Renu Electronics FlexiLogics series User manual

1
User’s Manual
for
FlexiLogicsTM

2
COPYRIGHT NOTICE
This manual is a publication of Renu Electronics Pvt. Ltd. and is provided for use by its customers only.
The contents of the manual are copyrighted by Renu Electronics; reproduction in whole or in part, for use other than in
support of Renu Electronics equipment, is prohibited without the specific written permission of Renu Electronics.
SERVICE
If service is required then pack the unit in its original packaging container or, if unavailable, any suitable rigid container.
If a substitute container is used, surround the unit with shock absorbing material; damage in shipment is not covered
by the warranty. Include a letter with the unit describing the difficulty and Hardware Revision and Software Version.
Send to the following address:
Renu Electronics Pvt. Ltd.
Survey No. 2/6,
Baner Road,
Pune-411045
All returns will be tested to verify customer claims of noncompliance with the product warranty. Improper return
packaging, which makes verification impossible, will void the warranty. If noncompliance is verified and is not due to
customer abuse or the other exceptions described with product warranty, Renu Electronics will, at its option, repair or
replace the Product returned to it, freight prepaid, which fail to comply with the foregoing warranty, provided REPL is
notified of such noncompliance within the one-year warranty period.
ASSISTANCE
Thismanualisdesignedtoprovidethenecessaryinformationfortrouble-freeinstallationandoperationofyournew
FlexiLogicsSeries. However, ifyou need assistance, please callRenu Electronics Pvt. Ltd. at 91-20-27292840 or
visitourwebsite at www.renuelectronics.com
MANUAL REVISION
Ifyou contact us inreference to this manual,please include the followingdocument number
Name : UserManualForFlexiLogics
PartNumber : URML104
Document : UMAN\FL\0110
Revision : 1.02B

3
RevisionNumber DocumentNumber Date Description
Rev1.00 UMAN\FL\0110 21-01-2010 FirstRelease
Rev1.01 UMAN\FL\0110 10-09-2010 FlexiLogicsfeaturesrevised
Rev1.02 UMAN\FL\0110 10-09-2010 FlexiLogicsmanual revised for images &
othercorrections
Rev1.02A UMAN\FL\0110 12-01-2011 Timings of ON/OFF pulse width is corrected on Pg. 85,
86, 88 & 90.
Rev1.02B UMAN\FL\0110 27-08-2011 Battery life specifications are corrected and
additionofcommunicationbaudrates.
Productconfiguration GUI changed.
Weights for FL series models are updated.
Revision History:

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Warranty Certificate
For New product: This product is warranted against defects in materials and workmanship for a period of 12 months
from the date of shipment to Buyer.
For Rectified Products:Any product that will be replaced will have Warranty for 6 months or upto Original Product
Warranty period whichever is greater.
The warranty is limited to repair or replacement of the defective unit at the option of the manufacturer. This warranty is
void if the product has been altered, misused, dismantled, or otherwise abused.
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, ARE EXCLUDED, INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE.
MAINTENANCE & SERVICE :There are no parts that can be serviced by the user. Service should be performed on a
unit substitution basis only. Do not attempt to remove, replace or service any printed circuit board, components or any
hardware/software related with display product. If problem within the display product occurs, contact the factory for
service information or repair.
NOTE : Renu Electronics Pvt. Ltd. is dedicated to providing complete customer service and customer satisfaction. If you
have any comments or criticisms about how to improve the product features/reliability, please make a note of the
problem/improvement and notify us. We are always open to new ideas and improvements. So please let us know your
ideas and comments.
IMPORTANT
FlexiLogics Series Products are Programmable Logic Controller modules which
actually take control actions. It is assumed that the user is well acquainted with the PLC
system being used and Windows based software usage, in general. Never use
FlexiLogics units to perform emergency STOP applications. It is advised that separate
switches be used outside the PLC forANY emergency Stops.
Any Mechanical or Electrical Modification to this Unit will
void all Warranties.

