ZOIDDX SERIES. Operating and Installation Instructions. for use with all ZOIDDA, ZOIDDB and ZOIDDC Models $ REV22JUN01

Transcription

1 ZOIDDX SERIES Operating and Installation Instructions for use with all ZOIDDA, ZOIDDB and ZOIDDC Models CLR A B C D E F - /+ 0 ENT SHIFT NEW DATA MODE REG. TYPE Kessler Ellis Products 10 Industrial Way East Eatontown, NJ Phone: FAX: Page 46 $ REV22JUN01

2 PROPRIETARY NOTICE The information contained in this publication is derived in part from proprietary and patent data. This information has been prepared for the expressed purpose of assisting operating and maintenance personnel in the efficient use of the instrument described herein. Publication of this information does not convey any rights to use or reproduce or to use it for any purpose other than in connection with the installation, operation and maintenance of the equipment described herein. Copyright 1997 by Kessler Ellis Products Contents Section... Page 1.0 Getting Started What is the ZOIDDX Series? The ZOIDDX Series and Its Environment Installation Instructions Mounting Instructions Location Considerations Making a NEMA4 Mounting Power Connections Power Requirements Grounding Requirements CE Requirements Safety Guidelines Communications Connections Connection to an External Device Connection to a Personal Computer Connection to a PC for PLC Programming CE Requirements EU directives General Installation Guide Lines for EU Installations General Safety Guide Lines for EU Installations Page 1

3 Section... Page 3.0 ZOIDDX Operations ZOIDDX Operations Mode Menu Set Up Operating Mode Selection Selecting the Access Mode Selecting the register Viewing Mode Selecting the Number of Registers to View Selecting Keypad Download Setting the Real Time Clock (RTC) Other Mode Menus The ZOIDDX Off-line Mode Keypad Overview Message Operations The Message Queue Using the Function keys Entering Numerical Values Using the ARROW keys Viewing Registers and Bits (REG. TYPE Key) Password Access ZOIDDX Response Response Time to Message Calls Response Time to Function Key Presses Response Time to Serial Port Transmissions Specifications Trouble Shooting Power Problems Communications Problems Commonly Asked Questions Repair and Return Policies Error Messages Page 2

4 Section... Page Function Key Insert Drawings Warranty ZOIDDX Panel Cutout Template (1:1) About this Manual This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information in this document may not cover all details or variations in hardware or software, nor does it provide for every possibility in connection with installation, operation, or maintenance. Features may be described herein which are not present in all hardware. Kessler Ellis Products assumes no obligation of notice to holders of this document with respect to changes subsequently made. Information in this document is subject to change without notice and does not represent a commitment on the part of Kessler Ellis Products. Some common terms used: PLC: Programmable Logic Controller. Typically, the ZOIDDX is connected to one of these devices. This is a generic term covering a large range of programmable devices used in machine control applications. MTR: This stands for Message Triggering Register. The MTR is the register that holds the message number for the ZOIDDX to display. Symbology Warning! Indicates that the reader should pay special attention to the accompanying text. Precautionary steps should be taken to insure that the installation is in compliance with warnings. Warnings include hazardous conditions that could cause personal injury or equipment damage if care is not taken. Page 3

5 1.0 Getting Started 1.1 What is the ZOIDDX Series? ZOIDDX Series ZOID Units are operator interfaces for PLCs. They allow the operator to interact with the machine by displaying messages that are preloaded with a Personal Computer and changing data in the PLC. They have legendable keys which can be programmed to perform various functions for the operator CLR A B C D E F - /+ 0 ENT SHIFT NEW DATA MODE REG. TYPE Equipment Checklist A ZOIDDX system should include: Å A ZOIDDX Series base unit. Å An SMIC interface cable to the programmable controller. Å A personal computer with ZOID programming software. A PC to ZOID cable is required. Designed For Use Provides a convenient way for a machine operator to: Å View machine status and parameters. Å Change machine status or applicable operating parameters of the machine. Å Maintain the running of the machine. It also gives enhanced capabilities to the machine through: Å RS232 ASCII output. Å Direct keypad interface. Å Visually displayed prompts. Å Real Time Clock downloading. Page 4

6 1.1.1 The ZOIDDX Series and Its Environment Where Used NEMA Rating Electrical Environment Mechanical Environment The ZOIDDX Series is designed for use in a factory environment. It is designed to operate under the same temperature conditions as PLC's used in an industrial environment. They may not be suitable for use in certain outdoor applications. Please consult the factory for advised usage in outdoor applications. The ZOIDDX Series front bezel is NEMA 4 rated. When installed properly in a NEMA 4 panel, the NEMA 4 rating of the panel will not be compromised. This means that fluids will not enter the panel during wash downs. The ZOIDDC Series has been tested to conform to European CE requirements. This means that the ZOIDDC circuitry is designed to resist the effects of electrical noise. This does not guarantee noise immunity in severe cases. Proper wire routing and grounding will insure proper operation of the ZOIDDC unit. Avoid installing ZOIDDX units in environments where severe mechanical vibration or shock are present. Caution! Do not operate the ZOIDDX in areas subject to explosion hazards due to flammable gases, vapors or dusts. The ZOIDDX should not be installed where fast temperature variations and/or high humidity are present. This will cause condensation of water in the device. Page 5

