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.
Thispublication isbased on information thatwasavailable at the timeitwasprinted.AtAutomationdirect.comäwe
constantly strivetoimprove ourproductsand services,sowereservethe right tomakechangestothe productsand/or
publicationsatanytimewithoutnotice and withoutanyobligation.Thispublication mayalso discuss featuresthatmay
notbe availableincertainrevisionsof the product.
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disclaimsanyproprietaryinterestinthe marks and namesofothers.
Copyright1999,Automationdirect.comäIncorporated
All RightsReserved
No partof thismanualshall be copied,reproduced,ortransmitted in anywaywithout the prior,written consentof
Automationdirect.comäIncorporated.Automationdirect.comäretainsthe exclusiverightsto all information
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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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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1
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.
1
Chapters
1
2
3
4
5
6
Appendices
A
Key Topics for
EachChapter

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Getting Started
OP--640 Overview
Let’slookat the OP--640 operatorpaneland itsindividually-supported features.As
you continue through thismanual, trytorelatethe examplestoyourOperatorPanel
application.The application worksheetslocated inAppendixAwill be helpfulduring
the design and configuration ofyoursystem.
It isimportant toread and understand all topics discussed beforeinstalling,
configuring and programming yourapplication.You should plan yoursystemwith all
operatorinterfacerequirementsinmind.
MACHINE
PLC
MemoryRequirements...
Process Data.....
OP--WINEDIT
Pushbuttons...
The OP--640 operatorpanelprovidesaman-machine interfacetoyourPLC
automation system.Thispanel isnotdesigned forapplicationswhich demand large
amountsofoperatordata entry.The panelcommunicateswithyourPLCusing
RS-232 orRS-422 serialcommunication.Detailson configuration software and
programming youroperatorpanelarecovered inlaterchapters.The OP--640
operatorpanelcan be used inastand alone fashion with one panelused with each
CPU RS-232 port, orcan be used inmulti-panelapplicationsusing an OP--9001
CommucationsMaster.You maynetworkup to 31 panelsusing an OP--9001.
BacklitLCD Displaywith 4
lines,20 characterseach.
The OP--640 featuresan LCD display
windowto displayuser-defined
messages.Upto 160 messagesmaybe
configured and stored inthe operator
panelusing OP--WINEDITconfiguration
software.The PLC logicprogram
controlswhichmessagesare displayed.
Detailson howto enterand use
messagesarecovered inlaterchapters.
PlanyourSystem
GeneralPanel
Information
LCD Display
Window

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Getting Started
Manyapplicationsrequire operator
panelpushbuttonsforcontrolling the
machine orprocess.These pushbuttons
are used asinputsignalstothe PLC
whichstartand stopamachine or
process.Configurethese pushbuttons
asmomentaryoralternating to best fit
youroperatorinterface application.You
may createcustomtextlabels.Pushbuttons
F1F2F3F4F5
The three lampsareturned
on,off and flashed through
yourladderlogicprogram.
You may createcustomtext
labels.
Lamp 1
Lamp 2
Lamp 3
The back panelcontainsaserialcommunicationsportwithtransmit(TX)and receive
(RX)LEDs,a power receptacle,and RUN/PGMand TERMswitches.
RXLED
(Green)
TXLED
(Red)RUN/PGMSwitch
SerialPort
PowerReceptacle
The serialcommunicationsportisa 15-pin, femaleD-shell connector,which
supportsusing RS-232 orRS-422 interfacewiring.Thisportisused for
communicationsbetween the OP-paneland PLC,aswell asforprogramming your
panelconfigurations. Inthe case ofaMulti-panelapplication, thisportmaybe
connected tothe OptiMateOP-9001 CommunicationsMaster.
The supplied block styleconnectorwithscrewterminalsisused toconnectan
external24VDC powersupply.
The RUN/PGMSwitchmustbe set toON(PGM) before downloading fromthe PCto
the panel.The TERMSwitchisonly set toON(rightposition)when the panel isat the
end ofasystemusing RS--422 communications. In all othercases,including
downloading,itis set toOFF (left position).
Pushbuttons
Annunciator
Lamps
Back-PanelLayout
Serial
Communications
Port
PowerReceptacle
RUN/PGMand
TERMSwitches