Table of Content
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Table of Contents
INTRODUCTION 7
1.1 Purpose of this manual 8
1.1.1 FlexiLogics Basics 8
1.1.2 Hardware Requirements 9
1.2 Features 10
1.3 FlexiLogics Overview 11
1.3.1 What is a FlexiLogics series unit? 11
1.3.2 How FlexiLogics Works? 13
1.4 Specifications of FlexiLogics Series 21
1.4.1 Comparison between basic models (FL010 & FL011) 22
1.4.2 Comparison between basic models (FL050 & FL051) 23
1.4.3 Specification for Basic Models 24
FL010 24
FL011 27
FL050 28
FL051 29
1.4.4 Specification for Expansion Models 30
FLD1600 30
FLD0016P (PNP Type transistor output) 31
FLD0016N (NPN Type transistor output) 32
FLD0016R (Relay Type output) 33
FLD0808R (Relay Type transistor output) 34
FLD0808P (PNP Type transistor output) 34
FLD0808N (NPN Type transistor output) 34
FLA0800L 38
FLA0800R 40
FLA0004 42
FLA0402U 44
HARDWARE 48
2.1 UnpackingTheUnit 49
2.2 Managing Electrostatic Discharge 49
2.3 CE Compliance 49
2.4 EnvironmentalConsideration 49
2.5 Safety Precaution 50
2.6 InstallationInstruction 50
2.7 InstallationInstructions 52
2.7.1 PanelMounting 52
2.8 Wiring Diagram 56
2.9 Communication Ports 56
2.10 Communication Cables 58
BEFORE YOU BEGIN 63
3.1 InstallingFlexiSoft configuration software: 64
3.2 Steps for starting FlexiSoft Software 67
3.3 UninstallingFlexiSoftSoftware 67
3.4 Procedure to launch ladder in FlexiSoft 68
3.5 Creating sample ladder 70
CONFIGURATION 73
4.1 Configuring unit using FlexiSoft 74
4.2 Tag Database 77

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4.3 Input (XW), Output (YW) and configuration (MW) Register allocation 81
SPECIAL INPUT AND OUTPUT 84
5.1 Special I/O Function overview 85
5.2 High Speed Counter Design 86
5.2.1 Single Phase Counter 89
5.2.2 Single Phase speed - counter 90
5.2.3 Quadrature bi-pulse counter 91
5.2.4 InterruptInput Function 93
5.2.5 Pulse Output Function 93
5.2.6 PWM Output Function 94
OPERATING SYSTEMS OVERVIEW 95
6.1 Operating System Overview 96
PROGRAMMING INFORMATION 97
7.1 Devices Registers 98
7.2 MemoryAllocation of XW, YW and MW 105
7.3 IndexModification 107
7.4 Real-time clock / calendar 109
7.5 User program 110
7.5.1 Main Program 110
7.5.2 Sub-program # 1 111
7.5.3 Timer interrupt program 111
7.5.4 I/O interrupt program 111
7.5.5 Subroutines 112
7.6 Programming Language 113
7.7 Program execution sequence 114
TROUBLESHOOTING 115
8.1 Troubleshooting Procedure 116
8.1.1 Power Supply Check 117
8.1.2 CPU Check 117
8.1.3 Program Check 117
8.1.4 InputCheck 118
8.1.5 Output Check 119
8.1.6 Environmental Problem 120
8.2 Self Diagnosis 121
MAINTENANCE AND CHECKS 126
9.1 Precautions during operation 127
9.2 Daily Checks 128
9.3 Periodic Checks 129
9.4 Spare Parts 130

Introduction
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INTRODUCTION
In this chapter. . . .
♦Purposeofthismanual
FlexiLogics Basics
HardwareConfiguration
♦FlexiLogicsFeatures
♦FlexiLogicsOverview
What is FlexiLogics series unit?
HowFlexiLogicsworks?
FlexiLogicsSpecifications

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1.1 Purpose of this manual
Thank you for purchasing FlexiLogics Series Products from Renu Electronics. FlexiLogics Series Products are
versatilehigh-performance programmable controllers with Microsoft®WindowsbasedconfigurationSoftware.
ThisManualexplains the operation of the FlexiLogics Seriesandhowto implement available features using the
FlexiSoftSoftware. This manual will helpyou to install, configure and operateyour FlexiLogics product.
1.1.1 FlexiLogics Basics
FlexiLogicsprovidemuchmore versatility than traditional programmable controllers. FlexiLogics unit supports basic
relayladder functions. In addition to thisitprovidesfunctions such as data operations,arithmaticoperations,various
functionsetc. Furthermore, its high speed counter functions,pulse output functions, anddata communication
functions allow its application to a wide scope of control systems.
What is a Project?
Aproject is an user created application in FlexiSoft Software.Aproject contains information such as FlexiLogics
model,NetworkConfiguration, ladder information, etc.
What is a Ladder?
You use Ladder Logic to writeyourprojectapplication. Ladder is based on Booleanprincipals.Ladder Diagrams are
composed of different types of contact, coil and function block elements. These elements are placed in nets.
In any Ladder Diagram, the contacts represent input conditions. They lead power from the left rail to the right
rail. Coils represent output instructions. In order for output coils to be activated, the logical state of the contacts
must allow the power to flow through the net to the coil.