7 2.0 Installation Instructions 2.1 Mounting Instructions Location Considerations. Care should be taken when locating equipment behind the ZOIDDX to ensure that AC power wiring, PLC output modules, contactors, starters, relays, and any other source of electrical interference are located away from the back of the unit. Particular note should be taken to the position of variable speed drives and switching power supplies. Their input and load cables should be screened to a central star earth point Making a NEMA-4 Mounting. Panel Details The ZOIDDX can be mounted into panels with a depth of 3"(76mm). It is recommended that the ZOIDDX be mounted on the front panel of a steel enclosure, through a 7.1"(180mm) X 5.1"(129mm) opening. Allow a clearance of 1"(25mm) on each side of the cutout for clip mounting hardware. Allow clearance for cable connections to the bottom of the unit. Clearance may vary according to cable type used. Typically, plan a clearance to accommodate at least 3"(76mm) below the cutout. PANEL CUTOUT (Not to Scale) See Table of Contents for location of full scale template. 5.1" (129mm) 7.1"(180mm) Page 6

8 Standard Mounting NEMA-4 Mounting Specifications Put the ZOIDDX through the panel cut out. Insert the Clamps into the case. Pull back on the clips until they seat into the retaining slots. Tighten the clamping screws to 3 in. lb. of torque in an even pattern until the ZOIDDX is secured in the panel. Slide the gasket over the case so that it rests behind the Bezel Frame. Continue with standard mounting as described above. Avoid over tightening. Note: To seal to NEMA-4 specifications, supplied gasket must be used and panel cannot flex more than 0.050". When a gasket is used, the gasket may be sealed to the case using an adhesive to maintain NEMA-4 rating. Mounting Clip Panel Gasket Bezel Frame Clamping Screw Connectors Page 7

9 2.2 Power Connections Make sure that all local and national electrical standards are met when installing the ZOIDDX. Contact your local authorities to determine which codes apply Power Requirements Power The ZOIDDA can be powered by 115 ±10% VAC power only. The ZOIDDB can be powered by 230 ±10% VAC power only. The ZOIDDC can be powered by DC power only. The specified voltage range is +12 to 27 Volts DC. This insures compatibility with most DC systems. 115 VAC LINE 115 VAC NEUTRAL EARTH GROUND 230VAC LINE 230 VAC NEUTRAL EARTH GROUND 12-24VDC DC GROUND EARTH GROUND ZOIDDA ZOIDDB ZOIDDC The power conditioning circuitry inside the unit is accomplished by transformer and switching power supply. Due to the nature of switching power supplies, a wide range of over and under voltages may be used without adversely affecting the unit. Fusing Requirements Caution Strain Relief The ZOIDDX series is fused internally with a self resetting 60V 400mA fuse. It is recommended that all input power lines be protected from product failure by a 1/4 Amp. fuse or breaker. If the display does not come on within 2 seconds of power up, remove power. (An internal diode will prevent damage if the polarity of the DC power is incorrect.) Check wiring to insure proper connections and try to power up again. Adequate strain relief must be provided for the power connector, to ensure that vibration or the disturbance of cables during maintenance does not cause the connector to pullout. Retention of the power cables by a tye-wrap onto the trunking, or an adhesive pad mounted tye-wrap point is normally suitable. Page 8

10 Caution High Voltage Connecting high voltages or AC power mains to the ZOIDDC input will make the ZOIDDC unusable and may create an electrical shock hazard to personnel. Such a failure or shock could result in serious personal injury, loss of life and/or equipment damage. DC voltage sources should provide proper isolation from main AC power and similar hazards. Caution Emergency Stop A hard wired EMERGENCY STOP should be fitted in any system using the ZOIDDX to comply with ICS Safety Recommendations. Caution Supply Voltage Condition Do not power the ZOIDDX and inductive loads, or input circuitry to the PLC, with the same power supply. The 24 VDC output from some PLC's may not have enough current to power the ZOIDDC. See specifications. Caution DC Power Cycling DC Power supplies with large capacitive outputs may cause problems if power is cycled within a short time period. The power supplyís capacitor will supply enough current to keep the microprocessor running for a few minutes but not enough to keep the display active. If full power is restored during that time, the microprocessor may not initialize the display module. The result is that the display will remain blank or show just the cursor in the upper left-hand corner and the rest of the unit will be fully functional. To remedy this problem, run power to the unit through a ìseal inî circuit or remove the capacitor (the ZOIDDC is not affected if power is unregulated) or wait sufficient time between power cycles. Page 9

11 Caution Signal Wire Routing Wire lengths should be minimized (Maximum 1600' (500 m) shielded, 1000' (300 m) unshielded). Wires should be run in pairs with a neutral or common paired with a hot or signal line. If wiring is to be exposed to lightning or surges, use appropriate surge suppression devices. Keep AC, high energy, and rapidly switching DC wiring separate from signal wires. Equip ungrounded DC supplies with a resistor and capacitor in parallel to earth ground. This provides a path for static and high frequency dissipation. Typical values to use are 1MOhm and 4700pF. Terminal Block Connections To make a connection, strip about 1/4" of insulation off the end of the wire, turn the connector screw counterclockwise until the gap is wide open, insert the wire all the way in, and turn the screw clockwise until it is tight. For AC powered units, connect AC Line to terminal 1 and AC neutral to terminal 2. For DC powered units, connect the positive DC line to terminal 1 and the DC ground to terminal 2. KESSLER - ELLIS PRODUCTS 10 INDUSTRIAL WAY EAST EATONTOWN, NJ PHONE: PLC PORT PROG / PRINT PORT PASS THROUGH PORT VDC DC GROUND EARTH GROUND Typical Label on Rear of ZOIDDX Series unit showing connection points. Page 10

