Eaton 500 User manual

PanelMate Series 500
Getting Started User’s Guide
Cutler-Hammer IDT
P.O. Box 6166
Westerville, OH 43086-6166
[phone]
09/18/96 P/N 01-00258-00

Preface
Cutler-Hammer IDT has prepared this manual for use by Cutler-Hammer IDT personnel
and customers. The information contained within is the property of
Cutler-Hammer IDT and shall not be reproduced in whole or part without written approval
from Cutler-Hammer IDT.
The material in this manual is for informational purposes only and is subject to change
without notice.
Cutler-Hammer IDT assumes no responsibility for any errors that may appear in this
manual.
The following are trademarks of Cutler-Hammer IDT and are not to be reproduced nor
used in any fashion without written approval from Cutler-Hammer IDT. All rights reserved.
PanelMate®
Microsoft® is a registered trademark of Microsoft Corporation.
Windows® is a registered trademark of Microsoft Corporation.
Any reference to trademark and/or copyrighted material is unintentional.
© Cutler-Hammer IDT, Inc., 1996
Printed in the USA

Foreword: Success with the PanelMate 500 F-1
Foreword
Achieving success with the PanelMate 500
Congratulations on your purchase of the PanelMate 500 electronic operator station!
Now that you have received your software and hardware, it’s time to determine how to
setup your operator station and put it into service.
SUCCESS - AND QUICKLY! We know that’s what every user wants and expects. You’ve
started at the right place: by opening this “Getting Started” manual. We know how most
people dislike reading volumes of material. So, if you’ll just follow the steps outlined in this
ONE booklet, you’ll be able to get a simple operator interface running with your PLC or
network in just a few hours.
We’ve provided several handy tools to help you “get to know” PanelMate 500. They are
further detailed in the pages ahead, but include:
* an overview of PanelMate 500 which you can run on your PC like a
slide show, using a built-in viewer
* a simulation built into every PanelMate 500 online unit
* a more detailed demonstration which can be loaded into the online unit
* a set of simple startup configurations that lets you verify communication
with many of the most common small PLCs

F-2Foreword: Success with the PanelMate 500
About the Other Manuals
In addition to this Getting Started manual, the following documents are furnished with
PanelMate 500 configuration software:
* Configuration Editor User’s Guide
This document contains reprints of over 100 help pages built into the configuration
editor. It provides answers to questions about software features and functions.
* Transfer User’s Guide
This document provides instruction on how to transfer files between your PC and a
PanelMate 500 online unit.
* Online Operation User’s Guide
This document describes how PanelMate 500 works online, and includes a summary
of communication errors which may be displayed.
* individual PLC brand communication manual(s)
A PLC communication manual will be furnished for each of the PLC communication
interfaces you purchased. (They can be bought as a group, or individually.) Each
manual contains detailed information about cabling to the PLC, addressing, etc.
This document is furnished with each PanelMate 500 online unit:
* Hardware Installation Guide
This document provides guidelines for physically installing the online unit, including
hole cutout information, power and ventilation information, etc.
DON’T READ ANY OTHER MANUALS RIGHT NOW. Please DO read and follow the rest
of this Getting Started manual - it will make your path to success much shorter and much
more fun! So, if you’ll look at the next page about Additional Help, then turn to Chapter 1,
let’s get started.

Foreword: Success with the PanelMate 500 F-3
Additional Help
If you make use of the demonstration materials and the sample PLC startup
communication files, you should be able to get your PanelMate 500 unit up and running
successfully with your PLC. And, you’ll see that your configuration software has many
built-in “help” pages to assist you with the page creation process.
However, PanelMate 500 has a wide variety of features available, including the powerful
Virtual Mentor feature in online models 542VM and 542LM. If you need advice on creating
your application, or if you need other help, please phone one of the numbers listed below,
for assistance.
Department Number Description
Customer
Support Center [phone] Answers your questions about
connection, configuration, and application
of Cutler-Hammer products. Available
8:00 AM to 5:30 PM (Eastern Standard
Time) Monday through Friday.
Bulletin Board [phone] Electronic bulletin board service allows
you to access product information,
documents, and demo files.
Log on with these settings:
(8/1/none/9600-28.8K baud)
Document
Faxback [phone] Automated document request service
allows product information and technical
bulletins to be automatically faxed.
Software Update
Service [phone]
Extension 7636 Registers your software and provides free or reduced price software updates for
Operator Station products.
Repairs and
Upgrades [phone] To obtain product repairs, upgrades and
spare parts.
Order Entry [phone] Helps you place a new order or check the
status of an existing order. All new
product sales are through our world-wide
distribution channel.
Emergency
Support (After
5:30 PM Eastern
Standard Time)
[phone] 24 hour emergency technical support for
plant down or safety issues.
(Note: This service does not currently
provide emergency product shipments.)

