Training Manual Ml200r 1w306p

This is an overview slide for MasterLogic product series. The products like MasterLogic - 50 (Nano/Micro PLCs), ML100, ML100R, ML200 PLC series with Local and Micro HMIs are available. Local I/Os (Analog/Digital) for fulfilling the various industrial requirements are available along with Smart I/O which is a Open-type remote I/O module, connected with a field network, for real-time controlling I/O modules distributed in a field. It also s CAN Bus communication for DeviceNet devices, Serial communication RS232, RS 422/485 for MODBUS RTU/ASCII, SoftMaster or Defined Protocol, RS 485 Communication with ProfiBus-DP devices, Ethernet Communication on twisted pair or fiber optic media for EPKS integration, P2P, MODBUS T or any defined Protocol.

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This is the agenda for the training session. The introduction session for ML PLCs will be followed by U specifications, module options, network/protocol s, Introduction to the engineering tool for ML PLC that is SoftMaster, Diagnostic features available and EPKS Integration.

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The 2MLI -UU is a MasterLogic-200 PLC U using IEC 61131-3 standard programming languages i.e. LD, SFC, ST. This document lists the specifications, and the procedures for installing, handling, configuring and programming the U module.

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The above slide explains different modules ed by ML 200 PLC. These modules are: Power Supply AC Input with Flexible Voltage U 2MLI-UU Digital Input/ Output Module Anaput/ Output Module

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Special Function Modules Communication Modules like Snet, FEnet, Profibus DP, Rnet.

These are various communication modules along with the smart I/Os. Smart DI – Profibus DP Smart DO – Profibus DP Smart AI - Profibus DP

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It is possible to configure retainable area from total memory using an engineering tool SoftMaster. When PLC stops and restarts the data required for operation or the data occurred during operation can be retained and can be used on restart.

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Program Execution methods: Cyclic Scan - This program performs the operation repeatedly from 0 step to last step in order prepared by the program to process the signal that is repeatedly regularly every scan. In case that the execution condition of interrupt by task interrupt or interrupt module while executing scan program is established, stop the current program in execution and perform the related interrupt program. Interrupt Program - This program stops the operation of scan program and then processes the related function in prior to process the internal/external signal occurred periodically/non-periodically. Types of Interrupt Programs • Task program is divided into 23 types as below. Time-driven task program: available to use up to 32 Internal device task program: available to use up to 32 • Time-driven task program Performs the program according to the fixed time internal. • Internal device task program Performs the corresponding program when the start condition of internal device occurs. The start condition detection of device shall be performed after processing of scan program. The maximum number of programming tasks for each type is shown in the table in above slide.

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An IEC 61131-3 Standard Programming Language • Ideal language for logical / relay / timer / counter operations • -friendly graphical editor for ladder language • Library comprising hundreds of functions/function blocks for various control requirements • Monitor mode

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• An IEC 61131-3 Standard Programming Language • Ideal language for state transition/step action based batch applications e.g. simultaneous operations • Graphical configuration of steps / transition diagrams

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• An IEC 61131-3 Standard Programming Language • PASCAL or BASIC like high level language • Reduces engg, easy to understand, portable • Ideal language for -defined functions/function blocks

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• Compatibility with other IEC languages e.g. a ladder program can call a sub-routine written in ST language • s named variables

• An IEC 61131-3 Standard Programming Language • A mnemonic programming language • View only mode • Toggling view with LD program editor

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A large number of Function Blocks are available in Function Block Library. The typical function block is explained in above slide.

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Symbolic Variable Area (%A): 512KB Direct Variable Area (%I): 16KB Direct Variable Area (%Q): 16KB Direct Variable Area (%M): 256KB

Above slide explains effect of cold/warm restart on the different memory areas. 17

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ARRAY Items are stored in Symbolic Variable Memory (512 KB) and hence there is no limitation until symbolic memory area is available 18

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Max ARRAY size of 32767 items Multi-dimensional arrays to suits your application requirement Initial Value of array items can be set through a graphical -interface

PLC System Alarms and Event Summary are stored in system memory (2MB). The log files created can be saved in .txt format.

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Direct Variable : Memory area with IEC standard address notations i.e. input, output, internal flags & s. Symbolic Variable : Memory area as named variables with automatic address allocation

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HOT SWAPPING: Online exchange of I/O Modules during RUN - U switch M.XCHG method - Software wizard Force I/O: To force any real Digital I/O to ON/OFF values.

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Skip I/O: To skip processing any selected I/O module or an entire I/O base. Fault Mask: To mask module errors in any selected I/O module and continue processing.

Online Editing: To modify the program online while U is running and changes. Data Tracing: Define the trace parameters and to U. View the traced U data in graph or table format

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Compact size: The 2MLI-UU has all the functionality packed in a compact size, thus enabling installation in small spaces. In addition, it reduces storage & freight costs.

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Modules can be inserted on the base in order to achieve the integrated system. Example: Power Supply Module, U Module, I/O Modules, Communication Modules etc.