12 2.2.2 Grounding Requirements Earth ground must be used. Terminal 2 is not directly coupled to Earth ground internally. It is preferable not to ground DC negative return to chassis ground, terminal 3, as poor site earths can introduce noise into a system, but if necessary an earth connection should be made, from the power supply return point to the central star earth point. Ground conductors should be as short and as large in size as possible. The conductors must always be large enough to carry the maximum short circuit current of the path being considered. Ground conductors should be connected from a tree from a central star earth ground point. This ensures that no ground conductor carries current from any other branch CE Requirements (ZOIDDC only) To make the ZOIDDC comply with EMC directives, and to reduce susceptibility to electrical interference, a separate #14 AWG ground wire should be taken to terminal 3 of the power connector. This ground connection should be run directly to the central star earth connection point (as recommended in most PLC Installation Instructions) Safety Guidelines This section presents recommended installation practices and procedures. Since no two applications are identical, these recommendations should be considered as guidelines. Hardware Considerations WARNING! The system designer should be aware that control devices in Programmable Controller systems can fail and thereby create an unsafe condition. Furthermore, electrical interference in an operator interface, such as the ZOIDDX, can lead to equipment start-up, which could result in property damage and/or physical injury to the equipment operator. If you, or your company, use any programmable control systems which require an operator or attendant, you should be aware that this potential safety hazard exists and take appropriate precautions. Although the specific design steps depend on your particular application, the following precautions generally apply to installation of solid-state programmable control devices. In addition, these precautions conform to the guidelines for installation of Programmable Controllers as recommended in the NEMA ICS Programmable Control Standards. Page 11

13 Programming Considerations To conform with ICS Safety Recommendations, checks should be placed in the PLC program to ensure that all writable registers, that control critical parts of plant or machinery, have upper and lower limit checks with an outof-limit safe shut down procedure to ensure safety of personnel. ICS Safety Recommendations: Consideration should be given to the use of an emergency stop function which is independent of the programmable controller. Where the operator is exposed to the machinery, such as in loading or unloading a machine tool, or where the machine cycles automatically, consideration should be given to the use of an electromechanical override or other redundant means, independent of the programmable controller, for starting and interrupting the cycle. If provision is required for changing programs while the equipment is in operation, consideration should be given to the use of locks or other means of assuring that such changes can be made only by authorized personnel. These recommendations are intended as safeguards against the failure of critical components and the effects of such failures or the inadvertent errors that might be introduced if programs are changed while the equipment is in operation.* * The ICS Safety Recommendations are reproduced by permission of the National Electrical Manufacturers Association from NEMA ICS 3-304, Programmable Controller Standard. 2.3 Communications Connections Connection to an External Device The DB9 port farthest from the power connector, labeled PLC PORT, as you look at the back of the case, is the port for connecting to a PLC or external device using KEP's SMIC adaptor cables. PLC PORT PROG / PRINT PORT PASS THROUGH PORT VDC DC GROUND EARTH GROUND Cable Requirements Different cables are required for various devices. The KEP part numbers have the SMIC prefix. Refer to the programming disk for the ZOIDDX model you have, a KEP catalog or ZOIDDX datasheet for a complete listing of compatible devices. Page 12

14 Cables can be obtained from the same distributor where you purchased the ZOIDDX. Caution Restrict cable length to less than 500' (150m) for RS485/422 devices and 50' (15m) for RS232 devices to avoid communications problems. Communications problems cause the ZOIDDX display to hold until communications can be established. PLC Port Pin Designations Shielded cable must be used for long lengths or cables run in an electrically noisy environment. Do not run cables next to AC power lines or near sources of electrical noise. Be sure that the cable ends have been inserted all of the way into mating connectors and are secure. Pin assignment of the 9 pole SUB-D RS232 to external device port Pin# Symbol Function 1 Not used 2 TxD Transmitted Data 3 RxD Received Data 4 Not used 5 GND Signal Ground 6 Vcc DO NOT GROUND THIS PIN 7 Not used 8 CTRL Flow Control Line for RS485 9 RSV DO NOT USE Reserved for ZOIDDX use Connection to a Personal Computer The middle 9 Pin Female connector on the bottom of the unit is the programming port (PC PORT). PLC PORT PROG / PRINT PORT PASS THROUGH PORT VDC DC GROUND EARTH GROUND Page 13

15 Connection Port Activation Print Out This port can be attached to a Computer via a DB9 Male to DB9 Female straight through cable. Make sure 2 and 3 are not reversed. This port is active only when the ZOIDDX is Off-line. When the ZOIDDX is Off-line, PLC operations are suspended. Note: The PC Port is not a pass through port to the PLC. The ZOIDDX has print out capabilities. When a message is assigned to be sent out the serial port, the transmit line of the computer port becomes active momentarily. PC Port Pin Designations Pin assignment of the 9 pole SUB-D RS232 to Computer port Pin# Symbol Function 1 Not used 2 TxD Transmitted Data 3 RxD Received Data 4 Not used 5 GND Signal Ground 6 Not used 7 Not used 8 Not used 9 Not used Connection to a Personal Computer for PLC Programming The 9 Pin Female connector closest to the power connector on the bottom of the unit is the programming port (PASS THROUGH PORT). PLC PORT PROG / PRINT PORT PASS THROUGH PORT VDC DC GROUND EARTH GROUND Connection Port Activation This port can be attached to a Computer via a DB9 Male to DB9 Female straight through cable. Make sure 2 and 3 are not reversed. This port is active only when the ZOIDDX is Off-line. When the ZOIDDX is Off-line, PLC operations are suspended. Page 14

