Introduction The SR family of programmable logic controllers provide a compact control unit offering a range of expansion options. The product family is supported with, a PC (Windows) based software development package that provides powerful programming, debugging, simulation and system monitoring support. Features 8 Input, 4 Outputs in a compact din-rail mounted design (71mm * 106mm * 67mm) or 14 Input, 8 Outputs (126mm * 106mmX 67mm). AC, DC and Analog inputs, Relay, Transistor outputs. Expandable I/O up to 50 Inputs, 32 Outputs Integrated LCD display/control module (SR-HMI), may be remotely mounted (SR-EHC) Programmable thru PC USB channel (SR-CP, SR-DCP) Powerful Programming support () Accessories RS232/485 Modbus Interface (SR-MC) Allows connecting unit to industry standard RS232/RS485 communication networks. Telephone/Voice Output Module (SR-VPx) Provides voice output of alarm conditions and allows dialing of phone, transmission of voice messages and accepting telephone response codes for remote control of alarm conditions. Operator Interface (SH-300) Expanded version of SR-HMI to provide front panel display and control. Remote Control (SR-RCx) Hand held remote controller allows controlling of program sequences 1 / 20
The SR logic controllers are programmed using Functional Control Blocks, which will be very familiar to those experienced in Ladder Logic programming of conventional PLC's. The software package operates on a Windows based PC and allows the user to write a program, simulate the program without requiring functional hardware, load and extract programs to an SR controller and to monitor the real time program execution on the controller. Functional Control blocks that define the inputs and outputs (I/O) and special functions (timers, counters etc.) are placed on a schematic using drag and drop capabilities found in many Windows applications. These blocks are interconnected using a combination of 'wires' and logic control blocks to provide the control program. Once created, the control program may be saved to disk, printed, transferred to an SR controller or run in a simulation mode. The simulator allows each input to be individually controlled and provides a graphic representation of the ON/OFF state of all the program blocks. The programs may be quickly edited to correct logic faults and add features. The SR controller family supports up to 128 logic blocks. Simple inputs, outputs and remote controller inputs are not counted in the logic block count. 2 / 20
Software Installation The software will run on Window based PC's (XP, Vista, Windows 7) and is available as a down-loadable file over the internet or as a stand-alone CD. If the software is downloaded select the 'RUN' option offered by the internet browser. If the software is being installed from a CD the setup program should automatically run. If the SETUP program does not automatically execute, open the CD drive and select the SETUP.EXE program. Note: In Windows 7 the file will be flagged as having an 'UNKNOWN PUBLISHER' with the option to ACCEPT or CANCEL. Select the ACCEPT option. The following installation sequences will be generated. In each case, the default option has been chosen. Standard disclaimer to exit all programs prior to installation Software license. Note duplication allowed for education and demonstration purposes. 3 / 20
Program is installed in the c:\program files\array\super CAD directory. A 'projects' directory will be automatically generated for user programs (c:\...\super CAD\Projects) Enter your Name and the Company Name (optional). The default serial number 123456 should not be altered. 4 / 20
Select the 'typical' installation Following the installation a new 'Super CAD' icon will be available on the desktop. USB Serial Support NOTE: If the software is being evaluated without connection to the actual device the USB Serial Support may be skipped. The USB installation is started by selecting the 'Install SR USB Support' icon on the CD. If the program is downloaded it will automatically run if the 'RUN' option is selected. Note: In Windows 7 the file will be flagged as having an 'UNKNOWN PUBLISHER' with the option to ACCEPT or CANCEL. Select the ACCEPT option. 5 / 20
Note: Connecting the hardware to the computer prior to installing the USB support files will likely cause the computer to explain that the driver files cannot be found and offers to search for the drivers. Exit the program, disconnect the device, install the drivers as explained below and then reconnect the device. Following the installation of the USB driver software the hardware device may be plugged in. The computer will report that it has found new hardware and is installing the device driver. At this point the is ready to communicate to the hardware. 6 / 20
Connecting the SR controller The SR controller is connected to the PC using the SR-DUSB assembly. The assembly plugs into the top of the SR controller and the USB cable into any of the computer USB connectors. 7 / 20
