Automationdirect.com OP-640 User manual

OP-640
OperatorPanel
Manual NumberOP-640-M

WARNING
Thank you forpurchasing automation equipment fromAutomationdirect.comä.WewantyournewDirectLOGICä
automation equipment to operatesafely.Anyone who installsorusesthisequipmentshouldread thispublication (and
anyother relevantpublications)beforeinstalling oroperating the equipment.
Tominimizethe risk ofpotentialsafetyproblems,you shouldfollowall applicablelocaland nationalcodesthatregulate
the installation and operation ofyourequipment. Thesecodes varyfromarea to area and usually change withtime. It is
your responsibilityto determine whichcodes should be followed,and toverifythat the equipment, installation,and
operation isincompliancewiththe latestrevision of thesecodes.
Ataminimum,you shouldfollowall applicablesectionsof the NationalFireCode,NationalElectricalCode,and the
codesof the NationalElectricalManufacturer’sAssociation (NEMA).Theremaybe localregulatoryorgovernment
officesthatcan also help determine whichcodesand standardsare necessaryforsafeinstallation and operation.
Equipmentdamage orseriousinjuryto personnelcan result fromthe failuretofollowall applicablecodesand
standards.We do notguarantee the productsdescribed inthispublication aresuitableforyourparticularapplication,
nordo we assume anyresponsibilityforyourproductdesign,installation,oroperation.
If you have anyquestions concerning the installation oroperation of thisequipment, orifyou need additional
information,pleasecall usat1--800--633--0405.
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Copyright1999,Automationdirect.comäIncorporated
All RightsReserved
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included inthisdocument.

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If you contactusinreferencetothismanual,be sure and include the revision number.
Title:OP--640 OperatorPanel User Manual
ManualNumber:OP--640--M
IssueDateEffective Pages Description ofChanges
Original9/99 All OriginalIssue

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Thisproductismanufactured incompliancewithEuropean Union (EU)Directivesand carriesthe CE
mark.The following information isprovided tocomplywithEUdocumentation requirements.
NOTE:ProductswithCEmarks perform their required functions safelyand adhere
torelevantstandardsas specified byEUdirectivesprovided theyare used
according totheirintended purpose and that the instructionsinthismanualare
adhered to.The protection provided bythe equipmentmaybe impaired if this
equipmentisused in a mannernotspecified inthismanual. Onlyreplacementparts
supplied byPLCDirectoritsagents should be used.Alisting ofinternationalaffiliates
isavailable atourWeb site http://www.plcdirect.com
If you need technicalassistance,pleasecall the technicalsupportgroup at
PLCDirect(3505 Hutchinson Rd., Cumming, GA30040,U.S.A.)at800--633--0405.
Theyare availableMondaythrough Fridayfrom9:00 A.M. to 6:00 P.M.Eastern
StandardTime.TheirWeb Site address ishttp://www.plcdirect.com
All electricalcircuits connected tothe communicationsportreceptacle arerated as
SafetyExtra LowVoltage (SELV).
Operating Temperature 0°to 50°C.....................
Storage Temperature--20°to 70°C......................
Operating Humidity95%(non-condensing)........................
AirComposition Nocorrosive gasespermitted...........................
No preventativemaintenanceisrequired.Toclean the exteriorof the panel
disconnect the inputpowerand carefullywipe the panel with a clothmoistened with
plainwater.
There arenointernalfusesforthe inputpowercircuits,so externalcircuitprotection
isneeded to ensurethe safetyofservice personneland the safe operation of the
equipmentitself. TocomplywithEUspecifications, the inputpower mustbe fused.
Useafuserated attwice the inputcurrentrating of the panel.Forexample,if the
panelhasan inputcurrentrating of0.5 amperes,useafuserated for1 ampere.
TechnicalSupport
SELVCircuits
Environmental
Specifications
Preventative
Maintenance and
Cleaning
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Protection
forInputPower

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TableofContents
Chapter1:Getting Started
Introduction 1--2.........................................................................
The Purpose of thisManual1--2.........................................................
SupplementalManuals1--2.............................................................
TechnicalSupport1--2.................................................................
Chapters1--3.........................................................................
Appendices1--3.......................................................................
ConventionsUsed1--3...................................................................
KeyTopics forEachChapter1--3........................................................
OP--640 Overview1--4...................................................................
Plan yourSystem1--4.................................................................
GeneralPanelInformation 1--4..........................................................
LCD DisplayWindow1--4..............................................................
Pushbuttons1--5......................................................................
AnnunciatorLamps1--5................................................................
Back-PanelLayout1--5................................................................
Serial CommunicationsPort1--5........................................................
PowerReceptacle 1--5.................................................................
RUN/PGMand 1--5....................................................................
TERMSwitches1--5...................................................................
FrequentlyAskedQuestions 1--6.........................................................
Chapter2:Installation and Specifications
Connecting aPowerSupply 2--2..........................................................
PowerSupplyConnections2--2.........................................................
Multi-panelPowerSupplyConnection 2--2................................................
Preparing thePanelforConfiguration 2--3.................................................
RUN/PGMSwitch 2--3.................................................................
Configuration Cable 2--3...............................................................
Preparing thePanelforCommunications 2--4.............................................
RUN/PGMSwitch 2--4.................................................................
OP--9001 Multi-PanelConfigurations 2--4..................................................
The TERMSwitch 2--4.................................................................
Connecting CableDetails 2--6............................................................
Connecting Cable 2--6.................................................................
Labeling theLamps and Pushbuttons 2--7.................................................
Labeling the Lampsand Pushbuttons2--7................................................
Creating the Labels2--7................................................................
Creating LabelsUsing OP--WINEDIT2--7................................................
Templates forManuallyCreating Labels 2--9...............................................
DimensionsforMounting 2--10............................................................
PanelSpecifications 2--11.................................................................

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Table ofContents
PhysicalSpecifications2--11.............................................................
EnvironmentalSpecifications2--11.......................................................
Operating Specifications2--11...........................................................
Chapter3:Understanding theFeatures
Learning theFeatures 3--2...............................................................
Status and ControlRegisters 3--3.........................................................
Statusand Control RegisterOverview3--3................................................
BitLevelAccess 3--3..................................................................
RegisterDefinition 3--4.................................................................
Statusand Control RegisterDefinition 3--4................................................
Messages 3--5...........................................................................
Displaying Messageson the LCD Screen 3--5.............................................
StaticMessages3--5..................................................................
DynamicMessages3--5................................................................
Displaying Messages 3--6................................................................
StaticMessage Operation 3--6..........................................................
StaticDisplay3--6.....................................................................
DynamicMessage Operation 3--7.......................................................
DynamicMessageTop Line 3--8.........................................................
DynamicMessage BottomLine 3--8.....................................................
Displaying DataWithaDecimalPoint3--9................................................
Displaying BCD and BinaryNumbers3--9................................................
Displaying BCD DoubleNumbers3--9...................................................
Displaying Floating PointNumbers3--10..................................................
Pushbuttons and Lamps 3--11.............................................................
Pushbutton Operation 3--11..............................................................
Pushbutton Example 3--11...............................................................
PushbuttonsUsing DirectAccess toStatusRegisterBits3--12...............................
Pushbutton LEDs3--12.................................................................
LampExample 3--12....................................................................
LampFlash 3--13.......................................................................
MemoryMapping Process 3--13...........................................................
OP BaseRegister MemoryDefinition 3--13................................................
OperatorPanelBaseMemory3--13......................................................
Mapping Operation 3--16..................................................................
Mapping Examples (DL05,105,DL205,D3--350,and DL405)3--16............................
Mapping the StatusRegister3--16........................................................
Mapping the Control Register3--17.......................................................
Mapping Example(D3--330/340)3--17......................................................
Mapping the StatusRegister3--17........................................................
Mapping the Control Register3--18.......................................................
Chapter4:Configuring YourOperatorPanel
Preparing forConfiguration 4--2..........................................................
OP--WINEDITSoftware 4--2............................................................
More about OP--WINEDIT4--2..........................................................
HELP Screens4--2....................................................................

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Table ofContents
Application Worksheets4--3............................................................
ComputerSystemRequirements4--3....................................................
HowtoConfigureYourPanel4--3.........................................................
Step 1 4--3...........................................................................
Step 2 4--3...........................................................................
Step 3 4--4...........................................................................
Step 4 4--4...........................................................................
Step 5 4--4...........................................................................
Step 6 4--5...........................................................................
Step 7 4--6...........................................................................
Step 8 4--6...........................................................................
Chapter5:Programming Examples
Examples Using DirectLOGICPLCs 5--2...................................................
RegisterUsage 5--2...................................................................
DL05,DL105,DL205,D3--350 and DL405 Examples 5--3....................................
Defining the StatusRegister5--3........................................................
UsingaFunction Button 5--5............................................................
Lighting a Lamp 5--6...................................................................
Flashing a Lamp 5--6..................................................................
Displaying Messages5--7..............................................................
Displaying BinaryNumbers5--8.........................................................
Displaying BCD DoubleNumbers5--9...................................................
Displaying Floating PointNumbersExample 1 5--10........................................
Displaying Floating PointNumbersExample 2 5--11........................................
ExampleUsing D3--330/340 5--12..........................................................
Example 5--12.........................................................................
Allen-Bradley SLC5/03 &5/04 and MicrologixExamples 5--13...............................
Interfacing toA-BMemory5--13..........................................................
Lighting a Lamp 5--13...................................................................
Flashing a Lamp 5--14..................................................................
UsingaFunction Button 5--14............................................................
Displaying Messages5--15..............................................................
Displaying MessagesExample 5--16......................................................
Displaying BinaryNumbers5--17.........................................................
Chapter6:Troubleshooting
Troubleshooting theOP--640 Panel6--2...................................................
Troubleshooting 6--2...................................................................
Panel Configuration Problems6--2......................................................
PaneltoPLC CommunicationsProblems6--3.............................................
Allen-BradleyPaneltoPLC CommunicationsProblems6--4................................
AppendixA:Worksheets
Application WorksheetsExampleA--2....................................................
Application WorksheetsForm A--2.......................................................
Index

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Getting Started
InThisChapter....
—Introduction
—ConventionsUsed
—OP-640 Overview
—FrequentlyAsked Questions

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Getting Started
Introduction
OP-640
Howto
Usethe
Thank you forpurchasing an OP--640
OptiMate panel.ThisUser Manual
shows you howtoinstall,configure,and
programthe OP--640.Alsoincluded are
application examples.Besuretokeep
thismanualhandyfor referencewhen
you run into questions.Ifyou understand
PLCsystemsand operatorinterface
units, thismanual will provide all the
information thatyou need to getand keep
yourpanelup and running.
The OP-1500 and OP-1510
Operatorpanelsmaybe
reconfigured to exchange data
withyourprogrammable
controller.
The OP-1500 and OP-1510
Operatorpanelsmaybe
reconfigured to exchange data
withyourprogrammable
controller.
The OP-1500 and OP-1510
Operatorpanelsmaybe
reconfigured to exchange data
withyourprogrammable
controller.
The OP-1500 and OP-1510
Operatorpanelsmaybe
reconfigured to exchange data
withyourprogrammable
controller.
The OP-1500 and OP-1510
Operatorpanelsmaybe
reconfigured to exchange data
withyourprogrammable
controller.
Referencethe appropriatePLC/CPU
user manualsforthe commandsand
address referencesrequired foryour
system. If you are using a DirectLOGIC
PLCproduct, you will want tokeep the
DirectSOFT User Manualhandywhile
programming yoursystem.Forother
PLCbrands you mustreferencetheir
user manualsto properlyprogramthe
ladderlogicrequired to operatethe
OP-panel.
Werealizethateven though westriveto be the best, wemayhave arranged our
information insuchawaythatyou cannot find whatyou arelooking for.First, check
theseresourcesforhelpinlocating the information:
STableofContents-- chapterand section listing ofcontents,inthe front
of thismanual
SIndex -- located at the end ot thismanual
SAppendices -- referencematerialforkeytopics,nearthe end of this
manual
You can alsocheck ouronline resourcesforthe latestproductsupportinformation:
SInternet-- the address ofourWeb siteiswww.automationdirect.com
If you still need assistance,pleasecall usat1--770--844--4200. Ourtechnical
supportgroup will be glad toworkwithyou in answering yourquestions.Theyare
availableMondaythrough Fridayfrom9:00 A.M. to 6:00 P.M.EasternStandard
Time.Ifyou haveacommentorquestion aboutanyofourproducts,services,or
manuals,pleasefill outand returnthe ‘Suggestions’cardthatwas shipped withthis
manual.
ThePurpose of
thisManual
Supplemental
Manuals
TechnicalSupport

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Getting Started
The maincontentsof thismanualare organized intothe following fivechapters:
Getting Started
Introducesthe physicaland functionalcharacteristics.
Discussespushbuttons,lampsand the LCD display.Also
providesintroduction to planning yoursystem.
Installation and
Specifications
Showshowto prepareforsysteminstallation,including
specificationsand mounting instructions. Includes
connecting cablespartnumbersand specifications.
Understanding the
Features
Explainsthe featuresand functionsof the OP--640.Teaches
conceptofhowdataisexchanged between the paneland
the PLC.Also discussesthe function of the statusregister.
Configuring the
OperatorPanel
Showshowto usethe OP--WINEDITconfiguration softwareto
configureyourpanel.Showshowtoload the softwareonyour
personalcomputer,call up the screens you will need and howto
download the configuration programtoyourpanel.
Programming
Examples
Providesexample programsforusing the standardfunctionsand
features.These examplesinclude ladderlogicforimplementing
pushbuttonsand messagesusing DirectLOGICcompatiblesand
Allen-BradleySLC5/03,5/04 and MicrologixCPUs.
Troubleshooting Provideshelpwithtroubleshooting yourOptiMate panel. Includes
tipson isolating communicationsfaultsbyuse ofLEDstatus.
Additionalreferenceinformation isinthe following appendices:
WorksheetsHasworksheetsthatyou can useto helpsetup yourOP-panel.
ConventionsUsed
The “note pad”icon inthe left--hand marginindicatesthe paragraph toitsimmediate
rightwill beaspecialnote.
The “exclamation mark”icon inthe left-hand marginindicatesthe paragraph toits
immediaterightwill beawarning orcaution.These areveryimportantbecausethe
information mayhelpyou preventseriouspersonal injuryorequipmentdamage.
The beginning ofeachchapterwill list the
keytopics thatcan be found inthat
chapter.
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Chapters
1
2
3
4
5
6
Appendices
A
Key Topics for
EachChapter