16 Pass Through Compatibility The ZOIDDX passes through the RxD, TxD and Ground signals. Special handshaking lines are not passed through. Refer to Pass through port pin designations below. For this reason, the pass through port does not support all PC programs for programming PLC's. This port is provided as a convenience for those PLC manufacturers whose programs are compatible with the port. Pass Through Port Pin Designations Pin assignment of the 9 pole SUB-D RS232 to Computer port Pin# Symbol Function 1 No Connection 2 TxD Transmitted Data 3 RxD Received Data 4 Jumpered to pin 6 5 GND Signal Ground 6 Jumpered to pin 4 7 Jumpered to pin 8 8 Jumpered to pin 7 9 No Connection 2.4 CE Requirements EU directives that apply to the ZOIDDC only: ï EMC Directive (89/336/EEC, 91/263/EEC, 92/31/EEC, 93/ 68/EEC) electromagnetic emissions and immunity ZOIDDC products will be CE-marked to indicate compliance with the EMC Directive. Declarations of Conformity that specify the directive(s) and the catalog numbers of the products covered are available from Kessler Ellis Products. Although the ZOIDDC products are CE compliant, it is the responsibility of the person who finally implements the system, that the machine (including other electrical and electronic devices) will meet the EMC requirements. The ZOIDDC has been designed to operate satisfactorily in electromagnetic noise (immunity) and without emitting high levels of electrical noise into the environment (emission). The ZOIDDC was designed to meet European Community standards when installed per the wiring instructions in this manual. Page 15

17 Compatibility Standards The ZOIDDC has been designed to meet electromagnetic compatibility for industrial environments. ï CISPR (EN 55011) Group 1, Class A Radiated Emissions levels ï EN ï EN Generic emission standard, industrial environment (Also US FCC Class A) Generic immunity standard, industrial environment General Installation Guide Lines for EU Installations. ï Be aware that wiring leaving the cabinet where the ZOIDDC is installed may be exposed to interference sources. ï The installation practices in the individual product installation manuals of other components in the system must also be followed. ï Locally applicable grounding safety regulations and machinery directives should be followed for providing a protective ground to earth. The EMC ground must be a low impedance, low inductance path to the machine chassis ground. ï The ZOIDDC power supply must be through an IEC-rated isolation transformer. ï The Power supply to the PLC must be controlled to ensure that it does not exceed overvoltage category II per EN (IEC 240). ï Other requirements of the Machinery Directive involving displays, languages, instructions, Emergency Stop functions, machine operation, protective guards and interlocks are the responsibility of the machine manufacturer General Safety Guide Lines for EU Installations. ï Only qualified personnel should be allowed to specify, apply, install, operate, maintain or perform any other function related to ZOIDDX products. Qualified persons are defined as follows: System application and design engineers who are familiar with the safety concepts of automation equipment. Installation, start-up, and service personnel who are trained to install and maintain automation equipment. Operating personnel trained to operate automation equipment and trained on the specific safety issues and requirements of the particular equipment. ï Before switching on the equipment, make sure that the voltage range for the equipment is correct. ï Emergency tripping devices in accordance with EN60204/IEC204 must be effective in all operating modes of the equipment. Resetting the emergency off device must not result in any uncontrolled or undefined restart of the equipment. Page 16

18 ï Automation equipment and its operating elements must be installed so that unintentional operation is prevented. ï Make sure that operating sequences interrupted by a voltage dip or power supply failure resume proper operation when the power supply is restored. If necessary, the equipment must be forced into the ìemergency offî state. ï Install the power supply and signal cables so that inductive and capacitive interference voltages do not affect automation functions. 3.0 ZOIDDX PROGRAMMING INSTRUCTIONS Note: The computer must be running DOS Version 3.1 or later. Earlier versions may not work. Step 1. Step 2. Step 3. Step 4. Step 5. Turn on your Personal Computer and power up the ZOIDDX. Connect the computer to the ZOIDDX with the appropriate RS232 cable, as described earlier. Insert the programming diskette into the floppy drive. Make the floppy drive the active drive. Windows users call the directory of the drive up in the File Manager. At the A: prompt type in the name of the *.exe file and press enter. The program will boot. Windows users double click on the *.exe file in the File Manager. Note: Copying the program to your hard drive and running it from there is suggested. The program is not copy protected and may be copied and distributed freely. Step 6. Use the cursor keys to move to menu items and use the enter key to select items and program the ZOIDDX. To fully describe every aspect of the ZOID software would be quite lengthy. The user is encouraged to run the software and use its on screen help to be guided through the program. The following programming sequence is suggested: 1) Program in SYNONYMs. 2) Program in Messages. 3) Save your work to disk. 4) Download work to ZOIDDX. Page 17