Table of Contents i
Table Of Contents
Foreword çç Start here for best success with PanelMate 500!
Chapter 1 Overview & Notes for Previous Users of PanelMate
Chapter 2 How PanelMate Units Work Online With PLCs
Chapter 3 From Opening the Boxes to Running Online:
A Master Startup Flowchart
Chapter 4 Loading the Software To Your Personal Computer
Chapter 5 Creating a New Configuration (set of pages)
Chapter 6 Assigning PLC Communications
Chapter 7 Creating New Pages
Chapter 8 Configuring with the Virtual Mentor Capability
Chapter 9 Saving the Configuration
Chapter 10 Compiling the Configuration
Chapter 11 Transferring the Configuration to an Online Unit
Chapter 12 Running the PanelMate 500 Unit
Online With the PLC
Appendix The communication startup files, two sample configurations,
plus 12 “Helpful Hints”

Table of Contents ii

Overview of the PanelMate 500 1-1
Chapter 1
Overview of the PanelMate 500
In this chapter, you will learn:
•How you can view an overview of PanelMate 500, presented using a Microsoft tool
called PowerPoint
•PanelMate 500 theory of operation
•How the PanelMate 500 relates to the PanelMate family

1-2Overview of the PanelMate 500
Congratulations on beginning with the Getting Started manual as the place to get familiar
with PanelMate 500. Have you glanced at the Foreword section a few pages back? It
highlights the other documents you get with PanelMate 500, and provides handy phone
numbers you may want.
We recommend that you first take 20 minutes to look at the PowerPoint-based overview
described in the next section. It’s well worth the time, as a way to get the who, what,
where, when and why of PanelMate 500.
How to See a Great Overview of PanelMate 500
Included with your configuration software is a separate group of 3 diskettes as shown
below. When transferred to your PC, the file on the Overview diskette permits you to view
a colorful and informative “slide presentation” about PanelMate 500, presented with a
Microsoft tool called PowerPoint. If you do not have PowerPoint installed on your
Windows-based PC, a copy of the PowerPoint slide “viewer” is provided for your
convenience. One of the diskettes is labeled “Examples”, and contains files which are
referenced in the Appendix and in the Virtual Mentor Users Guide.
Here are the contents of the diskette pack:
Diskette Label File Contents Description
PowerPoint Viewer pptview.exe “slide show” viewer software
pptview.dll
Overview over1.ppt PowerPoint-based overview
of PanelMate 500
Examples (various files) communication startup files and
sample configurations

Overview of the PanelMate 500 1-3
How to load the files to your PC and watch the “slide show”
overview:
1. Within the Windows Program Manager of your PC, select the File Manager.
2. If you already have Microsoft PowerPoint software installed on your PC, skip to step
#3. If you do not have PowerPoint already on your PC, insert the furnished
PowerPoint Viewer disk in your PC’s floppy disk drive. Use the File Manager to copy
both the pptview.dll and pptview.exe files into a directory of your choice in your PC
environment.
3. Insert the Overview disk into your PC’s floppy disk drive. Use the File Manager to
copy the over1.ppt PowerPoint file into the same directory into which you copied the
Viewer in previous step #2. If you skipped step #2 because you already have
PowerPoint on your PC, then copy the PowerPoint files into an appropriate directory of
your choice.
4. If you already have PowerPoint present on your PC, please enter PowerPoint and use
the slide show feature to view your just-loaded over1.ppt file. If you do not have
PowerPoint on your PC, proceed to step 5, to use the viewer you just loaded.
5. From your File Manager, double click on the PowerPoint Viewer file, pptview.exe.
When the screen presents you with a directory listing, double click on the file over1.ppt
to start your slide show.

1-4Overview of the PanelMate 500
Theory of Operation
Have you viewed the PowerPoint “slide show” overview of PanelMate 500? It’s a great
way to get familiar with the product, but we wanted to also provide a printed summary of
how the product works.
PanelMate 500 is a compact, rugged operator interface device for use with PLCs. The
PanelMate 500 Series is a family of multi-line text display units. However, each unit is
much more than just a message display - it permits operator pushbutton control and can do
sophisticated mathematical operations.
Online Operation
The online operation of the PanelMate 500 features individual pages which are "linked" to
each other to provide a prompted or guided operator interface. As a member of the
PanelMate Family, PanelMate 500 has the same basic operational characteristics which
include the concept of screen objects (templates), and alarming.
There are five different onscreen page types which are created when configuring the
system:
Menu Displays a list of items, one of which can be selected by using
the enter key or the numeric keyboard
Data Displays text messages, numeric data, bar graphs.
Permits numeric data entry and use of the Soft Function
Keys located below the display to send data to the PLC or to
change pages.
Maintenance Provides access to the Maintenance mode which permits on-
line access to any data point in the PLC.
Change Password Permits the modification of passwords stored within the unit.
Setup Permits selection of the Contrast Adjust, Offline Mode, or the
ability to read the internal System Information (name of the
configuration.)