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Getting Started
FrequentlyAskedQuestions
Q. Whatisrequiredto getstarted using theOP--640 inmy application?
A.You mustread thismanualand understand the OP-panelrequirementsand
application concepts.You musthave programming knowledge forthe PLCproduct
you’re using, the PLCserialcommunications capabilitieswhich are available,as
well ashook-up and connecting cable data.
Q. Howdo IconfiguretheOP--640 operatorpanel?
A.Using the OP-WINEDITconfiguration software availablefromAutomationdirect.
This software allows you toconfigurethe OP-panelsin a Microsoft Windowst
environment. You may configureyourprogramsoffline,upload,and/ordownload
themtoyourOptiMate panel.The OP-WINEDITsoftwareisprovided with
installation documentation and Helpscreens.
NOTE:OP--WINEDITversion 2.3 orlaterisrequired.
Q. CantheOP--640 beusedwith otherPLCproducts?
A.Yes.The OP--640 does supportAllen-BradleySLC5/03,SLC5/04,and
Micrologix.
Q. WhatarethepowersupplyrequirementsfortheOP--640?
A.The OP--640 panelrequiresa 24VDC externalpowersupply.See the
Specificationsfordetails.
Q. Will theOP-panels supportgraphics,animation,orcoloroperatordisplay screens?
A.No.The OP-panelswhichsupportdisplay capabilitiesallownumericdata display,
and some panelswill also allowtextmessage display.
Q. CanIconnectmorethan oneOP-panelto onePLC/CPU?
A.Yes, thisisreferred to asaMulti-Panelapplication.You maynetworkup to 31
panelstocommunicate using RS-422 multi-drop communicationsbetween the
OP-panelsand OP-9001 CommunicationsMasterunit. Also,ifyourCPUhas
secondaryports,you may connectasingle panelto each availableserialport.
Q. Whydoes mypanel lose communication afterbeing inservice foraperiod of time?
A.Once a panelgains communication withaPLCthere are onlyafewreasonswhyit
doesnotcontinue:1)RFI fromnearbymotors,welders,starters,etc.causing
anything from memory corruption to damaged driverchips;and 2)an inadequate
powersupply.
Q. WhenIhave mypanelconnectedtoaDL205,myLCD and/orlampswork,butmypushbuttons
don’t...why?
A.The OptimatemodulecannotWRITEtothe PLC’smemorywhen the CPU’s
RUN/TERMswitchisinthe Run position, therefore onlythe LCD and/orlamps
visuallyfunction.The CPUshouldbeset tothe Term position in orderforthe
Optimate paneltowritetoit.

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Getting Started
Q. Mymodulewill occasionallyfail whenIpowerup my system.Whydoes thishappen?
A.Normallythisis caused byan inadequate powersupply corrupting the memory.
When determining the size ofa powersupplybe suretoinclude ALL sourcesof
energy consumption and also account forthe surge these devicesrequire.For
exampleanOP--613 requires1.5Amps(for2milliseconds)atstart-up,butafter
start-up needsonly90 mAat24VDC tofunction.
Q. Mypanel lightsflashwhenconnectedtothebottomportofaD2--240.What’swrong?
A.The lowerporton the D2--240 defaultstoASCII mode and needsto be set toHEX
mode in ordertocommunicatewith an Optimate panel.Access the portsettingsfrom
DirectSOFT byPLC-->Setup-->Setup SecondaryComPort.
Q. Inamulti--panelsystem,howshouldI wirethepanelsifmorethan onepowersupplyisbeing
used?
A.It ishighlyrecommended thatall the powersupplygroundsbe wired together.
Failuretodosomayresultinfailed modules.Also,ensurethatpowersupplyand
wiresizeislarge enough to handlethe current, especiallyatlong distances. It isalso
highlyrecommended thatall shieldsbe tied to earth ground.Forpowercable
distancesgreaterthan 50’orin noisy environments,atwo-twisted pairshielded wire
such asBelden 9729 (orequivalent)should be used.Thereisan OP--9001
SupplementalSheetwith diagrams,included with all OP--9001’s,depicting the three
most typical wiring arrangements.
Q. Whydoes mymoduleworkina stand-alone situation,butnotwhenconnectedtomy
OP--9001?
A.The mostobviousreason isthat the modulewasnotconfigured foramulti-panel
situation orthat the OP--9001 wasnotconfigured forthe module.Next, the OP--9001
communicateswiththe moduleviaRS--422 cable,soverifythat the pin-outsare
correct. Lastly, the RS--422 driverinthe module orOP--9001 mayhavefailed due to
cabling orpowersupplyproblems.Pleasereferencethe OP--9001 Supplemental
Sheet forwiring directions.
Q. I’ve loadedanewconfiguration intomypaneland still getsomeof theoldmessages.Howdo I
getrid of theoldmessages?
A.The OP--WINEDITdoesnotclearthe message listinthe OPpanel when you load
a newconfiguration.Ifyou had moremessagesinthe oldconfiguration than the new
configuration, the extramessagesdo notgetoverwritten.You can clearthe
message list fromCONFIGURE>CLEARLIST>THECONNECTEDPANEL.Reload
the newconfiguration and the oldmessageswill be gone.