19 4.0 ZOIDDX Operations Once the ZOIDDX is programmed and connected to the PLC, running operation begins. The ZOIDDX establishes communications with the PLC, evaluates the Mode settings and updates the display accordingly. 4.1 Mode Menu Set Up Modes are selected as follows: Note: The menus listed below may not appear as shown in all units. See disk manual for an actual depiction of all MODE menus Operating Mode Selection MODE(1/2/3) 1:NORMAL 2:PLC 3:OPERATOR 1 Press the MODE button once. If a Write Password has been assigned to the ZOID, it must be entered before MODE access is allowed (See Section 4.8). Select one of the following: Operator Mode The unit acts like a register access panel. It allows the operator to call up and change registers. Function Keys are active in this mode. Messages cannot be called by the PLC in this mode. Typical Operation A list of frequently used registers is programmed into the ZOID. The operator uses the REG. TYPE key and Numerical keypad to call up register or bit values or the arrow keys to scroll through the preprogrammed list to view and/or change values in the PLC. The Function Keys are used to call up Setup menus and initiate machine actions. PLC Mode The ZOIDDX acts like a message display unit. The PLC prompts the operator with messages. The operator can only access the registers assigned to function keys or embedded in special messages. Typical Operation Messages are programmed into the ZOID. The PLC prompts the operator with the messages to show machine status and alarms or to change values in the PLC. The Function Keys are used to call up Setup menus and initiate machine actions. Page 18

20 Normal Mode Normal Mode is a combination of the Operator mode and PLC mode. The ZOID defaults to the PLC mode, displaying messages. When a key is pressed, the ZOID enters the Operator mode temporarily, displaying registers. After 10 seconds of no keypad activity in the Operator Mode, the ZOID returns to the PLC mode, displaying messages. Typical Operation A list of registers and messages are programmed into the ZOID. The operator uses the arrow keys to scroll through the list of registers to view and or change values in the PLC. The PLC prompts the operator with the messages to show machine status and alarms or to view and change values in the PLC. The Function Keys are used to call up Setup Menus and initiate machine actions Selecting the Access Mode REGISTER ENTRY (1/2) 1:SYNONYM 2:NUMBER 2 After Password entry, if applicable, press the MODE key twice to get to this item directly. The ZOID will go to this item once the above selection of Mode is made. This mode determines how registers and bits will be accessed in the Normal and Operator modes. The SYNONYM mode is recommended for unskilled users. The NUMBER mode allows the most flexibility and is recommended for experienced PLC programmers and / or maintenance personnel. Make a selection of one of the following: Synonym Mode 7 9 This allows the operator to use the arrow keys to scroll through the registers and bits which have been assigned SYNONYMs. The operator does not have to remember a list of register numbers. The operator simply scrolls to the SYNONYM which is familiar by name. From there any data entry is done. Registers cannot be called up directly by number in this mode. Page 19

21 Number Mode REG. TYPE This allows the operator to use the keypad to enter in the desired register number which has been assigned a SYN- ONYM. Registers which are not on the programmed list of synonyms are displayed as UNTITLED and can only be accessed via the Read Password. From there, any data entry is done Selecting the Register Viewing Mode 0:SIGNED INT 1:DEC 2:BIN 3:HEX 4:BIT 1 After Password entry, if applicable, press the MODE button three times to get to this item directly. The ZOID will go to this item once the above selection of Access Mode is made. Note: This mode affects the displayed value only if the NUMBER mode is selected and the register or bit viewed is UNTITLED. The menu presented above may differ from one PLC type to the next and is shown as an example. SIGNED INT Mode DEC Mode BIN Mode CAUTION! The value from the PLC register is converted to a signed decimal number within the range to and displayed. Only single register values can be viewed in this way. Timers are viewed as positive decimal numbers only. Positive numbers are NOT shown with a + sign in front of them. Not available on all PLC types. The value from the PLC register is converted to a decimal number with in the range 0 to and displayed. Single and double register values can be viewed in this mode. Not available on all PLC types. The value from the PLC Register is converted to an 8 bit binary value for display. Values are displayed as binary numbers ( i.e ). Binary values are always viewed as 1 word. Only the first 8, least significant bits, of 16 bit registers are shown. The upper 8 bits are not available for access. The upper 8 bits of binary displayed numbers will be cleared whenever new data is entered from the ZOID. Page 20

22 HEX Mode BIT Mode BCD Mode The value from the PLC register(s) is displayed as a hexadecimal number (#'s 0-9, A, B, C, D, E, F; i.e. 9C). Note: On some PLC's the hexadecimal mode is the only mode in which BCD numbers can be viewed properly. Bit values in the PLC are displayed as ON or OFF. If an entire register has a synonym assigned to it, the synonym will not be displayed in the bit mode. However, if a bit has a synonym assigned to it then the synonym will appear when the bit address is entered. Timer and Counter File registers and on some PLC's data registers are displayed as decimal values as described above. Not available on all PLC types. The value from the PLC register(s) is displayed as a decimal number in BCD format (#'s 0-9; i.e. 93). Not available on all PLC types Selecting Number of Registers to View DATA WORDS TO BE UPLOADED (1/2) 1 If the BIN or BIT mode has been selected above, this menu will be skipped. After Password entry, if applicable, press the MODE key four times to get to this item directly. The ZOID will go to this item once the above selection of viewing mode is made. This mode affects the displayed value only if the NUMBER mode is selected and the register or bit viewed is UNTITLED. The menu presented above may differ from one PLC type to the next and is shown as an example. Make a selection then press ENT to continue or CLR to exit the MODE menu. 1 Data Word or Byte Mode 2 Data Words or Bytes Mode 4 Data Bytes Mode A single register or byte is displayed as designated by the previous Viewing Mode. Not available on all PLC types. Two consecutive registers or bytes are polled for data. The two registers or bytes are then treated as a double word to make one large number. That number is then displayed as designated by the previous Viewing Mode. Not available on all PLC types. Four consecutive bytes are polled for data. The four bytes are then used to make one large number. That number is then displayed as designated by the previous Viewing Mode. Not available on all PLC types. Page 21