Overview of the PanelMate 500 1-5
In online operation, the operator responds to prompts on a page which may cause the next
page to be displayed. The linked pages form a complete machine control system which
can guide the operator through all five components of machine operation:
Startup
Run
Change
Troubleshooting
Shutdown
There is a sixth type of “page” which can be configured, which is called the System Page.
This page permits the assignment of functionality to 8 membrane keys and either 4 or 8
(depending on which model) built-in tri-color LEDs, to support pushbutton functions and
alarm annunciation. These function assignments are active for the membrane keys and
LEDs at all times in online operation, no matter which of the 5 onscreen pages is
displayed.
The Virtual MentorGuided Operator Capability is available with online models 542VM
and 542LM, to permit the operator station to perform “autopilot-like” functions.
Virtual Mentor
* adds extensive built-in decisionmaking tools
* can simplify the operator’s choices
* can guide operators through sequences
* can vastly simplify diagnostics
* can perform actions without operator or PLC initiation
* further reduces PLC programming
These features can greatly ease tasks and decisionmaking for the operator. Virtual Mentor
can be used to create very focused, “context-sensitive” startup or diagnostic sequences
which present limited choices to the operator. Virtual Mentor can also perform internal
calculations and transmit data back to the PLC without operator intervention.

1-6Overview of the PanelMate 500
Configuring the System
The page types are created and linked to each other using Windows-based software on a
personal computer. The following steps A, B, C, D, E and F represent stages in the
process of configuring a typical PanelMate 500 operator interface application.
HOME
NEXT
PREV
ALARM
SELECT
CYCLE
HELP
MANUAL
RESET
START
STOP
AUTO
PanelMate
Cutler-Hammer
IDT Products
TELL ME WHAT
YOU WANT ME TO DO
SETUP RUN DEBUG HELP Configure multiple onscreen pages selected
from 5 onscreen page types:
1) Menu page
2) Data page
(insert one or more object types:)
text
conditional indicator
state indicator
numeric data
alpha display
bar graph
3) Maintenance page
4) Change Password page
5) Setup page
A
B
C
D
Configure Alarms
Configure Virtual Mentor features
Configure PLC Name and Port Table
E
FConfigure System Parameters
Configure “System Page”
As suggested by the diagram above, your operator interface will be constructed from
onscreen pages which can be selected from five types. A typical application may have
multiple Data pages, several Menu pages, and perhaps only one each of the remaining 3
page types. In addition, you will need to configure the “system page” (the 8 control buttons
and 4 or 8 built-in LEDs), plus any alarms needed. If your online unit will be either a model
542LM or 542VM, you can also configure the autopilot-like Virtual Mentor features.
As you create each page in the system, you will use spreadsheet entries in the editors to
link it to other pages. This sets up a “navigation” strategy which leads the online unit
operator from one page to a next appropriate page.

Overview of the PanelMate 500 1-7
Additionally, the software provides Windows-based editors for System Parameters, PLC
Name and Port Table, System Online Labels and Message Library:
System Parameters
Set up system wide options such as Passwords, Audio Levels, Scan Delays, and Remote
Acknowledgment of Alarms
PLC Name & Port Table
Set up PLC communications and configure the PanelMate 500 ports
System Online Labels
Customize labels built into the system. Modify for your terminology or customize to your
language requirement.
Message Library
Display text messages that were configured on other pages in the system and which are
used on line to give the operator information on machine or process status. These
messages can be edited, but existing messages cannot be deleted, nor new messages
added from this library listing.

