsoft Windows 95, 98, NT, 2000, or XP 8 MB of RAM or higher 2 MB Hard Disk (free space) or higher 3-1/2 inch floppy disk drive VGA Monitor or higher The HMI Windows Setup Software is used to configure the PLS 210 during installation. I²T includes the software with the PLS 210 High-speed Programmable Limit Switch Module on two disks (P/N ) or on a single CD. The following procedure assumes that you have installed Windows on your computer and are familiar with basic Windows terminology. You are now ready to install the HMI Windows Setup Software onto your hard disk: 1. Start Windows (WIN 95, WIN 98, WIN NT, WIN 2000 or WIN XP). 2. Insert Disk 1 of the PLS 210 HMI Windows Setup Software (P/N ) into drive a: or b: 3. Select Run from the Start menu. 4. In the Open text box, type a:\installpls.exe or b:\installpls.exe, depending on your drive. 5. Click OK or press ENTER to begin installation. 6. Enter a directory to be used for the PLS 210 HMI Windows Setup Software (default is c:\i2t). The installation will include the following files: PLS.exe P210_XXX.abs (where XXX indicates the current Firmware version). Users can program the PLS 210 module by sending low-level commands direct to the PLC (see Programming Examples in Sections 5.6.2, 5.6.3, 5.6.4, and 5.6.5). While this manual only explains those commands that are most often used, a complete summary of PLC Low-level Commands may be referenced in Appendix B of this manual. 4-1

22 Chapter 4 PLS 210 SETUP SOFTWARE 4.2. Running the Software Before proceeding, you must have successfully completed the software installation described in Section 4.1. If you have completed the installation successfully, you may now connect your PC to the PLS 210 module using an I²T RJ35 Momentum Programming Cable (P/N ). NOTE " Any Windows Setup Software function described herein can also be done in real-time by issuing low-level commands from the PLC. A list of these commands can be found in Appendix B Windows 95/98/NT/2000 Startup To begin running your PLS 210 Setup Software, start Windows 95, 98, NT or 2000 and double-click the I²T PLS icon (shown below) that you previously installed on the Windows desktop during the software installation in Section 4.1. The following screen will appear: I²T PLS Interface Unconnected 4-2

23 PLS 210 SETUP SOFTWARE Chapter 4 When you first access the PLS 210 Setup Software there is no communication between the PC and the module (I²T PLS Interface Unconnected). To connect your PC to the PLS 210, select Connect under the Communications Pull-down Menu followed by choosing the type of connection to make: Serial or Ethernet. Once you complete the setup, select OK to allow the PLS 210 Windows Setup Software to read the setup from the PLS 210 module. If the connection is successful the following General screen will appear displaying I²T PLS Interface Connected PLS 210 Module. I²T PLS Interface Connected PLS 210 Module Another way to verify that your PC is communicating with the PLS 210 is to check the front of the module to see if the left-most green LED (Module Heart Beat) on the top row is flashing. If a communications lost message occurs, check your RJ35 programming cable (I²T P/N ) connection and Serial Port Setup followed by selecting OK. After examining your RJ35 programming cable, verify that the icons on the software tool bar change from gray to color. Color indicates that your PC is communicating with the PLS 210 module. If no error is returned, your PLS 210 is communicating with the PC and you are now ready to configure the module. 4-3

24 Chapter 4 PLS 210 SETUP SOFTWARE 4.3. Configuring the Module The PLS 210 Windows Setup Software consists of a title bar with five available pull-down menus (Communications, File, Setup, Tools, and Help). This section focuses on the menus that are required to configure the PLS 210 High-speed Programmable Limit Switch Module. A quick reference guide to all the pull-down menus, along with their functions is provided in the tables that follow. NOTE " Once you finish setting up the PLS 210 parameters, save them to FLASH memory (Save Settings to Flash under the File Pull-down Menu) so they will not be lost during a power-down. Menu See Section Function Description Communications Open and close communication with the PLS 210. Connect Setup communications parameters and open a connection to the PLS 210. Disconnect Disconnect communication from the PLS 210. Table 4-1: Quick Reference to Communications Pull-down Menu 4-4

25 PLS 210 SETUP SOFTWARE Chapter 4 Menu File See Section Function Description Get and Set setup information from the module to the PC, upload/download/verify Firmware, upload/download setup information to/from the PC, save setup to FLASH memory on the module, and exit the PLS 210 Setup Software application. Get Data from Module Set Data to Module Upload Firmware Download Firmware Verify Firmware Read the PLS 210 Setup into application memory for viewing and editing. Write the PLS 210 Setup from the application to the module. Note that this function does not automatically save the setup information to Flash. Extract current Firmware from the module and save it to a file on the PC. Load a new version of Firmware from a file on the PC to the module. This should only be done when you receive a new Firmware version from I²T and the PLS 210 is not controlling a machine. Compare the current version of Firmware on the module with a version stored as a file on a PC. The module Firmware is uploaded to the PC and compared byte-by-byte against the Firmware version of the selected PC file. At the end of the comparison, a message displays a success or a failure. Upload Settings Upload the current module configuration to a file on a PC. This file has a.cfg extension. Download Settings Save Settings to Flash Exit Download a module configuration from a PC file to the PLS 210. This file has a.cfg extension. Copy the module configuration to its non-volatile FLASH memory. This allows the module s configuration to be saved during a power cycle. Shut-down the PLS 210 Setup Software and exit the application. Table 4-2: Quick Reference to File Pull-down Menu 4-5

26 Chapter 4 PLS 210 SETUP SOFTWARE Menu Setup See Section Function Description Setup the PLS 210 general parameters, limit switch parameters, and functions, along with setting up input latched and position reset functions. General Limit Switch Input Latch Set Position Enter the counts/rev, speed setup, global enable parameters, along with the analog output functions and parameters. You may use the F2 function key as a shortcut to accessing this menu item. Setup each of the PLS 210 s limit switch parameters and functions. You may use the F3 function key as a shortcut to accessing this menu item. Setup input latch functions, input de-bounce, or the position reset function. You may use the F4 function key as a shortcut to accessing this menu item. Used to set the position of the resolver. Great for establishing a known position when the last position is unknown. Table 4-3: Quick Reference to Setup Pull-down Menu Menu Tools See Section Function Description View and reset faults, force analog and digital outputs, send low-level commands to the module, and change the PLS 210 Setup Software options. Fault Status Output Control Command Log Check and reset module faults. You may use the F5 function key as a shortcut to accessing this menu item. Force digital outputs and set voltages for the analog outputs. You may use the F6 function key as a shortcut to accessing this menu item. Send low-level commands to the module. You may use the F7 function key as a shortcut to accessing this menu item. A summary of the commands may be referenced in Appendix B. Table 4-4: Quick Reference to Tools Pull-down Menu 4-6