23 4.1.5 Selecting Keypad Download DOWNLOAD KEYPAD TO PLC? 0:NO 1:YES 0 After Password entry, if applicable, press the MODE key five times to get to this item directly. The ZOID will go to this item once the above selection of number of registers to view is made by pressing ENT. This selects if the keypad status will be downloaded to the PLC. Make a selection of 1 or 0, then press ENT to continue, or, CLR to exit the MODE menu. Download Action Downloading the keypad allows non-function keys to turn bits on in the PLC. The keypad status register is the next consecutive register after the MTR. When a key is pressed the corresponding bit is turned ON in the PLC. When the key is released the bit is restored to an OFF state. Note: To see this feature in action put the ZOID into the Operator mode. Call up the register that follows the MTR. As you press keys the displayed value of the register will change Setting the Real Time Clock (RTC) SET REAL TIME CLOCK? 0:NO 1:YES 0 After Password entry, if applicable, press the MODE key six times to get to this item directly. The ZOID will go to this item once the above selection of Keypad Download status is made by pressing ENT. Now select if you want to change the time and date or download status of the Real Time Clock (RTC). Pressing 0 then ENT advances to the next MODE menu. Press the 1 key then ENT to set the RTC. Setting Time Enter in the new time. As keys are pressed, digits will scroll in from the right-hand side of the display on the lower line. The CLR key will clear the value on the lower line to zeros. CURRENT: New Time? HH:MI:SS HH:MI:SS If the time is correct, press the MODE key. Upon correct entry, the display will advance to a prompt for entering the Date. If the value entered is not valid, the ZOID will display ERROR! Time out of range. Try Again! Page 22

24 Setting Date As keys are pressed, digits will scroll in from the right-hand side of the date display on the lower line. The CLR key will clear the value on the lower line to zeros. Wednesday New Date? MO/DD/YY MO/DD/YY If the date is correct, press the MODE key. Upon correct entry, the display will advance to a prompt for entering the day of the week. If the value entered is not a valid date the ZOID will display or ERROR! Date out of range. Try Again! ERROR! Month out of range. Try Again! Setting Day of the Week Select the correct day of the week. 0:Sun/1:Mon.../6:Sat New Day (0-6)? 1 Mon Setting Download Option 0 = Sunday 4 = Thursday 1 = Monday 5 = Friday 2 = Tuesday 6 = Saturday 3 = Wednesday The 7,8 and 9 keys are disabled for setting the day of the week. Press ENT after changing day or MODE if the correct day is shown. Upon entry, the display will advance to a prompt to choose if you want to download the Real Time Clock to the PLC or not. Select 1 to have the clock values downloaded into PLC registers following the MTR or 0 to disable this feature. Download RTC Values to PLC? 0:NO 1:YES 0 Make a selection then press ENT. The ZOID will then exit the clock setting menu. Page 23

25 4.1.7 Other Mode Menus Additional Mode menus that are PLC specific are located after the clock setting menu. For further details check the manual on the programming disk for your particular ZOIDDX model The ZOIDDX Off-line Mode SET ZOID Off line? 0: NO 1: YES 0 The ZOID can only be programmed when it is Off Line from the PLC. Programming is done by downloading information from a PC running the ZOID setup software. (See Section 3.0) After Password entry, if applicable, press the MODE key until you get to this item directly. The ZOID will go to this item after pressing ENT in the previous menu. Now select if you want to take the ZOID Off-line from the PLC. Pressing 0 then ENT or CLR exits the MODE menu. Going Off-line Getting Back On-line Press the 1 key then ENT to take the ZOID off line from the PLC and begin PC communications. Press the MODE key when the unit is Off-line and the first menu will be the On-line/Off-line Menu. Press 0 to put the ZOIDDX back on-line. Note: This menu replaces the On-line/Off-line switch on earlier versions of the ZOID. Page 24

26 4.2 Keypad Overview NEW DATA New Data Key: Active during register display only. Used to tell the ZOID that a new value is to be entered. SHIFT Shift Key: Must be held down to be active. Used to activate shifted characters, arrows, -/+ and Function keys MODE REG. TYPE Mode Key: Used to program the operating characteristics of the ZOID and for setting the Real Time Clock. Register Type Key: Active during register display when the mode is set to "NUMBER" only. Used to select the prefix of the register or bit to be viewed. - /+ + and - Key: Used with the SHIFT key to change the sign of a register 8 viewed as a Signed Integer when entering a new value. A B C Alphabet Keys: Used with SHIFT to select D E F the hexadecimal numbers A through F. Used when a hexadecimal register value is being changed. Left and Right Arrow Keys: Active when 7 9 registers are being viewed in the SYNONYM mode. Used to scroll through a list of predefined registers and bits. Active when messages are being displayed. Used with the SHIFT key to scroll through chained messages CLR A B C D E F - /+ 0 ENT Numerical Keypad: Used for entering values and register or bit numbers. Function Keys: Press key to activate function. Press SHIFT and key to activate upper shifted function. Message number assignments are shown to right of this text Page 25