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Field Termination made easy for connector type modules wiring time reduced Loop checks during startup made easy Maintenance/trouble-shooting made easy Less wiring errors Isolation of field signals made easy

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ML200 PLC works on various networks like Fast Ethernet, UTP/Fiber Optic, Serial RS232/422/485. It also provide to Profibus-DP, Devicenet and MODBUS ASCII/RTU/T protocols.

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HMI server acting as MODBUS RTU master communicates with PLCs over RS422 using modem. Each PLC act as a MODBUS RTU slave device with unique station address. SoftMaster-200 PC (PADT) communicates with Station1 on local RS232C but communicates with other PLCs on remote RS422 for programming.

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Architecture: RS232C and RS422 network communication RS232C port of Snet Module can be used either SoftMaster-200 interface or MODBUS RTU/ASCII slave device. RS422 port of Snet module used as MODBUS RTU/ASCII master to communicate with 3rd party MODBUS RTU slave devices e.g. MOSAIC .

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Architecture: RS232C and wireless modem Application: MasterLogic PLC can act as MODBUS RTU/ASCII Master. The 3rd party device acts as MODBUS slave on RS232C. Networking is through wireless modem

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Smart I/O is: Open-type remote I/O module, connected with a field network, for real-time controlling I/O modules distributed in a field.

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Only MPL (Profibus) series has analog Smart I/O. Profibus speed would drop from 1.2Mbps to 9.6Kbps for increasing distance upto 1.2km max. For distances > 500metres & when speed is critical, MRL (Rnet) series is recommended (1Mbps). Please note only Digital I/O is ed in MRL series.

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SoftMaster-200 is a software tool designed to program and debug MasterLogic-200 PLC.

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Features of SoftMaster-200 1. Multi-PLC, Multi-Program Allows the to edit, monitor or manage PLC system interlocked with several PLC included in a project at the same time. And the program can be made as divided into scan program and various tasks program. 2. Various Drag and Drop Makes editing easy and convenient with Drag and Drop function on most of editors such as Project, Variable/ Comment, LD Edit, Variable Monitor, etc. 3. Setting ’s Shortcut Keys Shortcut Keys provided as default can be changed or added as specified as familiar to . 4. Various Message Windows Provides various message windows to edit and inspect program easily. 5. Convenient Edit of Variable/Comment a Edit with MS Excel is available. b Various types of Edit is available through View Variable, View Device, View Flag, etc. c

Similar kind of Variables can be added easily with Auto-fill.

d Convenient Copy is available on the different Variable/Comment Windows with Drag and Drop. e Direct Edit is available without displaying dialog box just like Excel.

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6. Convenient Program Edit a Unlimited Undo/Redo function provided. b Block Edit available in cell unit. c

Screen-divided Edit available.

d Find/Replace function enhanced. e Execution in rung unit can be prohibited with Block Mask function. f

Convenient access allowed to specific position with Bookmark function.

g Memory of selected device can be referred when editing LD. 7. Various Monitoring Functions Various monitoring functions are provided such as variable monitoring, device monitoring, system monitoring, trend monitoring, special module monitoring, etc. 8. Custom Events If defined conditions are met for specific device, logging and reading data is available. 9. Module Changing Wizard Module can be safely and easily changed during Run without stopping PLC.

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Exercise 1 EXERCISE 1 Objective : To understand how to create a project, program a simple ladder logic program, run a simulator. 1. Open SoftMaster and create a new project ‘Exercise1’ 2. In the IO parameter, set Digital &Analog IO modules

3. Enable Channels for Anaput and Output.

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4. Special modules. (Select Global Variables/Address in the project window)

5. Write a program to map Digital Input to Digital Output, and Anaput to Analog Output

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6. Run a simulator (Tools -> Simulator) and write parameters to U. 7. RUN and MONITOR the program in the SoftMaster 8. Simulate the values in the Simulator and observe the changes.

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9. Check online features in the SoftMaster

Exercise 3 Objective : To understand how to configure Modbus serial communication between ML PLC and 3rd party devices 1. Configure Snet card as a Modbus slave using a SoftMaster-NM.

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2. Define Modbus area in the Modbus settings

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3. Setup a Modbus simulator tool in your PC as a Modbus master and configure the communication parameters as per the settings in your Snet card.

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4. Read and write values in the Modbus simulator tool and observe the changes.

5. Run the system diagnosis functions in the Online menu. (i.e. communication module information, frame monitoring, loop back test, status by service)

6. Repeat the steps with Snet as Modbus master.

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Note that P2P settings are required to read & write to Modbus slave device.

Enable Link in the Online menu to start P2P communication.

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Exercise 4 Objective : To understand how to configure Profibus slave devices on Pnet Master module 1. Create a new project in Sycon and select Profibus. .

2. Insert a Profibus master (COM-C-DPM)

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3. Search for connected Profibus slave devices using Automatic network scan (Online -> Automatic network scan)

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4. Open SoftMaster-NM and configure Pnet module in the HS link tab.

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5. Sycon parameters onto the SoftMaster-NM and configure.

6. Enable Link and check the communication.

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