27 PLS 210 SETUP SOFTWARE Chapter 4 Menu Help See Section Function Description Firmware Information View PLS 210 Firmware information along with information on the latest Version of Windows Setup Software that your PLS 210 is running. View the PLS 210 Firmware version and date. About PLS View the PLS 210 Setup Software revision and date. Table 4-5: Quick Reference to Help Pull-down Menu Communications Pull-down Menu Use this pull-down menu to setup communications parameters and connect to the PLS 210. It is also through this menu that a User may disconnect communication to the module Connect To connect your PC to the PLS 210, select Connect under the Communications Pull-down Menu. The following dialog box appears giving you a choice to connect using a Serial Port or by way of Ethernet. Connecting the PLS 210 with Serial Port In the Connect Using frame select the Serial Port radio button. In the Serial Setup frame select which communication port to use (1 or 2 for most computers) and the desired baud rate (9600, 19200, 28800, or 38400). Note that 9600 baud is the default for a new module. 4-7

28 Chapter 4 PLS 210 SETUP SOFTWARE Using PLS 210 with Ethernet This information will help you to connect a PLS 210 module across an Ethernet network. This method assumes that the top hat, either PLC processor, or basic communication adapter, attached to the PLS 210 has been configured with an IP address. (For more information on configuring communication adapters, see Modicon documentation.) Also, the PC that is running the PLS setup software must have its IP address and subnet mask configured such that it is on the same subnet as the PLS. (For more information about configuring your PC, see your network administrator.) A simple test to verify that your network connections are configured correctly is to ping the IP Address for the top-hat from a DOS prompt. To communicate with a PLS from the setup software, open the communications setup dialog box, from the Communications->Connect menu. Select the Ethernet radio button from the Connect Using: frame. This will activate the Ethernet Setup section of the dialog box. Enter the IP Address for the top hat in the IP Address: field. The Read Reg: and Write Reg: correspond to the starting Traffic-cop registers assigned to the PLS base. When using a communication adapter (non-plc) these registers are fixed in the top-hat to for both Read and Write. When using a PLC processor adapter, these values must be the values of the registers assigned in the PLC setup. It is important to disable communication from other sources with the PLS module when using the PLS Windows Setup Software, such as PLC programs. Since all communication must go through the Traffic-cop registers, the PLS Setup Software and other communications will all be using the same registers, and this will result in communications errors Completing the Serial or Ethernet Connection When you have completed the Serial or Ethernet setup, select OK. If the connection between the PC and the PLS 210 cannot be established, an Unable to connect to device! message appears. If this occurs, check all connections to the PLS 210. Make sure the right Serial Port is selected and verify that the Serial Setup communications are properly configured. Once you successfully connect to the PLS 210 module, a General screen appears. This screen is the default screen and is described in detail under the Setup Pull-down Menu. This screen is divided into two separate but related sections: Module Status (Left Pane) and Parameter Setup (Right Pane). NOTE: The Module Status pane (left-side) is present for all Pulldown Menu options. See Section Disconnect Select the Disconnect menu item when you wish to close communications to the PLS 210 module. 4-8

29 PLS 210 SETUP SOFTWARE Chapter File Pull-down Menu The following is a detailed description of the File Pull-down Menu selections Get Data from Module Select this option to read PLS 210 setup information into the application memory for viewing and editing. When selected, a progress bar will indicate Read setup from Module. Once the setup is complete the General screen will appear Set Data to Module Use this option to write setup information from the application to the module. This menu item will display two progress screens: Write Setup to Module, and Read Back Setup from Module. Note that this option does not automatically save the setup data to flash. To save the information to non-volatile memory, select Save Settings to Flash Upload Firmware When you select Upload Firmware, the following dialog box appears. Select the folder to store the Firmware file under. In the File name field, enter the name of the Firmware file that you want to upload. Press Save to start the upload. If the upload is successful, an Upload Successful message appears. 4-9

30 Chapter 4 PLS 210 SETUP SOFTWARE Download Firmware Use Download Firmware to load a new version of Firmware from a file on the PC to the PLS 210 module. When Download Firmware is selected, the following dialog box appears. Select the folder under which you want the new Firmware file to be saved. Double-click the new Firmware file or enter the name of the file in the File name field. Press Open to start the download. If the file download is successful, a Download Successful message appears Verify Firmware This option should be selected when you want to compare the current running version of Firmware on the PLS 210 module with another version stored as a file on a PC. When Verify Firmware is selected, the following dialog box appears. Select the folder that contains the Firmware file that you want to compare. Double-click this file or enter the name of the Firmware file in the File name field. Press Open to start the file compare. The module firmware is uploaded to the PC and compared byte-by-byte against the Firmware version of the selected PC file. If the file compare is successful, a Verify Successful message appears. 4-10

31 PLS 210 SETUP SOFTWARE Chapter Upload Settings Upload the current module configuration (.cfg) to a file on a PC. When Upload Settings is selected, the following dialog box appears. Select the folder where you want to save the PLS 210 configuration. Doubleclick on an existing file or enter a new file name in the File name field. Press Save to start the configuration upload. If the configuration upload is successful, a Setup Upload Successful message appears Download Settings Choose this menu item when you want to download a module configuration from your PC file to the PLS 210 module. When Download Settings is selected, the following dialog box appears. Select the folder that identifies where you want to save the PLS 210 configuration file. Double-click the file to start the configuration download. If the configuration downloaded successfully, a Setup Download Successful message appears. 4-11

32 Chapter 4 PLS 210 SETUP SOFTWARE Save Settings to Flash To save the PLS 210 configuration settings so that they are not lost during a power cycle, select the Save Settings to Flash menu item. Note that this menu option does not yield a screen or dialog box of any kind Exit This menu item allows the User to shut down the PLS 210 HMI Windows Setup Software and exit the application. There are no screens associated with this function Setup Pull-down Menu (Global Parameter Setup) As noted earlier, if you are successful at connecting to the PLS 210 module, the following General screen appears. This is the default General menu item under the Setup Pull-down Menu General [F2] The General screen is divided into two separate but related sections: Module Status and Parameter Setup. Each side of the screen is described in more detail on the pages to follow. Parameter Setup (Right Pane) Module Status (Left Pane) 4-12

33 PLS 210 SETUP SOFTWARE Chapter 4 Module Status Left Pane of General Screen The status of the PLS 210 is displayed on the left side of the screen. The details of this pane are described below: Parameter Position Abs Res Speed Setup Modified Fault Input Switch Output Description The Position is displayed in User Counts per Revolution of the resolver. This value will be between 0 and the value set in the Counts per Revolution field displayed on the right side of the screen. Absolute Resolver is the position in resolver counts. The Speed is displayed in User Units that are setup in the Speed Feedback Configuration frame on the right side of this screen. This indicator implies that the PLS 210 observed changes to the application setup. To save the information to non-volatile memory, select Save Settings to Flash under the File Pulldown Menu. If a fault is present on the module, the red Fault indicator will be on (bright red). Double click this indicator to clear the fault when the cause of the fault has been resolved. To view the fault status, press F5 or select the Fault Status menu item under the Tools Pull-down Menu. The state of the eight digital inputs (blue) are displayed within the Input frame on the left side of the screen. You may configure the function of each digital input using the Input Latch screen located under the Setup Pull-down Menu. Current switch status. The sixteen limit switches (green) are displayed within the Switch and Output frames. The mode of operation is configured on the Configure Limit Switch dialog box found in the Setup Pull-down Menu. State of the output. The sixteen outputs (red) are displayed within the Switch and Output frames. The mode of operation is configured on the Configure Limit Switch dialog box found in the Setup Pull-down Menu. 4-13