27 4.3 Message Operations How the ZOIDDX Displays Messages The ZOIDDX sends a command requesting the number in the Message Triggering Register (MTR), if used, and displays the corresponding message. In order for a new message number to be recognized it must be in the MTR at most 300 milliseconds. The ZOIDDX then looks up the corresponding message number in its memory and displays the message with all of its attributes The Message Queue Occasionally, messages are called up faster than they can be displayed. When this happens messages are held in a Queue and wait their turn to be displayed. The message Queue holds up to 8 message numbers. Queue Activation Messages are stored in the Queue when: 1. A series of Chained messages are being displayed. 2. A message with a long minimum display time is displayed. 3. A message with a long scrolling time is displayed. Queue Action Warning The Interrupt Message Example of Queue Operations The Queue is emptied on a first in, first out basis. If the Queue is full, additional messages will be lost. Function keys that have displayable message text assigned to them clear the Queue. Message number 512 is the Interrupt message. When message 512 is called, the Queue is immediately cleared. The next message number that appears in the message triggering register is then displayed. Message 23 is being displayed with a minimum time of 10 seconds. Display Queue 23 ó During that period message numbers 34, 15 and then 211 are called for by the MTR. Display Queue Page 26

28 The ZOIDDX will put message 34, 15 and 211 in the Queue. When message 23 has timed out, message 34 will be called up and displayed. Display Queue When 34 is done, message 15 will be displayed. Display Queue When 15 is done, message 211 will be displayed. Display Queue 211 EMPTY Message 211 will continue to be displayed until a new message number is put in the MTR or a function key is pressed. 4.4 Using the Function Keys F13 F1 Simply press a Function key to initiate their programmed action and/or call up their associated messages. SHIFT KEY SHIFT The SHIFT key is used to activate shifted functions. Hold the SHIFT key down and press the function key to activate the shifted function. Caution! Note: It is recommended that Function keys be defined in such a way that if the SHIFT key is not pressed hard enough to be activated, that no unexpected or dangerous action occurs when the non-shifted function takes place. Page 27

29 When a function key is pressed, one of the following conditions will apply The Function key may have message text assigned to it, request the operator to edit a value or chain to another message. 1. The Function key message will interrupt the active display. Note: Function keys with message text assigned to them clear the message Queue and interrupt minimum display times, chained and scrolling messages. 2. The message assigned to the Function key will be displayed. 3. At the end of a Function call and after all data entry and message chaining is done, the display does one of the 3 options listed in priority below in Normal or PLC Mode. A. Chains, if programmed, to the next message. B. Displays the message whose number is next in the message Queue. C. Displays the message whose number is in the MTR. In Operator Mode. A. Chains, if programmed, to the next message. B. Returns to Register Monitor display No message text is assigned to the Function key and no messages are chained to from the Function key. The function key is assigned to download a constant or change a bit status only. Press the Function key. The Queue is not cleared and the display is not interrupted but the function is carried out No message or action is assigned to the Function key. When the Function key is pressed, nothing happens. 4.5 Entering Numerical Values Values displayed in messages The ZOIDDX may have data embedded in a special message for the purpose of editing. Such data is usually machine status, setpoints or other setup parameters that may need to be changed from time to time. The last digit of such values flash when they are displayed. Page 28

30 Values displayed in Operator Mode NEW DATA The operator may change these values by the following procedure: ï Press the numerical keypad for data entry. The first key will clear the displayed value and put its value in the right-most position. Numbers are then entered the same way as dialing in a phone number. ï The shift key is used with the 1-6 keys to enter hexadecimal values if applicable. Hold the shift key down and press the appropriate keys. ï Press the ENT key. Only after the ENT key is pressed will the new value be written to the PLC. ï To escape from entering a value, wait ten seconds. The ZOIDDX will time out and display the value that is in the register in the PLC. The ZOIDDX displays register values or bit states which may be changed if not write protected. The operator may change these by the following procedure: ï Press the NEW DATA key. ï Press the numerical keypad for data entry. The first key will clear the displayed value and put its value in the right-most position. Numbers are then entered the same way as dialing in a phone number. Key in the new data value. ï Press 0 or 1 to change a bit state. 0 is OFF and 1 is ON. ï The shift key is used with the 1-6 keys to enter hexadecimal values if applicable. Hold the shift key down and press the appropriate keys. ï Press the ENT key. Only after the ENT key is pressed will the new value be written to the PLC. ï To escape from entering a value, wait ten seconds. The ZOIDDX will time out and display the value that is in the register in the PLC. Page 29