Starting Press the icon to start the program. To get the feel of how allows the user to build and simulate software step through the following sequence. 1 Select File-New Displays a menu to select which device to use. For our example, we will pick the SR-12xDC, although the exact model is not important at this point. 2 Select the 'IO' set of blocks (lower right of screen). Click on the Input Block. A rotating mouse icon will be shown. Place the mouse on the left handle of the grid an right-click. Select an Output Block and place it on the right hand side of the screen. There are three types of blocks I/O, FUNction and LOGical. Once placed on the grid area items may be edited by double right clicking or left clicking and selecting the 'Properties' menu option. For our example, we will simply place the default values. Some of the I/O blocks are specific to optional hardware. To enable these, go to the Controller menu item and select the additional hardware options. Block Types 8 / 20
3 Select the Link Tool icon. The mouse will change to a 'pencil' shape. As the mouse moves over valid connection points it will change to a '+' symbol. Right click the mouse on the IA0 connection point and then move the mouse to the connection point of OA0 and right click again. Link Tool Switching back to the 'edit' mode from the 'link' mode is done with either mouse button. The left button opens an 'edit option' menu that includes the 'properties' option. The right button highlights the block, allowing it to be dragged for repositioning. A double right click on a block opens the properties menu that will allow block specific parameters to be set. 4 Select the Simulator icon. Clicking on the IA0 block will cause it to switch between 'OFF' to 'ON'. As expected, the output OA0 will follow the input. Simulator As more complex blocks are inserted additional information is displayed, such as counter and timer values. Note that if the inputs are DC types they may be configured as Analog inputs using the input block properties menus, in which case the analog value may be set in the simulator mode. 9 / 20
Adding Some Logic The Functional Block Language used by the SR controller treats all items, including simple combinatorial functions as 'blocks' which differs from classic Ladder Logic. Consider an application in which there are three inputs, numbered 0..2 and an output. We desire that the output should be ON if both Input 0 AND Input 1 are ON OR if input 2 is ON. In a classic ladder logic 'program' this would be shown as follows. ( ) Input 0 Input 1 Output 0 Input 2 Elements that are in series are AND'd and elements that are in parallel are OR'd. The SR controller uses 4 input AND function blocks and 4 input OR function blocks to allow building the same functionality. Unused inputs of the function block should be assigned to either 'ON', when using AND functions or 'OFF' if using OR functions. The following screen shows the equivalent logic using functional blocks. Unused inputs are not examined by the Simulator but must be preset prior to loading a program onto a physical device. It is recommended that all unused block inputs be assigned a state. AND, NAND - ON OR, NOR - OFF Another option is to connect to 'Link Point P0..9. Link points may be inserted and connected to lines to avoid having common control signals create a 'rat's nest' of interconnect paths. The Properties menu allows assigning each block a 'name' by entering it in the comment section useful as programs grow in complexity. 10 / 20
To build this program: 1 Stop the Simulator (if running) by clicking the SIMULATOR button. Highlight the connection between IA0 and OA0 by right clicking it and select the Delete option. 2 Using the Input Block type in the Instruction Browser section place two new inputs on the left hand of the screen. 3 Select the LOGical block group and select the AND BIT block (B0). Place it on the screen as shown. Repeat, placing an OR BIT block (B1). 4 Using the LINK TOOL connect the IA0..IA1 inputs to the AND block (B0) inputs. Connect the IA2 and B0 output to the OR block (B1) and finally connect the B1 output to the physical OA0 input. 5 After placement the blocks may be dragged by selecting them with the mouse and holding down the right button. Any interconnects will be dragged with the block. 6 It is recommended that the unused inputs of the AND and OR blocks be assigned the appropriate ON or OFF states. Select the block by double clicking to open the properties menu and set the inputs accordingly. At this point the SIMULATOR may be again activated to test out the logic. Connecting to the SR Controller In order to communicate with SR Controller the USB interface must be established with the software. Communication Options Online / Offline options Selecting the COM button opens a Communications Configuration menu to allow selecting the correct COM port. If the wrong port is selected an error message is shown when the unit attempts to go online. The unit will automatically go 'online' after the com port is selected. It must be placed offline for editing and simulator operations. 11 / 20