34 Chapter 4 PLS 210 SETUP SOFTWARE Parameter Setup Right Pane of General Screen The global setup parameters are displayed on the right side of the General setup screen. General Screen Feedback Configuration Frame In the Feedback Configuration frame, the User can set the Counts per Revolution of the resolver. Set this value between 1 and This is the number where the position will rollover to zero when the resolver rotates one revolution (one cycle). Example: To display position in degrees, with a resolution of 1/10th of a degree, enter a value of 3600 in the Counts per Revolution field. The position will rollover to zero after it exceeds When the resolver is moving in the clockwise (CW) direction, looking at the shaft of the resolver, the value in the Position field (left side of the screen) will count up. If you want this value to count down when the resolver is turning clockwise (CW), check the Swap Direction checkbox. 4-14

35 PLS 210 SETUP SOFTWARE Chapter 4 Global Enable Configuration Frame The Global Enable Configuration frame determines how all of the limit switches will react to the Global Configuration function if their Use Global Enable checkbox is checked in the Configure Limit Switch dialog box. Use Global Enable checkbox and related Conditions: Always Enabled, Software Control, Speed Range, and By Input. The following is a table of the Global Enable Conditions (radio button options shown above) and a description of its Function when the Use Global Enable checkbox is checked (see Configure Limit Switch dialog box under the Setup Pull-down Menu). NOTE " The Switch Active button, that appears at the top of the Configure Limit Switch dialog box, must be on for the Global Enable function to operate. NOTE " Use Global Enable is an And function where each Global Enable Condition will occur based on whether it is enabled or disabled. 4-15

36 Chapter 4 PLS 210 SETUP SOFTWARE Global Enable Condition Always Enabled Software Control Speed Range By Input Function Description When this radio button is selected, the limit is active. When selected, the PLC or PLS 210 Setup Software, via a low-level command controls the global enable of the limit switch. Use the Toggle Global Enable button to turn the global enable off and on. When selected, the User can set a Low and High Speed range to enable/disable the limit switch. When the speed of the resolver is between the Low and High speed settings, the limit switch will enable. When the speed is below the Low speed or above the High speed settings, the limit switch will disable. When selected, the limit switch will be enabled or disabled by the state of the selected Input 1 through Input 8. Speed Feedback Configuration Frame In the Speed Feedback Configuration frame, the User can select the speed units and the scaling for these units. The units are selected from the Mode list. The choices are shown below: The scaling factor is selected from the Scale list. Since the resolution is an integer value it is sometimes difficult to for the User to visualize. Selecting one of the scale factors in the list (above) will scale the resolution up or down, depending on what scale factor you choose, for better viewing. You may filter the displayed speed by setting a value (in milliseconds) in the Avg. Time field. This is the time that the speed will be averaged over before it is displayed in the Speed field located on the Module Status (left side) part of the General screen. 4-16

37 PLS 210 SETUP SOFTWARE Chapter 4 Analog Output Modes Frame The value of the two analog outputs (Analog Output 1 and Analog Output 2) are controlled by the functions and values set in the Analog Output Modes and Speed Reference frames located on the right side of the General screen. The Analog Output Modes frame has four functions, displayed below. The User can send a low-level 2011 Set Analog Outputs command by selecting the User via 2011 option from the list. When the 2011 command is selected, the PLC or the PLS 210 Setup Software may set the value of an analog output. This is done by writing the 2011 command to the first Traffic Copped (I/O Mapped) register of the PLS 210 along with the raw analog output settings in the next two registers (see PLC Programming in Chapter 5). Selecting the User via Registers option from the list allows the User to write to an Analog Channel from the PLC. The user enters a value in the 4 th Trafficcopped register in the PLC to set the voltage for the Channel 1. Setting a value in the 5 th Traffic-copped register sets the voltage for Channel 2. This range is ±10 Volts with 0 being 10V, 8192 being 0 Volts, and being +10 Volts. By selecting Speed Reference, the value of the Analog Output (between 0 and 10Vdc) will be scaled between the Low Spd (0V) and High Spd (10V) settings in the Speed Reference frame. The following example shows the effect of the Low Speed and High Speed values on the analog output. The user units are in RPM. Setting the Low Spd (0V) to 10 and the High Spd (10V) to 1000 will cause the analog output to react as shown in the following graph. 10V Analog Voltage 0V 10 RPM 1000 RPM Actual 4-17

38 Chapter 4 PLS 210 SETUP SOFTWARE When the resolver is turning at a speed less than 10 RPM, the analog output voltage will be zero. Between 10 and 1000 RPM, the analog output will be scaled to a voltage between 0 and 10 volts. At speeds above 1000 RPM, the analog output will remain at 10 volts. If Position Reference is selected from the list, the value of the Analog Output, between 0 and 10Vdc, will be scaled between 0 and the value set in the Counts per Revolution field located in the Feedback Configuration frame (above). The Analog Output will rollover to 0V when the position value rolls over to zero. IMPORTANT " Save the new setup to the PLS 210 memory by selecting Set Data to Module from the File Pulldown Menu Limit Switch [F3] To configure the sixteen individual limit switch parameters, select the Limit Switch menu item, under the Setup Pull-down Menu. This screen displays the PLS 210 Module Status information on the left side of the screen along with the sixteen individual limit switch configurations on the right side. The PLS 210 Module Status information is described in Section The Limit Switch screen is shown below. Details about setting up the limit switches appear on the following page. 4-18

39 PLS 210 SETUP SOFTWARE Chapter 4 The following table describes each column on the Limit Switch Setup page. Parameter Range Description Sw# NA The switch number and status appear under this column. If the switch is active, the indicator to the left of the number will be bright green. If the switch is inactive, the indicator is grayed out. Global Use or Ignore If the Use Global Enable check box is checked in the Configure Limit Switch dialog box, Use appears in this column. If the Use Global Enable checkbox is not checked, Ignore appears under this column. Output Src 1-8, Snk 1-8 A physical PLS 210 output that will turn On and Off for the selected limit switch. Low High 0 - Counts per Revolution 0 - Counts per Revolution The position value (counts/rev) where the limit switch will turn On. If this value exceeds the rollover value, the switch is ignored. The position value (counts/rev) where the switch will turn Off, if rotating CW. If this value exceeds the rollover value, the switch is ignored. Pulse Time milliseconds Time (in milliseconds) that the output will be on after the resolver enters the On/Off range of the limit switch. This parameter is only active when Pulse Mode is on. Off Mode Range Only Time & Range There are two conditions for turning Off the limit switch s output after entering its Low/High position range (in User Units). Off after the Pulse Time value is exceeded or Off after either the Pulse Time is exceeded or the Position is not in the Low/High range setting of the limit switch. This parameter is only active when the Pulse Mode is on. Speed Comp milliseconds Speed Compensation (in milliseconds). The value entered is the response time of the device that is being controlled by the limit switch output. 4-19

