SYSTEM OVERVIEW - Pejawar Electronics

1 SYSTEM OVERVIEW . TM. PLC. AN ICON OF THE FUTURE. TM. AUTOMATION PEOPLE. CONTENTS. Introduction : Nexgen 5000 Product Highlights SaIient Features : Nexgen 5000 2-3. CoDeSys : PLC Program Development 4-6. Nexgen CPU 521x & 522x : Application Schemes Modbus Connectivity .. 7-8. Data Exchange via 9. Fault Message Alert .. 10. Servo Connectivity .. 10-11. Nexgen Slave .. 12. Micro PLCs in Multidrop Connectivity .. 12. Variable Frequency Drives in Multidrop .. 13. Specifications : Nexgen 521x & 522x Series of CPUs ..14-15. Detailed CPU Information Nexgen 522x Series of CPU .. 16-19. Nexgen 521x Series of CPU .. 20-23. CoDeSys : Programming Software for Nexgen 5000 Series Ladder Diagram (LD) .. 25. Instruction List (IL)..25. Structured Text (ST) .. 26. Function Block Diagram (FBD) .. 26. Sequential Function Chart (SFC) .. 26. Continuous Function Chart (CFC) .. 27. Dynamic Data Exchange .. 28. Sample Trace Function with Graphical Display.

2 29. Process Visualisation for On Line Testing .. 30. POUs & Data Types .. 30-31. CoDeSys: Instructions & Libraries .. 32. Communication Basics .. 32-35. Base & Expansion Plates .. 36. Power Supply Modules .. 36. Digital I/O Modules .. 37-38. Analog I/O Modules .. 38-41. Counter Modules .. 42. Smartline Jr. & Sr.. 43. E-Series Operator Terminals .. 44-45. Ordering Information HMI Connectivity .. 46. Nexgen CPU 5000 Series .. 47. Base & Expansion Plates .. 48. Input / Output Modules ..48. Power Supply Modules .. 48. Introduction INTRODUCTION. IEC 61131-3 AN ICON OF THE FUTURE. PLC. Messung Systems, a leading pioneer in indigenous PLC in India, has constantly innovated to achieve global standards in designing and manufacturing PLC products. With pride, it has now launched a high performance series of world class CPUs viz. Nexgen 5000; coupled with basic building blocks of its earlier launched and established Nexgen 4000 PLC.

3 This Nexgen 5000 PLC family offers a wide range of CPU variants, with . IEC 61131-3 compatibility, having performance excellence and Windows based programming software. Evolution Of PLCs on IEC 61131-3 Platform In the earlier days of industrial automation, application specific machines or process plants were designed with huge control panels having Relay Contactor Logic and Hardware Timers, Counters, Thumbwheels. These were very bulky in size, complex for fault finding, less reliable with limited and unpredictable life. Similarly these systems were very rigid in terms of any up-gradation. This has evolved concept of Programmable Logic Controllers (PLC) which were compact in size, having better edge over earlier electro-mechanical devices. PLC implementation has resulted in several benefits like: minimized panel and wiring volume, expedited program development, reliability of operations with an improved life, PLC re-usability across the applications (conditionally), easy and quick fault finding, and ease of interface with HMIs, SCADA like external devices.

4 Over the time, only application specific hardware and software products were developed by various vendors, which addressed the problem of compatibility and portability. This has initiated necessity of products standardization in terms of hardware as well as software. Similarly, with the growing Industrial Automation, industry has started facing typical problems of PLC. processing speed, memory, handling of a complex or very big program, logic re-usability, avoiding duplicate variables in programming, choice of programming language selection as per application, user friendly software along with documentation, standardized program interface. Subsequently, International Electro-technical Commission worked upon complete design of PLC, which comprised of hardware design, installation, testing, programming and documentation. Several inputs from various machine manufacturers, end-users and research institutes has evolved five part IEC 61131 standard.

5 This international standard IEC 61131-3 is the first substantial endeavor to standardize programming languages for industrial automation. It emphasizes on consistent method of PLC programming which encourages the development of quality software. IEC 61131-3 provides tools to improve intrinsic quality of software in terms of its persistent correctness, integrity, reliability, robustness, modularity, flexibility and safety. It also deals with programming, installation and maintenance phases of software development projects in industrial control. IEC 61131-3 compatible programming yields Rapid Application Development. Nexgen 5000 series of CPU family is programmed with CoDeSys, the Windows based, IEC 61131-3. compatible programming software. 1. Nexgen 5000 PLC : Product Highlights NEXGEN 5000 PLC : AN ICON OF THE FUTURE Max. 32. l A truly modular PLC modules an icon of the future NEXGEN. l More I/O Capacity - 1024 Inputs / 1024 Outputs l Enhanced Data Memory - 160 KB.