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1.1.2 Hardware Requirements
Thefollowingbasic PC hardware configuration is needed to configureandoperateyourFlexiSoftConfigurationSoftware.
MinimalPCconfigurationforWindows2000/XP:
DEVICE RECOMMENDED
Processor 800MHzPentiumprocessorOR euivalent processor
OperatingSystem Microsoft Windows 2000 with SP4
Microsoft Windows XP Professional / Home Edition with SP2
RAM 256MB
HardDiskSpace 800MB(including 200MB for the .NETFrameworkRedistributable)
Display 1024x768HighColor16-bit
Mouse/Keyboard Required
MinimalPCconfiguration for Vista:
DEVICE RECOMMENDED
Processor 1GHzPentiumprocessoror equivalent processor
OperatingSystem Microsoft Windows Vista Home and Vista Business edition
RAM 1GB
HardDiskSpace 800MB(including 200MB for the .NETFrameworkRedistributable)
Display 1024x768HighColor16-bit
Mouse/Keyboard Required
Thesearetheminimumsystemrequirementsfora computer running the FlexiSoft Configuration software.

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1.2 Features
ExpansionModels:
Thefollowingarethedigitalexpansionmodels:
-> 16 points DC input
->16 pointsDC output (NPNType)
-> 16 points DC output (PNPType)
->16 pointsDC output (RelayType)
-> 8 DC inputs + 8 DC outputs (NPN type)
-> 8 DC inputs + 8 DC outputs (PNP type)
-> 8 DC inputs + 8 DC outputs (Relay type)
Thefollowingare the analog expansion models:
->4UniversalAnaloginputs& 2analogoutputs(V-IType)
->8Analoginputs(Linear Type)
->8Analoginputs(RTDType)
->4Analogoutputs(V-IType)
Built-inhighspeedcounter:
Twosingle-phaseorone quadrature (2-phase) pulses can be counted. In single phase mode,upto50KHz
andinquadrature mode, up to 5KHz frequencycanbecounted.
Highspeedprocessing:
Sophisticatedmachinecontrol applications require high speed datamanipulations.TheFL is designed to
meettheserequirements.
· 1.4 ms per contact · 2.3 ms per coil
· 4.2 ms per 16-bit transfer · 6.5 ms per 16-bit addition
TheFlexiLogicsalso supports interrupt input function (DCinputtypeonly). This allows immediate operation
independentof program scan.
Highperformance software:
TheFlexiLogicsoffervariousbasic ladder instructions and other functional instructions. Subroutines,
Interrupt functions,Indirectaddressing,For/Next loops, Pre-derivative real PID, etc. are standard on the
FlexiLogics unit. These functions allow the unit to be applied to the most demanding control applications.
Pulse output / PWM output:
Onepointof variable frequency pulses (max. 5kHz)orvariable duty pulses can be output.Thesefunctions
can be used to drive a stepping motor or to simulate an analog output. (DC input type only)
Removableterminal blocks:
TheFlexiLogicsareequipped with removable terminal blocks. This supports the easymaintenancework.
Real-timeclock/calendarfunction:
The FlexiLogics has the real-time-clock/calendar function (year, month, day, day of the week, hours,
minutes,seconds) that can be used forperformingscheduled operations, data gathering with timestamps,
etc.The real-time-clock/calendardataisbackedup by a removable and replacable battery.
RS-485multi-purposecommunication port:
TheFlexiLogicsunit has an RS-485 multi-purpose communicationport.Using this port, one of thefollowing
communication modes can be selected.
Computer link mode: T-series computer link protocol can be used in this mode. Up to 32 FlexiLogics can
be connected to a master computer. By using this mode, MMI/SCADAsystem can be easily configured.
Data link mode: Two PLCs can be directly linked together. This direct link is inexpensive, easily config-
uredandrequires no special programming.
FreeASCII mode: User definedASCII messages can be transmitted and received through this port.A
terminal,printer,bar-codereader, or other serialASCIIdevice canbe directlyconnected.