40 Chapter 4 PLS 210 SETUP SOFTWARE To change the configuration of a specific limit switch (1-16), double-click on the limit switch. The following Configure Limit Switch dialog box appears. Switch Active button Switch Active Range frame To make a limit switch active, click on the Switch Active button at the top of the Configure Limit Switch dialog box so that the bar on the bottom turns green. Note that if the switch is not active (or enabled), the PLS 210 will not set the corresponding limit switch output. When the Use Global Enable check box is checked (enabled), the limit switch will be active based on the function checked in the Global Enable Configuration frame of the General screen (shown above). If Use Global Enable is not checked, the limit switch will always be active, no matter what state the Global Enable Configuration function is in when it is enabled (checked). In the Switch Active Range frame of the Configure Limit Switch dialog box, set the Low and High position values (User Units) for the limit switch. Any time the resolver is between these values, the limit switch will be On (active). These values can be set between 0 and the Counts per Revolution value set in the Feedback Configuration frame of the General screen (above). Values beyond the defined Counts per Revolution (set in the Feedback Configuration frame) will cause the switch to be ignored. In the Use Digital Output list (above), select the output that will be used for the limit switch. This can be one of the eight sinking outputs, eight sourcing outputs, or no output (none). It doesn t matter if no output is selected because the state of the limit switch is still reported back to the PLC. 4-20

41 PLS 210 SETUP SOFTWARE Chapter 4 The output of the limit switch can be pulsed on for a specific amount of time after it enters the Low/High range by selecting the Enable checkbox and entering a time (between 0 and milliseconds) in the Pulse Time field in the Pulse Mode frame of the Configure Limit Switch dialog box. If the Pulse time and range radio button is selected, the output will turn Off when the Pulse Time has timed out or when the resolver is out of the Low/High range of the limit switch. If the Pulse time only radio button is selected, the output will turn Off (disabled) after the Pulse Time has timed out. Note that the output turns On when the resolver enters the active range (Low or High) of the limit switch. To enable Speed Compensation, select the Enable checkbox in this frame and enter a value between 0 and milliseconds. This is the response time of the device that the output is controlling. The PLS 210 will calculate different On/Off positions for the limit switch based upon the resolver speed and the value entered (in msec) for the Speed Compensation Time (device response time). Select OK to accept these changes. IMPORTANT " Save this new setup to the PLS 210 memory by selecting Set Data to Module from the File Pulldown Menu Input Latch [F4] When the Input Latch menu item is selected, under the Setup Pull-down Menu, the following screen appears. 4-21

42 Chapter 4 PLS 210 SETUP SOFTWARE There are eight User Inputs that can be configured to either: Latch the position (one shot) of the resolver Latch the position continuously Set the position of the PLS 210 to a value or, perform no function (none). Latch Position Mode To setup the input to latch (capture) the position (in User Units), select the Latch Position option from the Mode list. Choose the Active state (Low or High) of the input that will latch the position. If you want the position to latch when the input goes from a high-to-low state, choose the Low option under Active. If you want the position to latch when the input goes from a low-to-high state, choose the High option under Active. The following will help to explain how to latch position. 4-22

43 PLS 210 SETUP SOFTWARE Chapter 4 Setup an Input to Latch a Position, Using Latch Position Mode If the input was setup to be Active Low, make sure the state of the physical input is High. Arm the latch position function by clicking on the input s Active indicator in the Latched Pos frame on the right side of the screen. Note that the Latch Position (capture) function of the PLS 210 can also be armed from the PLC by using the 2031 Arm Digital Input Capture Mode for Mode 1 of the 2030 Set Digital Input Mode command and the input number (0 to 7). See the PLC Low-level Command Set in Appendix B. The input s Active indicator will turn bright green. When the input changes state, the position will be latched and its latched value will be displayed in the input s Position field in the Latched Pos frame on the right side of the screen. At the same time, the input s Latch Count value will increment by one and the Active indicator will turn Off (dark green). In the Latch Position mode, the input will not latch the position until it is armed from the PLS 210 Setup Software or the PLC, no matter how many times the input changes state. To prevent the input from latching the position when the input state bounces, enter a Debounce Time (in milliseconds) in the Setup frame. The PLC can read the latched position, armed state, and trigger count with the 1031 Get Latched Position command and the input number (0 to 7). 4-23

44 Chapter 4 PLS 210 SETUP SOFTWARE Latch Position Continuous Mode To latch the position every time the input changes state, select the Latch Pos Cont. option under Mode in the Setup frame. Select the Active state (Low or High) and enter a denounce time (in milliseconds) as explained earlier. Choose the Active state (Low or High) of the input that will latch the position. If the Active parameter is set to Low, a new position (in User Units) will be latched (captured) every time the input transitions from a high-to-low state. The input s Active indicator will be bright green when the input is in the High state. If the Active parameter is set to High, a new position (in User Units) will be latched (captured) every time the input transitions from a low-tohigh state. The input s Active indicator will be bright green when the input is in the Low state. When the input changes state, the position will latch and its latched value will display in the input s Position field in the Latched Pos frame. At the same time, the input s Latch Count value in the Latched Pos frame will increment by one and the Active indicator will turn Off (dark green). To clear the Latch Count values, double-click on the input s Latch Count field in the Latched Pos frame. To clear Latch Count from the PLC, use the 2033 Reset Digital Input Counter command with the input number (0 to 7). A complete list of the PLC Low-level Commands appears in Appendix B. IMPORTANT " Save your new setup to the PLS 210 memory by selecting Set Data to Module from the File Pulldown Menu. 4-24

45 PLS 210 SETUP SOFTWARE Chapter 4 Set Position to: Mode To have the PLS 210 set the position to a value when the input is activated, select Set Position to in the Setup frame. This activates the parameter box. Enter a value, in the Parm field, between 0 and the Counts per Revolution value set in the Feedback Configuration frame on the General screen under the Setup Pull-down Menu. This is the value that the position will be set to when the input transitions state. Select Active state (Low or High) and enter a debounce time, explained earlier. IMPORTANT " Save this new setup to the PLS 210 memory by selecting Set Data to Module from the File Pulldown Menu. If the Active state of the input is set to Low and the Parm value is set to 100 User Units, the position will be set to 100 User Units when the input state transitions from high-to-low. CAUTION! If the input s Active state is set Low and the physical state of the input is Low, the position of the PLS 210 will be set to the Parm value as soon as the Set Data to Module menu item is selected from the File Pull-down Menu. 4-25

