Product Manual 8652 Pushbutton Station for Modicon Programmable Controller MODBUS Interface Quartech Corporation 15923 Angelo Drive Macomb Township, Michigan 48042-4050 Phone: (586) 781-0373 FAX: (586) 781-0378 www.quartechcorp.com PM8652 Revision 1 The product described in this document can have a variety of uses, the user and those responsible for applying this equipment must satisfy themselves as to the acceptability of each application and the use of the unit. Under no circumstances will QUARTECH CORPORATION be responsible or liable for any damage, including indirect or consequential losses resulting from the use, misuse, or application of the unit. The text, illustrations, charts, and examples included in this document are intended solely to help explain applications of the product. Due to the many variables associated with specific uses or applications, QUARTECH CORPORATION cannot assume responsibility or liability for actual use based upon the data provided in this document. No patent liability is assumed by QUARTECH CORPORATION with respect to the use of circuits, information, equipment, or software described in this document. This document is subject to change without notice.
Table Of Contents Subject Page 1.0 Introduction... 1 2.0 Operating Modes... 1 3.0 Reserved Register Block... 1 4.0 Switch Configuration Bits, Mode A and Mode B... 2 4.1 Watchdog Timer Accumulator, Mode a and Mode B... 2 4.2 Switch and LED Image Bits, Mode B only... 3 4.3 Switch Image Bits, Mode A only... 3 4.4 Green/Amber/Red Color Bits, Mode A only... 4 5.0 DIP Switches... 4 6.0 Status and Error Codes... 5 7.0 Communication Cable... 5 8.0 Installation... 6 Electrical Requirements... 6 Environment... 6 Wiring Considerations... 6 Legend Cards... 7 Mechanical Dimensions... 7
Page 1 1.0 Introduction The 8652 is a combination tricolor annunciator and switch station. Sixteen Light Emitting Diodes (LED) can be individually controlled to illuminate Green, Amber or Red. Each of the sixteen switches can be configured as a momentary Pushbutton or a two position selector utilizing a push on/push off method. The 8652 communicates directly with the Modicon processor through its RS-232 Modbus communication port eliminating the need for I/O modules and discrete wiring. The 8652 may also be connected through a Quartech 8517 multiplexer allowing four Quartech devices to share a single Modbus port. The 8652 is not compatible with the 484 and Micro 84 processors. 2.0 Operating Modes The 8652 has two operating modes built in and selected by a DIP switch accessed through the rear cover of the 8652. Mode A allows the tricolor LEDs to be controlled independent of the switches. Mode B controls the LEDs as an integral part of the switch function. Both modes provide a watchdog timer reset which allows the processor to detect a loss of communications. 3.0 Reserved Register Block Depending on the mode selected a consecutive group of three or six 4xxxx Registers must be reserved within the PLC for use by the 8652. The location of this group is defined by DIP switches on the 8652. DIP switch setup is explained in section five. In all but one case the sixteen bits of the reserved registers are associated directly with the sixteen switches and LEDs of the 8652. The following tables show the register assignments for both Mode A and Mode B. OPERATING MODE A Register Number (Word Address) X X + 1 X + 2 X + 3 X + 4 X + 5 Bit Number 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Green LED color bits Amber LED color bits Red LED color bits Switch Image bits Watchdog Timer Accumulator Switch configuration bits
Page 2 OPERATING MODE B Register Number (Word Address) X X + 1 X + 2 Bit Number 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Switch Image bits Watchdog Timer Accumulator Switch configuration bits In both of the above tables Register 4xxxx is the first register of the Reserved Register Block and is assigned by setting a group of DIP switches on the 8652. The following table shows the relationship between register bit numbers and 8652 switch/led numbers. Register Bit # 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Switch / LED # 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4.0 Switch Configuration Bits, Mode A and Mode B On initial power up the 8652 will read this register from the processor and configure the sixteen switches based on the state of the individual bits in that register. If a bit is zero (0) the corresponding switch will operate as a momentary pushbutton. If a bit is one (1) the corresponding switch will operate as a push on/push off selector. Bit = 0 = Momentary pushbutton switch Bit = 1 = Selector switch (push on/push off) 4.1 