Having established the communications port, it is now possible to download the previous program. First, select the SR RUN icon (small green arrow) to gain access to the unit. Then, select the 'download' button (large red arrows) to start the download process. At this point the system will ask for the Password, which defaults to 0001. Unless the password has been changed, simply select the 'OK' to proceed with the download. SR Control The factory default password is preset to 0001. During development it is probably wise to leave the factory default set. To change the password select the 'KEYS' symbol. NOTE: If you forget the password the only solution is to try each of the 9999 combinations until the correct one is found! After the program has been downloaded it is possible to restart the program using the SR-RUN button. Once the program starts, the MON button option is enabled. Selecting the Monitor mode allows displaying the state of the software in real time. The SR Status, Com Status and Software mode are always shown along the top of the screen. Monitoring must be disabled before the other run control options are re-enabled. Monitoring allows viewing the state of each of the function blocks but does not allow overwriting the blocks. While monitoring, function blocks that have internal parameters (timers, counters etc.) may be selected to view the real time values. 12 / 20
Logic Blocks The SR controller support 8 different LOGical blocks, summarized below. The Properties menu of each block provides and illustration of the 'truth table' of block specific functionality. The Help menu will provide additional information. The best method to gain an understanding of how these blocks interact is to place them in a circuit connected to digital inputs and outputs and then run the simulator. Alternatively, once placed on a circuit the properties menu of the Function Block may be opened by double clicking. Each property menu includes a 'simulation' button that allows observing the operation. Note: Blocks that include the 'RLO' functionality will only generate a single pulse which may be difficult to 'see' during simulation. It is recommended that these 'pulse generators' be connected to a simple PONS block (see FUNction blocks). The properties menu single point simulator includes a 'pulse stretching' function to allow observing the overall operation of RLO based functions. BLOCK NAME INPUTS Unused Inputs FUNCTION AND Bit 0..3 ON Output will be ON if all inputs are ON AND Bit RLO 0..3 ON Output will generate a PULSE when all inputs are ON. At least one input must then transition from ON OFF ON for another pulse to be generated. OR Bit 0..3 OFF Output will be ON if any input is ON NOT Bit 1 N/A Output will be the complement of the input. XOR Bit 2 N/A Output will be ON if both inputs are the same (both ON or both OFF) NAND Bit 4 ON Output will be OFF if all inputs are ON. Equivalent to an AND connected to a NOT. NAND Bit RLO 4 ON All inputs must then be ON to 'arm' the logic. After being 'armed' the Output will generate a PULSE when at least one of the inputs transition from ON to OFF. NOR Bit 4 OFF Output will be OFF if any input is ON. Equivalent to an OR connected to a NOT. 13 / 20
The 'RLO' function blocks generate a single pulse which is difficult to capture during simulation. A PONS function block inserted between the ANDRLO or NAND-RLO and output will better allow observing the operation. The integral simulation function available in each block's property menu provides an easy to use walk thru of the functionality of the block Block Simulator FUNCTION Blocks The SR Controller supports 14 advanced FUNCTION blocks. Their use is similar to the simpler I/O and LOGICAL function blocks described above, yet they offer a wide range of programming capability with minimal effort. 14 / 20
Devices with a 'P' output may have their parameter information displayed on the optional LCD display unit. This allows counter / timer values and presets to be displayed on the LCD and allows preset values to be written from the LCD display. Timed functions include Time-On, Time-Off, re-triggerable one-shot pulse generators and delays, with resolutions between 0.01 and 99.99 seconds. Pulse functions include S(et)-R(eset) latches, toggle function blocks, pulse generators, 6 step sequencers and up/down counters. Comparator functions allow comparing analog inputs, with built in linearization or counter/timer count values. Sequencing support includes schedulers that trigger at a specific time(s), and 7 output time sequencers. To support Time-Of-Day sequencers the SR maintains an internal clock which may be set using in the Options menu. The only limitation on how many of each block type is used is the overall limitation of 128 function blocks. 15 / 20
BLOCK NAME INPUTS P Output TOND TRG RESET Yes Generates an ON state after a preset time interval. Reset override resets the output and time delay. TOFD TRG RESET Yes Generates an ON state for a preset time interval after the input goes OFF. Reset over-ride resets the output and time delay. PONS TRG RESET Yes Generates an ON state for a preset time interval after the input goes ON. Reset over-ride resets the output and time delay. SPBL TRG RESET No Toggles Output ON-OFF each time Input goes ON. Reset over-ride resets the output. TPBL SET RESET No Set inputs latches output ON. Reset latches output OFF. BLNK ENABLE RESET Yes Generates continuous pulses when enable is ON with fixed ON/OFF time. Reset forces output OFF. MTOD TRG RESET Yes Generates an ON state a preset time interval after the input goes ON. Reset over-ride resets the output and time delay. UDCT CNT DIR RESET Yes UP/DOWN count function when CNT goes ON. DIR determines whether counter increments or decrements. RESET count to 0. Output is active if count value > the preset value. CMPR INPUT 1 INPUT 2 Yes Provides analog comparator between two analog input points or analog input and preset. Auto-scaling & linearization support. Selectable comparison to determine state of Output. CMPR INPUT 1 INPUT 2 Yes Provides comparator between two counter/timer values or counter/timer value and preset. Selectable comparison to determine state of Output. SCHD No Output ON (or OFF) based on 128 settable scheduled times. Schedules may be set daily, weekly, monthly or yearly. SSEQ TRG RESET Yes When TRG is ON up to 7 Outputs will sequentially switch ON based on time values. TSEQ TRG RESET Yes Each time TRG transitions from OFF to ON up to 6 Outputs will sequentially switch ON based on time values. 16 / 20 FUNCTION