6 64 KB - Data Memory (Selectively retainable). 32 KB - Marker Memory (Selectively retainable). 64 KB - File Marker Memory (Super retainable). l Better processing speed - Boolean - sec max. Word - sec upto 9 mtrs. l Higher program memory - Application Program Code - 256 KB. Application Source Code - 1 MB. l Wide assortment of Analog modules - Thermocouple, RTD, Fast Analog Input and Output Modules Nexgen 5000 PLC with full capacity IMPROVED PG PORT OPERATION. l Supports RS-232C interface l Dual operation - Program mode or Open Protocol l Auto detect programming cable plug in & switch to program mode l User memory cassette interface l Supports all protocol FBs ENHANCED FILE MARKER MEMORY. l Super retained battery backed up memory l Not cleared by cold start or even after program change l Large capacity of 64K bytes PLUGGABLE KEYBOARD DISPLAY UNIT (OPTIONAL). The Keyboard Display interface is a extremely user & maintenance friendly tool, which provides 4-character alpha-numeric display with 6 keys key-pad.

7 Highlights : l User has an optional choice of pluggable keyboard display l It has built-in freely programmable 6 functions keys &. 4 character alphanumeric display l The keyboard display can be used as a self diagnostic tool. This is helpful for assistance in : n Displaying fault messages n Displaying systems messages n Viewing / modifying PLC variables n Redirection of Digital I/O points 2. Nexgen 5000 PLC : Product Highlights l The display and keyboard are freely programmable for application specific functionality . Display and keyboard is accessible in the application program through the SYSTEM variables. Using these SYSTEM variables, the user can develop their own function blocks to handle display and keypad as per the application need. l Standard FB library for I/O/M Monitoring, Redirection of Digital I/O points are also available. l The Keyboard Display Unit can be fixed to / removed from, the Processor module during the module powered ON condition.

8 COMPACT & HANDY MEMORY CASSETTE : The memory cassette is used to store an application program code and source code. It is a flash PROM type of intelligent memory cassette. The cassette is compatible with all the Nexgen 522x series CPUs and it is available in various memory sizes. The application program code and source code can be downloaded to processor module (Nexgen CPU) from the cassette. Application Program Transfer : CoDeSys to Memory Cassette The front side provides a push button and two LED indications for user interface. The backside provides 9-pin D female connector for the interface with PC or processor module. APPLICATION PROGRAM DOWNLOADING. l First, cassette needs to be set using PC based software 'Bootstrap Loader Tool'. l For transferring a program, memory cassette is plugged in to serial port-1 of PLC. Now pressing a push button twice, initiates the 'Program Transfer'. l If an application program code is valid, green LED will be ON.

9 If the application program code is blank, green LED blinks with 1Hz frequency. In case of invalid application program, red LED will be ON. Bootstrap Loader Tool / CoDeSys Memory PC COM. Cassette Programming cable 9910 Port Cassette adapter 30 VAC to 5 VDC. power supply 5 VDC Power supply To 230 VAC power supply Fig : Set Up to download the Program to Memory Cassette 3. CoDeSys PLC Program Development Suite Windows Based IEC Programming Software IEC 61131-3 : A GLOBAL STANDARD. l Better Structuring of large programs l High Reusability l Combination of ladder program and high level programming language VARIETY OF PROGRAM EDITORS. l LD : Ladder Diagram ST : Structured Text l ST : Structured Text l FBD : Function Block Diagram l IL : Instruction List l SFC : Sequential Function Chart l CFC : Continuous Function Chart LD : Ladder Diagram IEC 61131-3. FBD : Function Block Diagram HIGH PERFORMANCE EVENT TASK SUPPORT.

10 L Execution of POU on an event occurrence (Immediate action, as per priority). l Dynamic attach / detach POUs to events l Global masking via application program INCREASED PROGRAMMING functionality . l Online functionality : Program modifications, Monitoring of all variables, Power flow monitoring l Offline simulation now possible (limited). l Variable trace function with graphical display l Visualization (Limited for process monitoring). ADVANTAGE - BUILT IN PROTOCOL FUNCTION BLOCKS. l Modbus RTU Slave / RTU Master l Nexgen Slave l XMP8-10 Micro PLC Master l Frequrol - Inverter l Printer 4. New Possibilities of Remote Operation REMOTE PROGRAMMING VIA MODEM. PSTN. Network PC. Port - 1, RS-232 C CoDeSys Dial-up modem Dial-up modem remote operation Remote programming / on-line monitoring of Nexgen-5000. PLC via dial-up modem is possible on PG port. The PLC. programming software- CoDeSys can communicate with Nexgen-5000 PLC via modem.