Watchdog Timer Accumulator, Mode A and Mode B The 8652 will force this register to zero (0) on a regular and continuous basis. When used as the accumulator of a timer, the timer will time out only when communications are lost between the 8652 and the processor. A preset value of two second is usually sufficient for most applications. The following example shows the logic required to force the switch image register to a predefined state should communications be interrupted. Assume the 8652 is in Mode B and Reserved Register Block address is: 40050 40050 = Switch/LED Image 40051 = Watchdog Timer Accumulator 40052 = Switch Configuration Bits * +))))), +))))), /)))100020/)))14xxxx* 4xxxx Holds the predefined * *T0.1 * / ) ) * Default switch state * *40051* *40050* *.)))))- / ) ) * * WATCHDOG *BLKM * If the timer times out the predefined state * TIMER *00001* in register 4xxxx is moved to the switch image.)))))- register (40050)
Page 3 4.2 Switch and LED Image Bits, Mode B only The function of these bits is dependant on the switch configuration - pushbutton or selector switch. Pushbutton switch When a switch is configured as a momentary pushbutton, its image bit will be zero (0) when the switch is not being pressed. Its corresponding LED will be off. When the switch is pressed its image bit will become one (1), and the corresponding LED will light red. Pushbutton truth table Switch Image Bit LED Open 0 Off Pressed 1 On Selector switch When a switch is configured as a selector switch, its image bit will be unaffected if the switch is not being pressed. The corresponding LED will light Green if the image bit is currently zero (0) and Red if the bit is one (1). When the switch is pressed the image bit will toggle to the opposite state. That is, if it was a one it will become a zero, if it was zero it will become one. Switch Image Bit LED Selector switch truth table Open No Change If Image Bit = 0 = Green If Image Bit = 1 = Red Pressed If 0 change to 1 Red If 1 change to 0 Green Since switch image bits are always located in 4xxxx registers the BIT SENSE function can be used to detect a single switch state. Refer to the following example. Assume the 8652 is in Mode B and Reserved Register Block address is: 40100 40100 = Switch/LED Image 40101 = Watchdog Timer Accumulator 40102 = Switch Configuration Bits * +))))), /)))100001* Switch # (1-16) * / ) ) 1 00101 Coil 00101 will follow the * *40100/)))))))))))))))))))))))))( ))) State of switch one * / ) ) 1 Image Address * *SENS * * *00001* Always Zero *.)))))-
Page 4 4.3 Switch Image Bits, Mode A only The function of these bits is dependant on the switch configuration - pushbutton or selector switch. Pushbutton switch When a switch is configured as a momentary pushbutton, its image bit will be zero (0) when the switch is not being pressed. When the switch is pressed its image bit will become one (1). Refer to table in section 4.2 for further explanation. Selector switch When a switch is configured as a selector switch, its image bit will be unaffected if the switch is not being pressed. When the switch is pressed the image bit will toggle to the opposite state. That is, if it was a one it will become a zero, if it was zero it will become one. Refer to table in section 4.2 for further explanation. Note that the LED's are not directly controlled by the switches in Mode A. The LED's must be controlled through the bits of the three color registers. 4.4 Green/Amber/Red color bits, Mode A only Each LED monitors one bit from each color register. If all three color bits are off the corresponding LED will be off. Setting a LED to a particular color is accomplished by setting the corresponding color bit to a one (1). The three colors have been prioritized to resolve instances when two or three color bits are set to a one (1) for a single LED. Red has priority over Amber and Green, Amber has priority over Green. Since the LED color bits are always located in 4xxxx registers the BIT MODIFY BIT MODIFY function can be used to control individual LED's. Refer to the following example. Assume the 8652 is in Mode A and Reserved Register Block address is: 40100 40100 = Green LED color bits 40101 = Amber LED color bits 40102 = Red LED color bits 40103 = Switch/LED Image 40104 = Watchdog Timer Acc. 40105 = Switch Configuration Bits * +))))), /)))))))))100005* LED # (1-16) * 00105 / ) ) 1 /)))[ ])))140101* Amber register * / ) ) 1 * *MBIT * * *00001* Always Zero *.)))))-! When contact 00105 is open LED five will be off providing it is not being forced Green or Red.! When contact 00105 is closed LED five will be forced Amber providing it is not currently being forced Red. Red has priority over Amber.