31 4.6 Using the Arrow keys When messages are displayed SHIFT 7 9 SYNONYM Mode 7 9 The arrow keys on the ZOIDDX are used to step up or down through chained messages. A chain of messages may be called up by the PLC or by pressing a Function key. Once the chain is active, the unit will display the messages from the chain until a new message number or chain is called by the MTR, or a Function Key is pressed. Hold down the SHIFT key and press the arrow keys to step through (right arrow) or back up (left arrow) a series of chained messages. When the top of the list is reached, the left arrow is ignored. When the bottom of the list is reached, the right arrow is ignored. Note: You can never back up to a function key message that starts a chain. The left and right arrow keys are used to step up or down through a pre-programmed list of labeled registers or bits. The list is always active in the Operator Mode or may be called up in the Normal Mode by pressing any number key. Once the list is active, the unit will display only registers and bits from the list. The SHIFT key does not have to be held down isn this Mode. Press the left and right arrow keys to step through the list. When the top of the list is reached, the left key steps to the bottom of the list. When the bottom of the list is reached, the right key steps to the top of the list. 4.7 Viewing Registers and Bits ( REG. TYPE Key) The REG. TYPE key is active only in the Operator / NUMBER Mode. It is used to select the register or bit to view. REG. TYPE ï Pressing the key steps through the various prefixes for your particular PLC. For a list of prefixes refer to the manual on the ZOIDDX programming disk. ï The numerical keypad is then used to enter the register or bit number to view. ï Press ENT to accept the register value. The display will show the label attached to the register (or UNTITLED if not labeled) and the value of the register or state of the bit. Page 30

32 4.8 Password Access The ZOID has 4 types of security available. 1. Uses a Read Password to deny access to registers. 2. Allows Read access with data changes allowed only by a Write Password. 3. Allows the operator to Read and Write to registers within assigned SYNONYM limits. 4. The Function keys can be selectively locked out. The Read, Write and Function key protection is accomplished by assigning Passwords in the set up portion of the PC programming. The default Passwords are The Read, Write and Function key access codes are 4 digit Codes. Read Password Write Password Mode Key Password Function Key Password The Read Password is active if the ZOID is in the NORMAL or OPERATOR Mode with the NUMBER Mode selected for register access. If a register or bit is not in the list of programmed SYNONYM's, then the Read Password must be entered before it can be accessed. A Read Password of 0000 disables the security feature for Read (register access). If a register or bit is assigned to be "Write Protected" in the SYNONYM programming or if no SYNONYM is assigned to it, then the Write Password must be entered before it will accept new values. A Write Password of 0000 disables the security feature for Write (data changes). The Write Password is also the access Password for making Mode changes. When the MODE key is pressed, the ZOID will prompt the operator to enter the Write Password. If a Function Key has a password assigned to it, then the Function Key password must be entered before it will perform it's function. A Function key Password of 0000 disables the security feature on Function keys. Page 31

33 Hi and Lo Write Limits Limits can be assigned to a register by assigning a SYN- ONYM to it. Once this is done the limits are checked whenever new data is entered into the register with the ZOID. If the register is embedded in a special message the limit checks will be done on any new values entered in the message. Note: The ZOID does not do limit checks on values that are already in a register or put there by the PLC. There is no way to override the limits with a password. The only way to change a limit is to download a new limit into the ZOID using the PC program. For further details on the Hi and Lo limits see manual on the programming disk. Entering Passwords When the Password protected Register, Bit or Function key is pressed the display will show a message requesting the appropriate password. For example: Key Write Protected Enter Password: In the above example, the operator enters in the four digit Function key Password. Asterisks are always displayed as the password is entered. If the correct password is entered, then the function will be executed this one time. Whenever the entered password is incorrect, the display will show INCORRECT PASSWORD ACCESS DENIED! then go back to its previous display. 4.9 ZOIDDX Response The ZOIDDX is limited in its response to key presses and information update by the serial communications to the PLC. The ZOIDDX has been optimized to provide reasonable response times to events Response Time to Message Calls A message number must be in the MTR or bit sequence change in the LED register for at least 300 milliseconds to be recognized by the ZOIDDX. Page 32

34 4.9.2 Response Time to Function Key Presses Function keys are handled on an interrupt basis. As soon as a key is pressed, a communication is sent to the PLC. Response to a key press by the PLC depends on the PLCís scan time and communications handling. Typically, response times are less than 1 second. We do not recommend using the function keys for JOGGING applications Response Time to Serial Port Transmissions When a normal message is designated to be sent to the serial port, the ZOIDDX will send the message to the port before displaying it. Response time is determined by the number of registers/bits embedded in the message. The serial port baud rate also determines how long it will be before the message is displayed. A 200 character scrolling message with several embedded registers and bits sent out at 300 baud may take up to 10 seconds to appear on the display. Special messages requiring data entry are sent to the serial port after the ENT key is pressed or the message has timed out. 5.0 Specifications Power Memory Battery Life Temperature Display PC Port Communications ZOIDDAX VAC ±10% 50/60Hz 4W ZOIDDBX VAC ±10% 50/60Hz 4W ZOIDDCX - 12 (275 ma) to 24 (150 ma) VDC 3.6W unregulated, Maximum voltage limits 8 to 30 VDC 32K Byte Battery Backed SRAM 10 Years (Calculated) VFD Type: 32 to 140 F (0 to 60 C) LCD Type: 32 to 122 F (0 to 50 C) Vacuum Fluorescent or backlit LCD; 2 Lines of 20 characters each; Character height is 0.2" Serial RS232 output during serial out operations only. Selectable 7 or 8 bit, Odd, Even or No Parity, 1 Start, 1 Stop bit, No handshake, 300, 600, 1200, 2400, 4800, 9600 or Baud. Note: Serial communications specifications apply to ZOIDDX printer setup and do not affect PC to ZOIDDX or Controller to ZOIDDX communications. Page 33