2
Installation and
Specifications
InThisChapter....
—ConnectingaPowerSupply
—Preparing PanelforConfiguration
—Preparing PanelforCommunications
—OP--9001 Multi--panel Configurations
—Choosing Connecting Cables
—Connecting CableDetails
—Labeling the Lampsand Pushbuttons
—Templatesfor ManuallyCreating labels
—Dimensionsfor Mounting
—PanelSpecifications

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Installation and Specifications
Connecting aPowerSupply
An externalpowersupplyisadapted tosupplyoperating voltage tothe OP--640 unit.
The powersupplymustdeliverarange between 8 to 30 VDC,and provide a
minimumof5watts continuouspowertothe units.Connectyourpowersupplyusing
the terminalblock connectorsupplied with each panel.The connectoris keyed to
preventreversing the polarity.
Use 18--24 AWGconductorwire and connect the
powersupplytothe connectorblock whichis sup-
plied with each operatorpanel.The terminalmarked
1isthe positive(+8--30 VDC)connection and termi-
nal2isthe common ground (0V)connection.
Plug the terminalblock con-
nectorintoPower receptacle
located on the back side of the
panel.
Receptacle
+24VDC
Ground
--0V1 2
+--
InMulti-panelapplications,ifseparate powersuppliesare used,makesurethe
electricalground connectionsdo nothave a greatpotentialdifference.When using a
single powersupplyinaMulti-panelapplication, the powersupplymustmaintainthe
specified voltage and currentconsumption levelsunderall conditions(including
power-up)foreach of the individualunits.See individualpanelpower requirements
underPanelSpecifications.
+J1 J2
Power
Supply
(CommunicationstoPLC)
OP--9001
(RS-422)
Power
Supply
Panel1Panel2Panel3
Power
Supply
Power
Supply
etc...
Ground
0VDC
8to30VDC
PowerSupply
Connections
Multi-panelPower
SupplyConnection

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Specifications
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Installation and Specifications
Preparing thePanelforConfiguration
The RUN/PGMSwitchmustbe set toPGM (ON)before downloading fromthe PCto
the panel.The TERMswitchshouldremain off.
NOTE:You mustcycle powertothe panelto activatethe newswitchsettings.
PGM
TERM
RUN 1
2
ON
Set toPGM
Connect the configuration cable(OP--ACBL--1)between the serialportof the
OP-paneland the serialportof the personalcomputer.The panelmaythen be
configured using the OP--WINEDITconfiguration software.The figure belowshows
programming cableconnectorsand wiring specifications.Wiring diagramsreferto
the cableconnectors,notthe communication ports.
OP--ACBL--1
ComputerPanel
1=notused
2=Dout
3=Din
4=notused
5=0V
6=notused
7=notused
8=notused
9=notused
10=notused
11=notused
12=notused
13=notused
14=notused
15=notused
5=0V
4=notused
3=Dout
2=Din
1=notused
9=notused
8=CTS
7=RTS
6=notused
DB9DB15
3 3
22
55
7
8
1
1
9FemaleMale
RUN/PGM
Switch
Configuration
Cable