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1.3 FlexiLogics Overview
1.3.1 What is a FlexiLogics series unit?
FlexiLogics Series units are compact, easy-handling block style programmable controller. It also has modular
expandability.
ConfigurationofFlexiLogicsunit:
Each FlexiLogics base unit has to be configured using the FlexiSoft Software before connecting it to the system.
NormalOperation:
The FlexiLogics family is designed to offer practical PLC features in a compact and expandable design, and at the
same time offer a simple-to-use philosophy.An external powered FlexiLogics series base models by itself can be
used as a complete PLC system with optional built-in I/O points, or the system can be expanded with the addition of
up to eight I/O modules.
TheFlexiLogicscan be mounted in DIN railplate.Thebase CPU and I/O modules are connectedtogetherviaan
expansion port on the sides of the modules.Avariety of I/O modules are available for flexible and optimal system
configuration.
R
H
F
L
0
1
0
FIG-1: FlexiLogicsBase with eightexpansions

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ApplicationExamples1:
HMI FlexiLogicsPLC base unit PLC
As shown above, FlexiLogics base unit can be connected to another PLC as well as to HMI. Thus can be worked
with two different protocols at a time.
ApplicationExamples2:
SCADA FlexiLogics PLC base unit HMI
As shown above, FlexiLogics base unit can be connected to SCADA as well as HMI.

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1.3.2 How FlexiLogics Works?
The FlexiLogics follows a specific sequence and the sequence is as shown below:
No
Yes
Initialize
Watchdog
Check for
valid
Ladder
Check for
Valid
Firmware
Initialize serial and
USB ports
Wait till Firmware
Download. Flash
Error and RUN led
at 1 sec interval
Soft restart
Initialize serial and
USB ports
Wait till Ladder
Download.
Flash Error led at 1
sec interval.
Soft restart
Yes
Check for
valid
Application
Initialize serial and
USB ports
Wait till Application
Download.
Flash Error led at 1
sec interval.
Soft restart
No
No
A
START
Yes

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Set internal configuration according
to application. ( Base Timer,
(100uSec) Timer 1, IO configuration
and other system parameter read )
Initialize USB
Restore Keep memory data,
Event History
A
Detect the expansion modules and
update Expansion module information
( Only at Power on)
Read the ladder address information.
Main Loop Start
Clear All PLC registers
expansion module
information and event history
Configure communication channel and
detect slave serial devices.( if master )
Check for
type of
restart
Power On Reset
Soft restart
Clear All PLC registers
except keep memory,
CPU Watch-
dog reset
Power Up Self Diagnosis
Set Power On system bit to ‘1’

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RUN Position
Read
RUN/STOP
Switch
Turn On RUN Led
Clear non retentive PLC registers.
Execute Power-On Tasks.
Execute Power-Up ladder.
Enable User Timer Interrupt.
Initialize digital filter constant to
default 10 mSec.
Reset Power On system bit to ‘0’
HALT MODE
STOP Position
Self Diagnosis ERROR MODE
Error Down
OK
Mode
check
RUN Mode or Switch position
change from Stop to RUN
Halt Mode
HALT MODE
Start counting Main Loop
Scan Time
Update PLC mode from software
Main Loop Start
HOLD
If power On System
bit is ‘1’
Hold Mode
Yes
No
B
Scan Local and
expansion inputs
C
D

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Scan Local and
expansion inputs
Execute Global Tasks
B
Feed the CPU watch-dog
Execute main Ladder
Execute First Scan operations
(1. Initialize special inputs and
outputs. 2. Load Digital filter
constant.)
Update High speed
counter registers
Update local,
expansion and PWM
outputs
Feed watch-dog
Respond to the
monitor query (if any)
on USB.
Start counting ladder scan time
Stopcountingladderscantime
Stop counting main loop
scan time
Update local, expansion.
C
D

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HALT MODE
Feed Watch-dog
Turn OFF all Outputs and
RUN Led
Respond to the monitor
query (if any) on USB.
Stop counting main loop
scan time
Main Loop Start
Set Power On system bit to ‘1’
Feed Watch-dog
Turn ON ERROR Led.
Turn OFF RUN Led.
ERROR MODE
Set the state of output as per ‘ERROR
STATE OUTPUT CONDITION’
(Local, expansion and PWM)
Respond to the monitor
query (if any) on USB.
Stop counting main loop
scan time
Main Loop Start

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HOLD MODE
Read Local and Expansion Inputs
Update Local, Expansion
and PWM outputs
Respond to the monitor
query (if any) on USB.
Stop counting main loop
scan time
Main Loop Start

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Power-Up Self
Diagnosis
if
1. IO Mismatch
2. CPU Watchdog reset
Log event in
Event History
Set Error down
mode flag
Return
if
1. RTC error
2. Retentive data loss
Return
No
Yes
Log event in
Event History
Return
Yes
No

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Self Diagnosis
if
1. IO BCC error
Log event in
Event History
Set Error down
mode flag
Return
if
1. User watchdog error
2. Scan time over error
Return
No
Yes
Log event in
Event History
Return
Yes
No