1-8Overview of the PanelMate 500
Notes to Previous Users of PanelMate
1. Although PanelMate 500 shares similar screen-based "objects", mathematical
capabilities and PLC communication software as other PanelMate family members,
the small display size changes the way an operator interacts with the unit. With other
PanelMate units, operators actively select from a small library of detailed pages
(typically 10 or 20), to “navigate” through the pages available. PanelMate 500 allows
the developer to design a navigation sequence linking together what may be a large
number of simpler pages (perhaps 100). This pre-defined linkage helps eliminate
operator confusion and indecision. It is still also possible to create menu listings from
which operators select numbered entries, to navigate to another page in the system.
A key difference with PanelMate 500 is that anything the user wishes to present on the
screen must be configured from one of 5 available onscreen page types:
Menu page
Data page
Maintenance page
Change Password page
Setup page
Refer back to the Theory of Operation section of this chapter for more explanation of
each page type.
There are many ways pages in a PanelMate 500 unit can be linked to each other. The
operator may choose to navigate to another page in a sequence or the operator’s
response to a question on a page or an alarm may automatically link to another page.

Overview of the PanelMate 500 1-9
2. The keypad layout is new. There are four Soft Function Keys located below the
display area. These keys are similar to the control buttons located to the right of the
PanelMate display and have different definitions on different pages. They are used to
write data to a PLC or to change pages.
There are 8 Fixed Function Keys and either 4 or 8 LED’s (depending on model of PM
500) located on the outside edges of the unit. These keys operate independently from
the display, and can be custom labeled by the user. One key will serve as access to
the Alarm Page which contains both alarms and system error messages. The blue
keys are the Navigation Keys. They can be used to select the Previous Page, Next
Page, or Home Page. The Tab Left and Tab Right keys are used to move within a
page.
The numeric keypad is used to enter numeric data on pages and to select items on
Menu Pages.
3. The Menu page can list from one to 99 items. They may be selected with the numeric
keypad. One can also use the Tab Left and Tab Right keys to scroll the list and press
the Enter Key to select and item.
4. The Data page type is similar to a page in earlier PanelMate products, in that it permits
placement on the page of tools called “objects”, each of which has a specific purpose.
The 6 object types are:
Text
Conditional Indicator
State Indicator
Numeric Data
Alpha Display
Bar Graph
The six objects are further explained in Chapter 2.
5. The Maintenance Page presents the Maintenance Template functionality (TCAM like
functionality). This page enables the operator or maintenance person to display (and
optionally change) any value in the PLC register table.
6. The Change Password Page is created to permit the user to change passwords on-line.

1-10 Overview of the PanelMate 500
7. The Setup Page provides the functionality found on the Setup Page of PanelMate. It
permits contrast adjustment, access to system information, and can be used to select
offline mode.
8. Note that all pages can be password protected. A check is made before page entry.
The seven levels of passwords each have independent time-outs. Clearing a higher
level password opens all lower level passwords.
9. Alarming is different than with the rest of PanelMate. There is a separate editor for
alarms. One tab is for discrete bit alarms and the other is for value range checking.
The developer must enter the alarm messages; they do not configure automatically. A
new feature is that each alarm can write a unique bit to the PLC and can also be
associated with a diagnostic page. One of the up to 8 function keys must be selected
as the alarm key. The associated LED will flash when an alarm or a system error or
communications error occurs. Pressing the assigned Alarm Function Key will jump to
the alarm page which operates in a fashion similar to the alarm page in other
PanelMate models. If you scroll to an alarm which has an associated diagnostic page,
pressing the soft function key labeled "HELP" will take you to the appropriate page.

How PanelMate Series 500 Units Work Online With PLCs 2-1
Chapter 2
How PanelMate Series 500 Units Work Online
With PLCs
In this chapter, you will learn:
•What role a PanelMate Series 500 unit plays in factory automation
•How PanelMate Series 500 partners with a PLC
•How operators interact with PanelMate Series 500
•How PanelMate Series 500 uses standardized on-screen tools called “objects”
•What functionality the Virtual Mentor feature provides
•PanelMate Series 500 alarm annunciation capability
•What additional features are available
•How operators access multiple screens or “pages”
•Using a simulation built into each PanelMate 500 online unit

2-2How PanelMate Series 500 Units Work Online With PLCs
What Role a PanelMate Series 500 Unit Plays in Factory
Automation
Conventional operator stations consist of individual devices (pushbuttons, lamps, etc.)
hard-wired to I/O points on a PLC.

How PanelMate Series 500 Units Work Online With PLCs 2-3
The PanelMate Series 500 is an electronic operator station which replaces conventional
operator stations and associated hard-wired devices:
HOME
NEXT
PREV
ALARM
SELECT
CYCLE
HELP
MANUAL
RESET
START
STOP
AUTO
PanelMate
Cutler-Hammer
IDT Products
TELL ME WHAT
YOU WANT ME TO DO
SETUP RUN DEBUG HELP
The unit illustrated above features a 4-line text display area, which is available as either
vacuum fluorescent or LCD display type. PanelMate 500 is also available in 2-line
vacuum fluorescent or LCD display versions.