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Installation and Specifications
Preparing thePanelforCommunications
The RUN/PGMSwitchmustbe set toRUN afterloading the configuration program.
The TERMswitchshouldremain off.
NOTE:You mustcycle powertothe panelto activatethe newswitchsettings.
PGM
TERM
RUN 1
2
ON
Set toRUN
OP--9001 Multi-PanelConfigurations
If you areconnecting morethan one OptiMate panelto a singleCPUthisisreferred
to asMulti-panelconfiguration.Multi-panelconfigurationsrequirethe OP--9001
CommunicationsMaster.The OP--9001 communicateswiththe CPUaswell asthe
connected OP--panels.The OP--9001 looks foran address withinthe range of0to
30 foreach panelconnected.Each panelconnected in an RS-422 linkmusthave a
unique address.Amore detailed description ofmultiple panelconfigurationsand
installation isgiven inthe OP--9001--M User Manual.
When using an RS-422 communicationslink, the lastpanelmustbe terminated by
setting the TERMSwitchtoON.Systemswhich are using the OP--9001 in a
multi-panelapplication useRS-422 wiring. Operatorpanels communicating more
than 50 feetdistancemustuseRS-422 links.The TERMSwitchstays OFF for
RS--232 communications.
NOTE:Onlythe lastpanelofeachRS-422 link shouldbeterminated (TERMswitchON).All
otherpanelsmusthavethe TERMswitchOFF.Afterchanging the DIPswitchsettings,
remembertocycle poweron the panelto activatethe newswitchsettings.
PGM
TERM
RUN 1
2
ON
RUN/PGM
Switch
TheTERMSwitch

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Specifications
Choosing
Connecting Cables
Depending on whichPLCyou are
using,you mayrequire asmanyas
twocables.Here arethe
requirements:
DOP-ACBL-1:all unitsrequire
this cableforconfiguration.This
isa 9-pinfemaleto 15-pinmale
cablethatconnects your
personalcomputertothe
OP-panel.This cableisalso
used toconnectan OP-panelto
the Allen-BradleySLC500
CPUs.
DCPU Cables:You will also need
the appropriatecabletoconnect
yourCPUtothe OP-panel.Use
the chartshowntothe right to
choosethe correct
communications cable.
OP-9001 CableConnectors
If you’re planning to usemultiple
panelsand an OP-9001, then you’ll
need to buildyourowncustom
cables.Sincethe propercable
choicereallydependson your
application,we offerthe following
connectors.
DOP-CMCON--1—pack of4
ribbon cableconnectors.
DOP-CMCON--2—pack of4
solder-type connectors.
DOP-CMCON--3—pack of2
D--shell connectorswithscrew
terminalsforusewithOP-9001
&multipleOP-panels.
DOP-PSCON—pack of4 power
supplyblock connectors.
Forelectricallynoisy environments,
werecommend an individuallypaired
and shielded cable,such asBelden
9729 orequivalent. Thistype ofcable
will requirethe solder-type orD-shell
withscrewterminalconnectors. If
you’re going 30 feetorless,you can
useribbon cable.For ribbon cable,
werecommend Belden 9L28015 or
3M3365/15.
**-- also availableinDC versions
*—requiresRS232 DataCommunicationsUnit(D3--232--DCU)
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Installation and Specifications
OptiMateCables
Family
C
P
U
(
o
r
o
t
h
e
r
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e
v
i
c
e
)
P
o
r
t
C
a
b
l
e
F
a
m
i
l
y
C
P
U
(orotherdevice)
P
o
r
t
C
a
b
l
e
DirectLOGICt
DL05 /DL105
DL05:D0--05
DL105:DL130
DL05:Both ports
DL105: Onlyone port
OP--2CBL
DirectLOGICt
D
L
2
0
5
DL230 Onlyport OP--2CBL
D
L
2
0
5
DL240 Top port OP--2CBL
Bottomport OP--2CBL
DL250 Top port OP--2CBL
Bottomport OP--2CBL--1
D2--DCM (module)Onlyport OP-4CBL--2
DirectLOGICt
D
L
3
0
5
DL330 RequiresDCU*OP--4CBL--2
D
L
3
0
5
DL330PRequiresDCU*OP-4CBL--2
DL340 Top port OP-3CBL
Bottomport OP-3CBL
DL350 Top port OP-2CBL
Bottomport OP-4CBL-2
DirectLOGICt
D
L
4
0
5
DL430 Top port(15-pin)OP-4CBL--1
D
L
4
0
5
Bottomport(25-pin)OP-4CBL--2
DL440** Top port OP-4CBL--1
D
L
4
4
0
*
*
Bottomport OP-4CBL--2
DL450** Phone Jack OP-2CBL
Top port(15-pin)OP-4CBL--1
Bottomport(25-pin)OP-4CBL--2
D4--DCM (module)Onlyport OP-4CBL--2
SliceI/O panelsOnlyport OP-4CBL--1
GEâSeries1IC610CPU105/106 RequiresDCU*OP-4CBL--2
TI305t/
S
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M
A
T
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C
â
T
I
3
0
5
t
325--07,PPX:325--07 RequiresDCU*OP-4CBL--2
S
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M
A
T
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C
â
T
I
3
0
5
t
330--37,PPX:330--37 RequiresDCU*OP-4CBL--2
325S--07 (or325 w/Stage Kt)RequiresDCU*OP-4CBL--2
330S--37,PPX:330S--37 RequiresDCU*OP-4CBL--2
335--37,PPX:335--37 Phone Jacks OP-3CBL
If DCU isused*OP-4CBL--2
TI405t/
S
I
M
A
T
I
C
â
T
I
4
0
5
t
425--CPU,PPX:425--CPU** Onlyport OP-4CBL--1
S
I
M
A
T
I
C
â
T
I
4
0
5
t
PPX:430--CPUTop port(15-pin)OP-4CBL--1
Bottomport(25-pin)OP-4CBL--2
435--CPU,PPX:435--CPU** Top port(15-pin)OP-4CBL--1
Bottomport(25-pin)OP-4CBL--2
SmartSlicetI/O panelsOnlyport OP-4CBL--1
A--B SLC500 5/03,5/04 Bottomport OP-ACBL--1
A-BMicroLogixOnlyport OP-ACBL--2

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Installation and Specifications
Connecting CableDetails
The OP--640 connecting cablemay varydepending on the CPUused.Refertothe
previouspage toconfirm the propercableis chosen forconnecting toyourPLC.
OP--2CBL
OP--3CBL
OP--4CBL--1
OP--4CBL--2
1 2 3 4
PLC
Panel
3 4 5 621
1=0V
2=notused
3=Din
4=Dout
5=notused
6=notused
1=Din
2=Dout
3=notused
4=0V
8=YOM
7=CTS
6=notused
5=notused
4=On-line
3=Din
2=Dout
1=YOP
8=notused
7=0V
6=notused
5=CTS
4=RTS
3=Din
2=Dout
1=notused
1=notused
2=Dout
3=Din
4=notused
5=0V
6=notused
7=notused
8=notused
9=notused
10=notused
11=notused
12=notused
13=notused
14=notused
15=notused
13=notused
12=notused
11=notused
10=notused
9=notused 21=notused
20=notused
19=notused
18=notused
17=notused
16=notused
15=notused
14=notused
25=notused
24=notused
23=notused
22=notused
RJ12
RJ11
RJ12 (PLC)DB15
4 3
23
RJ11 (PLC)
2 3
21
DB15
54
DB15 (PLC)
2 3
23
DB15
54
RJ12
RJ11 DB15
DB15
DB15
DB15DB25
DB15
13
14
15
1
7
8
DB25 (PLC)
2 3
23 57
4
5
DB15
51
(6P6C)
(4P4C)
1
25
1
15
15=tied (0V)
14=tied (0V)
13=tied (0V)
12=notused
11=notused
10=notused
9=notused
1
15
OP--ACBL--2
Mini--DINDB15
DB15
7 3
24 52
34
2
5
7
1
6 8
8PinMiniDIN
Din+
Din--
Dout+
Dout--
RTS+
CTS+
RTS--
CTS--
=Dout+
=Dout--
=Din--
=Din+
PLCPanel
11
12
9
10
0V=0V
5
RS-422 Pinout
=0V
5
3=Din
2=Dout
OP--2CBL--1
8=notused
7=0V
6=notused
5=CTS
4=RTS
3=RXD
2=TXD
1=notused
15-pin(PLC)
2 3
23
DB15
57
DB15
15-pin
15=notused
14=notused
13=notused
12=notused
11=notused
10=notused
9=notused
4
5
Connecting Cable