EXPANSION I/O Blocks In addition to the standard INPUT and OUTPUT blocks found in the I/O selection there are several blocks specific to optional peripheral devices. BLOCK NAME INPUTS OUTPUTS -- Q1 Activates the Output when a specific key is pressed on the remote control module. Each remote control supports 6 RCI blocks. DOUT TRG Q1, Q2 When TRG goes active an external telephone call will be made. Q1 and Q2 indicate the state of the call (received/no answer etc.) DIN TRG -- Outputs messages to telephone when activated. Interactive with telephone 'responses'. PMSG ON OFF No When activated (ON) messages will be played through a local audio system. The OFF signal will deactivate the playback. SCLD TRG P -- Allows setting specific display information which will appear on the LCD when the TRG is activated. The P signal connects to multiple different Function Blocks to allow access to specific parameters. RCI 17 / 20 FUNCTION
TANK LEVEL CONTROLLER The following illustrates a Tank Level controller application. A storage tank contains 4 level (ON-OFF Float switches), a control valve to allow fluid to flow into the tank and a control valve to allow fluid to flow out of the tank to a down-stream process. The down stream process will provide a 'demand input' when down-stream fluid is required. The controller is required to maintain the fluid level between the Hi level and Low level and must report alarms if the level is below the Empty level or above the Overflow level or if the Fill level is active too long. The Supply output will be activated when the Demand input is active provided that the fluid is at least above the Low Level and no Error condition exists. A Warning signal is generated if the Fill output is active for longer than expected. Fill (OUT) Overflow (IN) Hi Level HiLevel (IN) Low Level LowLevel (IN) Empty (IN) Supply (OUT) DownStream 18 / 20 Demand (IN) ALARM (OUT) UpStream WARNING (OUT) UpStream
NOTES The SUPPLY Output is ACTIVE if the DEMAND input is active and the level is above EMPTY and the LOWLEVEL has been initially active (B15 acts as toggle) and there is NO ALARM condition. Block B15 is triggered ACTIVE when the LOWLEVEL becomes active. It is cleared if the EMPTY level becomes active. The FILL Output is ACTIVE if there is NO OVERFLOW and the level has not reached the HILEVEL (B7, B3) and there is NO ALARM. Block B3 is triggered when the LOW LEVEL goes inactive and cleared when the HILEVEL is reached. In Operation, once the level drops below the LOW LEVEL the FILL will become active until the level rises to the HILEVEL. 19 / 20
The WARNING output will become ACTIVE if the FILL TIME WARNING timer expires. The time starts when the FILL output is active and there is NO DEMAND. If the DEMAND input is active it is assumed that the FILL may be continuously active so no warning is generated. The ALARM output is latched ON by the B17 toggle block if the OVERFLOW output is active or the NO LOW LEVEL TIMEOUT timer has triggered or there has been a level decrease with no DEMAND (leakage) or the NO HILEVEL timer has triggered. The ALARM condition latch may only be cleared by the RESET ERROR input, which is conditioned by B19 to generate a single pulse, eliminating the possibility that the RESET switch is left in the ON condition which would override the ALARM output. The NO LOW LEVEL timer is started when the FILL output is active and is cleared when the LOWLEVEL input is active or the ERROR RESET switch pulse. The LEVEL DECREASE, NO DEMAND time will be started if, after the HILEVEL, LOWLEVEL and EMPTY switches have all been satisfied, one of the switches goes inactive and there is no DEMAND signal. This effectively will detect a leak condition since the levels should not change if there is no DEMAND. The NO HILEVEL Timer is activated by the FILL output and NO DEMAND (B10, B12). It is cleared if the HILEVEL input is active. This ensures that if there is NO DEMAND and the FILL is active that the level reaches the HILEVEL within a prescribed time. Failure to do so would indicate a problem with the fill line. SCREEN FORMATING The screen format shown in the previous example has been 'tweaked' using the OPTIONS menu. This menu allows changing the colors of the background/lines/comments etc. It also allows setting up the title block at the bottom of the page and inserting a company logo. While interconnecting the blocks will draw connecting 'wires' which although functionally correct may leave a 'rat's nest' of interconnects. These may be cleaned up by physically dragging the wires. By right clicking a line it is also possible to use the 'cut line' option, which removes the line and inserts blue 'continuation' points illustrated on the B11/1and OA3 points. This allows lines to interconnect widely separated points. Finally, the File-Print menu option allows printing the final drawings, including a block/system usage summary for documentation purposes. 20 / 20