46 Chapter 4 PLS 210 SETUP SOFTWARE Set Position To establish a recognized or known position for the axis, select the Set Position option from the Setup Pull-down Menu. The following screen appears: The value that is entered into the New Position field will assume the units set in the Speed Feedback Configuration frame of the General screen Tools Pull-down Menu There are three menu options under the Tools Pull-down Menu. Each item is described below Fault Status [F5] To view the PLS 210 faults, select the Faults Status menu item under the Tools Pull-down Menu or press F5. The following screen appears. 4-26

47 PLS 210 SETUP SOFTWARE Chapter 4 Module Faults The Module Faults frame includes the most common faults that may occur on the module. Below is a list of the PLS 210 module faults. Flash Memory Fault PROBLEM/CAUSE Module failure on flash device. SOLUTION Contact your I²T distributor. Flash Memory Defaulted PROBLEM/CAUSE Module is in a default state. Note: Modules are shipped in this state. SOLUTION User must configure the module to clear this status. Note: This is a good indication of an un-programmed module. PLC Command Error PROBLEM/CAUSE PLC issued an invalid or unknown command to the PLS 210 module. Registers designated for the module are being un-initialized or used for other purposes. SOLUTION Ensure valid module command data is present in these registers and no other logic is writing to the I/O Mapped Registers. This fault remains latched until cleared by the 1001 Get Fault/Status Codes command and will not prevent operation while active. For a complete list of PLC low-level commands, see Appendix B. 4-27

48 Chapter 4 PLS 210 SETUP SOFTWARE Serial Command Error PROBLEM/CAUSE PC issued an invalid or unknown command to the PLS 210 module via the serial port. Cause may be communication failure due to faulty cables or from removing the serial connection while communicating. Note: A complete list of PLC Low-level Commands appears in Appendix B of this manual. SOLUTION Ensure serial cable is in good condition and well secured to the module and PC. Note: This fault remains latched until cleared by the 1001 Get Fault/Status Codes command and will not prevent operation while active. Note: If communicating at higher baud rates and this error frequently occurs, try choosing a lower baud rate. Serial Checksum or Timeout Error PROBLEM/CAUSE Module received corrupt data from the PC via the serial port. May be caused by communication failures due to faulty cables or by removing the serial connection while communicating. SOLUTION Ensure serial cable is in good condition and well secured to the module and PC. Note: This fault remains latched until cleared by the 1001 Get Fault/Status Codes command and will not prevent operation while active. Note: If communicating at higher baud rates and this error frequently occurs, try choosing a lower baud rate. Code Checksum Failure PROBLEM/CAUSE Failure on startup self check of Firmware code. SOLUTION Re-download Firmware and Setup to the module. If this re-occurs, contact your I²T distributor. 4-28

49 PLS 210 SETUP SOFTWARE Chapter 4 Setup Changed PROBLEM/CAUSE When active, the User has modified module settings that were not stored in Flash memory. The settings will be lost on a power-down. SOLUTION To clear this indicator, save the setup to Flash. When active, any changes to the setup since the last power-up or save will be lost when the module is reset. Resolver Status Below is a list of the Resolver conditions that appear in the Resolver Status frame. Resolver Ok PROBLEM/CAUSE This is not truly a problem, but will assure you (bright green) that the resolver connected to the PLS 210 is functioning properly. SOLUTION Move on to other possible faults that may be present on the resolver. Bad Latched PROBLEM/CAUSE When on (bright red), the module latched an instantaneous resolver fault. A wire may be broken or noise interrupted the signal. SOLUTION Check all resolver wiring and connections. 4-29

50 Chapter 4 PLS 210 SETUP SOFTWARE Open Wire PROBLEM/CAUSE When on (bright red), the PLS 210 senses that one of the wires (sine, cosine, or reference) is open. SOLUTION Check all wiring to the module terminal connections. Do not place any intermediate terminal connections between the resolver and the PLS 210. Range Error PROBLEM/CAUSE When on (bright red), the auto sensing circuit of the PLS 210 cannot detect a connected resolver. Verify the resolver is OK and within the allowable electrical specifications. SOLUTION Check all connections and verify that the length of the cable is within the allowable limit (150 feet or meters for #18 gauge wire). NOTE " Pressing the Reset Faults button will reset the PLS 210 fault if it has been cleared. 4-30

51 PLS 210 SETUP SOFTWARE Chapter Output Control [F6] To view the PLS 210 Output Control screen, select the Output Control menu item under the Tools Pull-down Menu. The following screen appears. 4-31

52 Chapter 4 PLS 210 SETUP SOFTWARE Forcing Digital Outputs From this screen, the User can control the two analog outputs (Analog Output 1 and Analog Output 2) and the sixteen digital outputs (Eight Sourcing and Eight Sinking). To use one of the digital outputs, make sure that it is not controlled by any of the sixteen programmable limit switches. See the Limit Switch screen under the Setup Pull-down Menu. Make sure the output to be tested is not configured in the Output column of the Limit Switch screen of the Setup Pull-down Menu. If the output has not been configured, single-click on the output to change its state. In the Configure Limit Switch dialog box, select None in the Use Digital Output field. Select the OK button. Under the File Pull-down Menu select Set Data to Module to save the changes to the PLS 210 memory (data saved to the module in this way is not preserved in the case of a power cycle see Save Settings to Flash in the File Pull-down Menu). Return to the Output Control screen under the Tools Pull-down Menu. Turn on the output with a single mouse click on the output s switch (Source 1-8 or Sink 1-8) in the Digital Outputs frame of this screen. The physical output will turn on. The green indicator on the output s switch and the output s red indicator on the left side of this page will also turn on (bright).testing Analog Outputs To test an Analog Output, make sure it is not being controlled by the PLC or configured by the PLS 210 to represent the position or speed of the resolver. On the General screen under the Setup Pull-down Menu, select the User via 2011 for the Analog Output, in the Analog Output Modes frame. Under the File Pulldown Menu select the Set Data to Module option to save the changes to the PLS 210 memory. Return to the Output Control screen. Drag the analog output s arrow on its dial indicator to the desired output voltage. Note the analog output s voltage is displayed on the indicator and in the Analog Out field on the left side of the General screen. Once you select the analog indicator, use the right and left cursor keys to raise and lower the analog voltage by 0.1 volts. IMPORTANT " Return the analog outputs and digital outputs to their previous configuration before closing the PLS 210 Setup Software. Make sure that you save the configuration to the PLS 210 nonvolatile memory by selecting the Save Settings to Flash option under the File Pull-down Menu. 4-32

53 PLS 210 SETUP SOFTWARE Chapter Command Log [F7] By selecting the Command Log menu item from the Tools Pull-down Menu, the following screen appears. This screen allows a User the ability to send low-level commands directly. It is helpful in debug and development. A Send Data dialog box (shown below) pops up allowing the User to enter the low-level data. An example of a command sent in this way may be entered (left to right) as: W1 W2 W3 W Blank Blank Blank This command would return the version of Firmware running on the PLS 210. For a complete list of PLC Low-level Commands, see Appendix B. Data sent appears on the left under Write Registers, while the received data appears on the right under Read Registers. Data may be displayed in Decimal or Hexadecimal format by toggling the Display Hex button. When in Hex mode, the indicator will be lit (bright green). Use the Clear Log button to erase all commands from the screen. 4-33

54 Chapter 4 PLS 210 SETUP SOFTWARE Help Pull-down Menu The following is a description of the Help Pull-down Menu options Firmware Information Selecting the Firmware Information option from the Help Pull-down Menu provides the User with the Version of Firmware that is running along with the date and time that corresponds to the last time that I²T updated the Firmware version About PLS By selecting the About PLS menu item from the Help Pull-down Menu will return the Software version that is running on the PLS 210 module as well as data on how to contact I²T. 4-34

55 PLS 210 PLC PROGRAMMING Chapter 5 In this Chapter you will learn about: PLC Programming I/O Mapping the Module Peer-Copping the Module PLS 210 to PLC Communications Testing 5. Chapter 5 PLC PROGRAMMING 5.1. PLC Programming The PLS 210 Momentum High-speed Programmable Limit Switch Module can be used with any Schneider Electric Momentum processor or communication adapter. This allows the PLS 210 to be I/O mapped into any Momentum, Quantum, or E series slot mount PLC network. NOTE " The PLS 210 does not need a PLC to operate. The module can operate in a stand-alone mode. This section only applies to User s who are connecting the PLS 210 to a PLC I/O Mapping the Module Knowledge of programming the Momentum and the Schneider Electric line of PLCs is critical to properly install and program the PLS 210 module. The procedures in the following sections may vary based on the type and version of programming software and PLC hardware used. The PLS 210 is I/O mapped (Traffic Copped) as an AEC High-Speed Counter module that uses eight binary (BIN) bi-directional registers (4xxxx and 3xxxx). The following screens are examples of how the PLS 210 is I/O mapped using different PLC programming packages: Screen 5-1: I/O Mapped using Taylor ProWorx Plus PLC Programming Software 5-1

56 Chapter 5 PLS 210 PLC PROGRAMMING Screen 5-2: I/O Mapped using Taylor ProWorx NxT Programming Software Screen 5-3: I/O Mapped using Schneider Electric Concept Programming Software 5-2

57 PLS 210 PLC PROGRAMMING Chapter Peer-Copping the Module The following is an example of peer-copping the PLS 210 in a Modbus Plus network. The PLS 210 can be used with a Modbus Plus communication adapter in a Quantum, an E series slot mount, or a Momentum Modbus Plus (MB+) network. This example uses Schneider Electric s ProWorx NxT programming software to peer-cop the PLS 210 as specific I/O on Address 2 on the MB+ network. After the PLS 210 module is peer-copped, the PLC program can send commands and observe the status of the module. Screen 5-4: Set Configuration Extension Size to for one MB+ Node under the General Tab of the Controller Configuration Box. Extra Nodes require additional words. Screen 5-5: Select Add Extension Under Configuration Dialog Box 5-3

58 Chapter 5 PLS 210 PLC PROGRAMMING Screen 5-6: Select Peer Cop in the Add Configuration Dialog Box Screen 5-7: Configuration Dialog Box from Selecting Peer Cop 5-4

59 PLS 210 PLC PROGRAMMING Chapter 5 Screen 5-8: Select Specific I/O, Select 2 in Specific Output Field, then Select Edit Screen 5-9: Enter 8 in Length Field. In Reference Field enter the starting 4xxxx Register for 8 consecutive registers that will Peer-cop as specific I/O to the PLS 210. Press OK after entering data. 5-5

60 Chapter 5 PLS 210 PLC PROGRAMMING Screen 5-10: Select Specific I/O, Select 2 in Specific Input Field, then Select Edit Screen 5-11: Enter 8 in Length Field. In Reference Field, Enter Starting 3xxxx Register for 8 Consecutive Registers that will Peer-cop as Specific I/O to the PLS 210. Press OK after entering data. 5-6

61 PLS 210 PLC PROGRAMMING Chapter 5 Screen 5-12: Configuration Extension dialog box Should Appear as Above. Press OK to Peer-cop the PLS 210 Module as Address 2, Specific I/O as Registers and in the Modbus Plus Network. Note that Seventeen Words were Used in Configuration Extension After I/O Mapping the PLS 210, put the PLC in the RUN state and verify that the PLS 210 LEDs (see Chapter 6 on Troubleshooting) are in the following state: 1. Ensure that the PLS 210 Module Heartbeat (Top Row, LED 1) is blinking. 2. Ensure that the PLS 210 module PLC Communication Active (Top Row, LED 3) is on. 3. Ensure that the following fault LEDs are NOT on. o Serial Communication Fault (Bottom Row, LED 7) o PLC (Command) Fault (Bottom Row, LED 8) 5-7

62 Chapter 5 PLS 210 PLC PROGRAMMING I/O Map Register Description The PLS 210 is I/O mapped as an AEC High Speed Counter module that uses eight binary (BIN) bi-directional registers (4xxxx and 3xxxx). The first 4 input and 4 output registers are used to send and receive commands and data back and forth between the PLC and the PLS 210 module. Read registers 5 through 8 are used to report the position and status of the PLS 210 module. Write registers 5 and 6 are used to set the value of the analog channels 1 and 2. The following tables describe the registers and status register bits I/O Mapped Registers Register Description Register Description 4xxxx+0 Command Register 3xxxx+1 Echo Register 4xxxx+1 Data to PLS 210 3xxxx+2 Data from PLS 210 4xxxx+2 Data to PLS 210 3xxxx+3 Data from PLS 210 4xxxx+3 Data to PLS 210 3xxxx+4 Data from PLS 210 4xxxx+4 Analog Out 1 (if configured) 3xxxx+5 Position (in User Units) 4xxxx+5 Analog Out 2 (if configured) 3xxxx+6 Limit Switch Status 4xxxx+6 Reserved 3xxxx+7 Digital Output Status 4xxxx+7 Reserved 3xxxx+8 Digital Input & Module Status Table 5-1: I/O Mapped Registers NOTE " Analog registers 4xxxx+4 and 4xxxx+5 allow the PLC to write a value to the analog output channels, if configured via the 2011 option in the Analog Output Mode section of the General screen under the Setup Pull-down Menu of the PLS 210 Setup Software (see Analog Output Mode Section , Page

63 PLS 210 PLC PROGRAMMING Chapter Limit Switch & Output Register Bits Limit Switch Register 3xxxx+6 Digital Output Register 3xxxx+7 MASK BIT Description BIT Description 8000 Bit 1 Switch 16 Bit 1 Output Bit 2 Switch 15 Bit 2 Output Bit 3 Switch 14 Bit 3 Output Bit 4 Switch 13 Bit 4 Output Bit 5 Switch 12 Bit 5 Output Bit 6 Switch 11 Bit 6 Output Bit 7 Switch 10 Bit 7 Output Bit 8 Switch 9 Bit 8 Output 9 80 Bit 9 Switch 8 Bit 9 Output 8 40 Bit 10 Switch 7 Bit 10 Output 7 20 Bit 11 Switch 6 Bit 11 Output 6 10 Bit 12 Switch 5 Bit 12 Output 5 8 Bit 13 Switch 4 Bit 13 Output 4 4 Bit 14 Switch 3 Bit 14 Output 3 2 Bit 15 Switch 2 Bit 15 Output 2 1 Bit 16 Switch 1 Bit 16 Output 1 Table 5-2: Limit Switch & Output Register Bits Digital Inputs / PLS 210 Status Register 3xxxx+7 MASK BIT Description MASK BIT Description 8000 Bit 1 Resolver Fault 80 Bit 9 Input Bit 2 Reserved 40 Bit 10 Input Bit 3 Reserved 20 Bit 11 Input Bit 4 Reserved 10 Bit 12 Input Bit 5 Reserved 8 Bit 13 Input Bit 6 Reserved 4 Bit 14 Input Bit 7 Reserved 2 Bit 15 Input Bit 8 Reserved 1 Bit 16 Input 1 Table 5-3: Input & Status Register Bits 5-9

64 Chapter 5 PLS 210 PLC PROGRAMMING 5.6. PLS 210 to PLC Communication Test Start up the PLC programming software package (Schneider Electric s ProWorx Plus, ProWorx NxT, or Concept). Schneider ProWorx NxT version 2.20 is used for the following examples. Go online and bring up a Data Watch Window under the Data menu. Bring up the eight I/O mapped Read and Write registers of the PLS 210 module. Enter a command in the first I/O mapped Write register to the PLS 210 (see Appendix B for a list of PLC Low-Level Commands). For example, enter 1020 Get Current Positions in User Units into the first I/O mapped register of the PLS 210 (see example below) PLC Communication Test Example In this example, the PLS 210 is I/O mapped from and A 1020 Get Current Positions in User Units command was placed into The echo of the 1020 command appears in Register The position in User Units (a value between 0 and the Counts per Revolution as entered on the General screen of the PLS 210 Setup Software) is displayed in Register The resolver s absolute position (a value between 0 and 65535) is displayed in Register The speed (in User Units) is displayed in Register Registers through report the position, limit switch status, output status, and input and module status as described above. 5-10

65 PLS 210 PLC PROGRAMMING Chapter PLC Programming Example (Get Position & Speed) The following is a programming example of sending a 1020 Get Current Positions in User Units command to the PLS 210. When input goes high, the 1020 command is loaded into Register with the use of the SUB block. When registers and are equal, with the use of the TEST block, the values in registers through are block moved, with the BLKM block, to registers through Register holds the position (in User Units) of the PLS 210, Register holds the absolute value of the resolver, and Register holds the speed of the resolver in User Units. See Appendix B for a complete list of PLC Low-level Commands. Registers through report the position, limit switch status, output status, and input and module status as described above. These registers can also be block moved to a set of four holding registers. Command 1020 Get Current Positions in User Units 5-11

66 Chapter 5 PLS 210 PLC PROGRAMMING PLC Programming Example (Clear Module Faults) The following is a programming example for sending the 1001 Get Fault/Status Codes command to the PLS 210 module. When input goes high, a 1 is loaded into Register with the use of the SUB block. This value is the data that the 1001 command will use to clear the PLS 210 faults. If this value is a 0, the faults will not be cleared. NOTE " When a command needs to send data to the PLS 210, in the logic, the data needs to precede the command. The 1001 Get Fault/Status Codes command is loaded into Register with the use of the SUB block. When registers and are equal, with the use of the TEST block, the values in registers through are block moved, with the BLKM block, to registers through Register holds the PLS 210 module Status/Faults bits (see Table T1 in Appendix B), register holds the Resolver Status (see Table T5), and Register holds the module echo. See the 1001 Get Fault/Status Codes command in Appendix B. Command 1001 Get Fault/Status Codes 5-12

67 PLS 210 PLC PROGRAMMING Chapter PLC Programming Example (Set Current Position in UU) The following is a programming example that sends a 2020 Set Current Position in User Units command to the PLS 210 module. When input goes high a 100 is loaded into Register with the use of the SUB block. This is the position value in User Units that the PLS 210 will be set to when input goes high. The position must be set to a value between 0 and the value set in the Counts per Revolution field entered on the General screen of the PLS 210 HMI Windows Setup Software. NOTE " When a command needs to send data to the PLS 210, in the logic, the data needs to precede the command. The 2020 Set Current Position in User Units command is loaded into Register with the use of the SUB block. When registers and are equal, with the use of the TEST block, coil is turned on indicating that the PLS 210 s position has been set to 100 User Units. Command 2020 Set Current Position in User Units 5-13

68 Chapter 5 PLS 210 PLC PROGRAMMING PLC Programming Example (Setup Speed Monitoring) The following is a programming example that sends a 2071 Setup Speed Monitoring command to the PLS 210 module. When input goes high a 2 is loaded into Register 40002, a 3 is loaded into Register 40003, and a 100 is loaded into Register with the use of the SUB block. Register values for command 2071 appear in Appendix B. The 2 represents Degrees/Second, the 3 represents a scale factor of 10, and the 100 represents a Speed Averaging time of 100 milliseconds. NOTE " When a command needs to send data to the PLS 210, in the logic, the data needs to precede the command. The 2071 Setup Speed Monitoring command is loaded into Register with the use of the SUB block. When registers and are equal, with the use of the TEST block, coil is turned on indicating that the PLS 210 s Speed Setup is completed. Command 2071 Setup Speed Monitoring 5-14

69 PLS 210 TROUBLESHOOTING Chapter 6 In this Chapter you will learn about: Troubleshooting Procedures Diagnostic LEDs PLC Diagnostics 6. Chapter 6 TROUBLESHOOTING 6.1. Troubleshooting Procedure The information in this chapter will help you isolate and resolve system hardware and software problems. When your system does not function properly (or as you expect it to operate), the first thing that you must do is identify and isolate the problem. When you have accomplished this, you can effectively begin to resolve the problem. The first step to troubleshooting is to isolate each system component and ensure that each component functions properly when it runs independently. You may have to dismantle your system and rebuild it piece-by-piece in order to detect the problem. If you have additional components available, you may want to try replacing them with existing components or components that are working in another system. You should also try removing features until the component is running in its most basic mode. Determine if the problem is mechanical, hardware, or software-related. Try to recreate or repeat the problem. Do not attempt to make quick rationalizations about the problem. Random events may appear to be related, but they are not necessarily contributing factors to the problem. You must carefully investigate and decipher the events that occur leading up to the problem. You could be experiencing more than one problem. Try to isolate and solve one problem at a time. Document all testing and problem isolation procedures for review with a technician at a later time. When you feel that you have exhausted all possibilities and the problem still exists, call your local distributor or I²T Technical Support at (412) Please have the following information available when you call: Product Part Number (P/N) Product Serial Number (SN) Detailed Description of the Problem Description of the Application Firmware Version Number HMI Windows Setup Software Version Number (see Help Pull-down Menu in Chapter 4) 6-1

70 Chapter 6 PLS 210 TROUBLESHOOTING 6.2. Diagnostic LEDs A diagnostic LED array is mounted on the circuit board of the PLS 210 directly above the terminal connections (see Figure 6-1). This array consists of 10 LEDs: five green LEDs in the top row and five red LEDs in the bottom row. When the PLS 210 is configured into the I/O network and the Momentum PLC is in RUN mode, the 3 rd green LED (PLC Communications Active) in the top row is illuminated (active). The PLS 210 is capable of displaying more than one fault at any time (multiple LEDs lit red). Table 6-1 summarizes these LEDs as they appear on the PLS 210 module. Module Status (Green) Module Heartbeat Resolver Active Global Enable Active Serial Communications Active PLC Communications Active Faults (Red) Code Checksum Fault Serial Communications Fault PLC (Command) Fault Resolver Fault Latch Setup NOT Saved to Flash Figure 6-1: Diagnostic LED Array LED Description LED Description Green Module Status LEDs (Top Row) Red Fault LEDs (Bottom Row) 1 Module Heartbeat 6 Code Checksum Fault 2 Serial Communications Active 7 Serial Communications Fault 3 PLC Communications Active 8 PLC (Command) Fault 4 Resolver Active 9 Resolver Fault Latch 5 Global Enable Active 10 Setup NOT Saved to Flash Table 6-1: Module Status / Fault LEDs Green Module Status LEDs Top Row The following is a description of the top row green LEDs on the PLS 210 module Module Heartbeat [LED 1] This green status LED continuously blinks at a rate of ½ second when the PLS 210 module is functioning properly. If this LED is not blinking (solid/on or off), try resetting the 24 Vdc power to the PLS 210 module. If this does not resolve the problem, call your local I²T representative for further assistance. 6-2

71 PLS 210 TROUBLESHOOTING Chapter Serial Communication Active [LED 2] This green status LED blinks when there is communication between the User s PC and the PLS 210 serial port PLC Communications Active [LED 3] This green status LED is on (solid) when the Momentum PLC is issuing commands to the PLS 210 via a top hat connection Resolver Active [LED 4] This green status LED is on (or solid) when there is a resolver connected to the PLS 210 and there are no resolver faults present. This LED will be off and the Resolver Fault Latch LED will be on (red) if the resolver is disconnected, if a resolver wire is open, or if there is some other resolver fault. When both of these lights are on, the resolver fault was corrected and the Resolver Fault Latch LED indicates that the fault was latched. Reset the faults to clear the error Global Enable Active [LED 5] This green status LED is on (or solid) when the global enable for the PLS 210 is active (see Section , Page 4-15 for a description of the Global Enable) Red Module Fault LEDs Bottom Row The following is a description of the bottom row of red LEDs on the PLS 210 module. All of these faults can be reset from either the PLC or the PLS 210 Windows Setup Software, after the problem that caused the fault has been cleared Code Checksum Fault [LED 6] This red fault LED is on when the PLS 210 code is corrupt. Try resetting the 24 Vdc power to the PLS 210 module. If this does not work, download (write) the latest Firmware to the module (see Download Firmware in Section , Page 4-9). If this does not resolve the problem, call your local I²T distributor or I²T technical support at for further assistance Serial Communication Fault [LED 7] This red fault LED is on whenever there is a serial communication problem between the PC and the PLS 210 module. Make sure that the serial cable is properly connected and that the serial port parameters are properly set. Also, verify that the serial cable is not in a noisy environment PLC Command Fault [LED 8] This red fault LED is on whenever the PLC is sending a bad command to the PLS 210 module. See Appendix B for a complete list of PLC Low-level Commands. 6-3

72 Chapter 6 PLS 210 TROUBLESHOOTING Resolver Fault Latch [LED 9] This red fault LED is on whenever the PLS 210 detects a problem with the resolver or its circuitry. Make sure that the cable from the resolver is wired properly (see Section 3.7) and within the allowable length (150 ). Also check to see if the resolver cable is at a sufficient distance away from any high voltage equipment. Finally, verify that the resolver is within the allowable electrical specifications of the PLS 210 (0.47:1 to 1:1 transformation ratio) Setup NOT Saved to FLASH [LED 10] This red LED is on whenever any of the PLS 210 setup parameters have been changed without saving the setup to FLASH memory. This LED does not indicate a fatal fault. The purpose of this LED is to provide a warning to the User to save the setup parameters to FLASH. This fault is cleared after the Set Data to Module menu item is selected from the PLS 210 HMI Windows Setup Software or a 2093 Copy RAM Setup to Flash command is issued from the PLC. Note that a Set Data to Module menu item does not save the configuration to non-volatile memory (see Save Settings to Flash in Section ) PLC Diagnostics By using the four Traffic-copped registers to the PLS 210, the PLC can get and clear the faults from the module with the 1001 Get Fault/Status Codes command (see Appendix B for a list of PLC Low-level Commands). Table 6-2 shows how to read and clear faults to the PLS 210 module. Register Description Register Description 4xxxx+0 Command xxxx+1 Echo 4xxxx+1 Reset Faults 1 or 0 3xxxx+2 PLS 210 Status/Faults 4xxxx+2 N/A 3xxxx+3 Resolver Faults 4xxxx+3 N/A N/A Data from PLS 210 Table 6-2: Read and Clear the Faults to the PLS 210 See the Clear Module Faults programming example in Section for PLC code that is used to clear the PLS 210 faults. If a 0 is placed in the Reset Faults Register, the PLC will only read the faults. If a 1 is placed in the Reset Faults Register, the faults will be cleared, if the problem that caused them has been resolved. 6-4

73 PLS 210 TROUBLESHOOTING Chapter PLS 210 Status/Faults & Resolver Status Registers The following tables describe the PLS 210 Status/Fault registers and the Resolver Fault registers. BIT Mask Description 16 0x0001 PLC Error 15 0x0002 Reserved 14 0x0004 FLASH Memory Fault 13 0x0008 FLASH Memory Default 12 0x0010 PLC Command Error 11 0x0020 Serial Command Error 10 0x0040 Serial Checksum or Timeout Error 9 0x0080 Code Checksum Error 8 0x0100 Setup Changed (Not Saved to FLASH) 7 0x0200 Global Enable Active Table 6-3: Module Status / Faults BIT Mask Description 16 0x0001 Resolver OK 15 0x0002 Resolver Fault Latched 14 0x0004 Resolver Open Wire 13 0x0008 Resolver Range Error Table 6-4: Resolver Faults 6-5

74 Chapter 6 PLS 210 TROUBLESHOOTING PLS 210 Setup Software Diagnostics Screen The PLS 210 Windows Setup Software can be used to obtain the status and fault information from the PLS 210 module (see Section for a complete description of the Fault Status menu item). To view the Fault screen, select the Faults Status menu item from the Tools Pull-down Menu. The following screen will appear. Fault Status Screen 6-6