Page 5 5.0 DIP SWITCHES A group of DIP switches are provided to allow the programmer to define the location of the Reserved Register Block and select operating Mode A or Mode B. The DIP switches are accessible through a hole in the rear cover of the 8652. +))))))))))))))))))))))))))))))), * ON * * 1 2 3 4 5 6 7 8 * *+), +), +), +), +), +), +), +),* *.)-.)-.)-.)-.)-.)-.)-.)-* 0 ASSUMED.)))))))))))))))))))))))))))))))- * MSB LSB *.)))))))))))))))0))))))))))))- * * MODE RRB START SELECT ADDRESS DIP switch 1 selects the operating mode. ON = Mode A, OFF = Mode B. DIP switches two (2) through eight (8) are used to set the beginning of the Reserved Register block (RRB). This address is the least significant three digits of the forty thousand series value. The least significant bit of this address does not have an assigned DIP switch and is assumed to be zero (0) always. This forces the RRB address to always be even. The highest address which can be assigned is 254 (40254). The lowest RRB address that will be accepted is two (40002). If the address is set to zero an error will be signaled (refer to error code section). EXAMPLE DIP SWITCH SETTINGS Register Number DIP 2 DIP 3 DIP 4 DIP 5 DIP 6 DIP 7 DIP 8 40002 Off Off Off Off Off Off On Off 40050 Off Off On On Off Off On Off 40100 Off On On Off Off On Off Off 40254 On On On On On On On Off 128 64 32 16 8 4 2 1 Binary Weight
Page 6 6.0 Status and Error Codes On initial power up, several diagnostic tests are preformed. During this period several LED's will light. These LED's have been coded to indicate the software version of the unit. If all diagnostics pass and communication are established with the processor normal operation will begin. Six error conditions are annunciated by flashing all 16 LEDs as described below. Error Condition Indication Possible cause Internal RAM failure Internal ROM failure Flash 1-8 Red, 9-16 Green. Flash 1-8 Green, 9-16 Red. Power down then up. If error continues replace unit Illegal response Flash 1-16 Green. Check PLC and cable No PLC response Flash 1-8 Red, 9-16 Amber. Check PLC and cable. Invalid Dip Address Flash 1-16 Red. Set correct address. No CTS (Clear To Send) Flash 1-16 tricolored. Check cable, power and PLC. 7.0 Communication Cable The following schematic and mechanical drawings describe the cables required to connect the Model 8652 Pushbutton Station to various Modicon Programmable Controllers. These cables, in a standard ten foot length, are available from Quartech. Longer cable lengths are available; please consult Quartech. Model 8565 Communication Cable for use with 25-pin Modbus ports
Page 7 Model 8570 Communication Cable for use with 9-pin Modbus ports Model 2142 Communication Cable for use with Modicon Micro PLC
Page 8 8.0 Installation The 8652 is designed to be mounted in the door of an enclosure or on an operators console for ease of use. A template is provided to assist in the drilling and cutting of the mounting holes for the unit. Care should be taken to protect the unit from metal chips and conductive particles. Failure to protect the unit may cause damage when power is applied and may void warranty. A minimum clearance of six inches should be kept between the unit and any other device that generates heat. In the event that the internal enclosure temperature periodically exceeds 55 degrees Celsius (131 degrees Fahrenheit), fans or a purge air system should be used to increase the air flow, and eliminate "Hot Spots" that occur within the panel. Electrical Requirements: Power to the 8652 must be provided by an external power supply meeting the following requirements: Output voltage: 5.1 VDC to 5.3 VCD at 50 mv max. ripple. Output current: 450 ma (Minimum). Quartech Model 8552 power supply is an excellent choice for most applications. Environment: Operating Temperature:... 0 c to 60 c Storage Temperature... -20 c to 70 c Operating Humidity... 0% to 95% (non-condensing) Storage Humidity... 0% to 95% (non-condensing) Vibration (10Hz to 55Hz)... Displacement: 0.5mm, Constant X,Y,Z axis Shock... 40G Wiring Considerations: Care should be taken when routing DC power supply cable and the communication cable. Follow these guidelines for a trouble free installation. The power supply should be mounted as close as possible to the 8652. If the 8652 is to be mounted a long distance from the PLC, the power supply should be mounted local to the 8652 to allow short supply cables. Use at least 16 AWG wire for the 5 VDC power supply cable. If the 8652's power source must be 10 ft or longer 14 AWG wire should be used. Do not make a power supply cable longer than 20 ft. The DC power lines and communication cable must be kept away from AC power lines. Keep both at least one foot away from 120 VAC lines, and two feet away from higher voltage lines. This especially applies to the communication cable. If the cables must cross AC power lines, cross them at right angles (90 ). Keep the cables away from sources of high energy fields such as arc welders, AC motors, motor starters, servo controllers, generators, induction heaters, and transformers.
Page 9 Legend Cards: The 8652 allows the user to customize the legend area beneath each LED. A pocket between the layers of the polycarbonate is accessed by pealing the gasket back from the faceplate. The pocket extends completely across the faceplate to aid in removal of the tags. A sheet of blank legend strips has been included. The area for customizing will allow three lines by nine charactersof type (12 cpi). The strip measures 4 x 0.7 inches (0.01 inch max. thickness). Quartech can provide custom legends produced to your specifications. Custom graphics and color may be included in each legend. Contact Quartech Customer Service for price and delivery. The 8652 is gasketed for NEMA 12 panel applications. However, under high humidity conditions a NEMA 4 rating can be accomplished by sealing the gasket to the polycarbonate faceplate. This may be accomplished by using either a black RTV sealant or LOCTITE 403 gel adhesive. Use of the LOCTITE will make the seal permanant, where as the RTV can be pealed off if desired. Mechanical Dimensions: