Training Manual En

Manual Draft 2

SoMachine

Training Manual SoMachine Version 3.0

Schneider-Electric Pty Ltd

245 route des Lucioles BP147

Sophia Antipolis Cedex 06903

FRANCE

DISCLAIMER

The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us.

No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric.

All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components.

When devices are used for applications with technical safety requirements, the relevant instructions must be followed.

Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results.

Failure to observe this information can result in injury or equipment damage. © 2010 Schneider Electric. All rights reserved.

TRADEMARKS

Schneider Electric SAS has made every effort to supply trademark information about company names, products and services mentioned in this manual. Trademarks shown below were derived from various sources.

Windows, Windows NT, Windows 2000, Windows XP, MSSQL Server and Excel are trademarks of Microsoft Corporation.

General Notice:

Some product names used in this manual are used for identification purposes only and may be trademarks of their respective companies.

About Us

Members of Schneider’s team of Instructional Designers have tertiary qualifications in Education, Educational Course Development and are also experienced trainers in their own right; some are also published authors. Currently, the team is supporting a range of over 70 courses in multiple languages and multiple software environments.

Authors

Alynda Brown, Bruce Howlett, Eric Pauchet

Contributors

David Chapman, Michel Beridot

February 2011 Edition for SoMachine Version 3.0 Manual Draft 2 Written, Printed and bound in France

ii SoMachine Version 3.0 February 2011

SoMachine Manual Draft 2 iii

Contents

CHAPTER 1: INTRODUCTION TO SOMACHINE........................................................... 1-1

Overview .................................................................................................................... 1-1 Safety Information...................................................................................................... 1-2 Before the Course Begins........................................................................................... 1-4 Course Overview...................................................................................................... 1-10 Conventions Used in this Manual ............................................................................ 1-12

CHAPTER 2: SOMACHINE AT A GLANCE ................................................................... 2-1

Overview .................................................................................................................... 2-1 Introduction to SoMachine......................................................................................... 2-2 System Requirements................................................................................................. 2-3 Features of SoMachine............................................................................................... 2-4 The SoMachine Interface ........................................................................................... 2-6 Home Screen .............................................................................................................. 2-7 General Functions Menu ............................................................................................ 2-9 Project Work Flow ................................................................................................... 2-11 Show Existing Machine ........................................................................................... 2-13 Properties Screen...................................................................................................... 2-17

CHAPTER 3: PROJECT MANAGEMENT....................................................................... 3-1

Overview .................................................................................................................... 3-1 New Projects .............................................................................................................. 3-2 Create New Machine.................................................................................................. 3-3 Start with Empty Project ............................................................................................ 3-4 Start with Standard Project......................................................................................... 3-8 Archive Projects ....................................................................................................... 3-12

CHAPTER 4: NEW PROJECT CREATION..................................................................... 4-1

Overview .................................................................................................................... 4-1 The Configuration Screen .......................................................................................... 4-2 Display Manager ........................................................................................................ 4-4 Add a Device to a Project........................................................................................... 4-5 Add an Expansion Module to a Device...................................................................... 4-8

iv SoMachine Version 3.0 February 2011

CHAPTER 5: CONTROLLER PROGRAMMING ............................................................. 5-1

Overview .................................................................................................................... 5-1 Program Screen .......................................................................................................... 5-2 Tasks .......................................................................................................................... 5-8 PLC Program Execution............................................................................................. 5-9 POU Program Creation ............................................................................................ 5-10 Gateway Configuration ............................................................................................ 5-16 Task Configuration................................................................................................... 5-17 PLC Simulator.......................................................................................................... 5-21 CoDeSys Program Languages.................................................................................. 5-26 Watchdog Mechanisms ............................................................................................ 5-36 Structuring an Application ....................................................................................... 5-37 The POU Function ................................................................................................... 5-38 Sample Project.......................................................................................................... 5-44 Global Variables....................................................................................................... 5-47

Chapter 1: Introduction to SoMachine

Overview

SoMachine is OEM machine programming software that provides an all-in-one software environment designed specifically for OEM machine builders. SoMachine combines all the necessary elements to:

All-in-One Software

design

commission

service

OEM machines in a single environment.

This Chapter Covers These Topics:

Safety Information................................................................. 1-2

Before the Course Begins...................................................... 1-4

Course Overview................................................................. 1-10

Conventions Used in this Manual........................................ 1-12

1-2 SoMachine Version 3.0 February 2011

Safety Information

NOTICE Important Information

Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists, which will result in personal injury if the instructions are not followed.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety alert messages that follow this symbol to avoid possible injury or death.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.

CAUTION

CAUTION, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in equipment damage.

SoMachine Manual Draft 2 1-3

Safety Information (cont.)

PLEASE NOTE Important Information (cont.) Electrical equipment should be installed, operated, serviced, and maintained only

by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.

A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and the installation, and has received safety training to recognize and avoid the hazards involved.


Before the Course Begins

This training manual is a supplement to the authorised training. In order to make proper use of the software students should also refer to the Online Help and SoMachine Knowledge Base.

Scope of this Training Manual

The graphics displaying screen shots have been taken using the Windows XP operating system using Classic mode display properties. If students are running a different version of Windows then screens may differ slightly from the ones shown in the training manual.

Some screen shots may have been taken from beta versions of the software and may vary slightly from release screen shots.

Validity Note This document has been updated with the release of SoMachine V3.0.

The technical characteristics of the device(s) described in this training manual may also appear online. To access this information online:

Step Action

1 Go the Schneider Electric home page www.schneider-electric.com

2 In the Search box type the model number of a product or the name of a product range.

Do not type any blank spaces in the model number.

To get information on a grouping of similar modules, use asterisks (*).

3 If you entered a model number, go to the Product datasheets search results and click on the model number the interests you.

If you entered the name of a product range, to the Product Ranges search results and click on the product range that interests you.

4 If more than one model number appears in the Products search results, click on the model number that interests you.

5 Depending on the size of your screen, you may need to scroll down to see the data sheet.

6 To save or print a data sheet as a .pdf file, click Download XXX product datasheet.

The characteristics presented in this manual should be the same as those that appear online. In line with our policy of constant improvement we may revise content over time to improve clarity and accuracy. In the event that you see a difference between the manual and online information, use the online information as your reference.


Before the Course Begins (cont.)

WARNING

UNINTENDED EQUIPMENT OPERATION

Only use software approved by Schneider Electric for use with this equipment.

Update your application program every time you change the physical hardware configuration.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

Product Related Information

WARNING

LOSS OF CONTROL

The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and overtravel stop, power outage and restart.

Separate or redundant control paths must be provided for critical control functions.

System control paths may include communication links. Consideration must be given to the implications of unanticipated transmission delays or failures of the link.

Observe all accident prevention regulations and local safety guidelines1.

Each implementation of this equipment must be individually and thoroughly tested for a proper operation before being placed into service.


1 For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems" or their equivalent governing your particular location.



The products specified in this document have been tested under actual service conditions. Of course, your specific application requirements may be different from those assumed for this and any related examples described herein. In that case, you will have to adapt the information provided in this and other related documents to your particular needs. To do so, you will need to consult the specific product documentation of the hardware and/or software components that you may add or substitute for any examples specified in this training documentation. Pay particular attention and conform to any safety information, different electrical requirements and normative standards that would apply to your adaptation.

User Responsibilities

WARNING

REGULATORY INCOMPATIBILITY

Be sure that all equipment applied and systems designed comply with all applicable local, regional and national regulations and standards.


The use and application of the information contained herein require expertise in the design and programming of automated control systems. Only the user or integrator can be aware of all the conditions and factors present during installation and setup, operation, and maintenance of the machine or process, and can therefore determine the automation and associated equipment and the related safeties and interlocks which can be effectively and properly used. When selecting automation and control equipment, and any other related equipment or software, for a particular application, the user or integrator must also consider any applicable local, regional or national standards and/or regulations.


Before You Begin (cont.)

Some of the major software functions and/ or hardware components used in the examples described in this training document cannot be substituted without significantly compromising the performance of your application. Further, any such substitutions or alterations may completely invalidate any proposed architectures, descriptions, examples, instructions, wiring diagrams and/or compatibilities between the various hardware components and software functions specified herein and in related documentation. You must be aware of the consequences of any modifications, additions or substitutions. A residual risk, as defined by EN/ISO 12100-1, Article 5, will remain if:

User Responsibilities (cont.)

it is necessary to modify the recommended logic and if the added or modified components are not properly integrated in the control circuit.

you do not follow the required standards applicable to the operation of the machine, or if the adjustments to and the maintenance of the machine are not properly made (it is essential to strictly follow the prescribed machine maintenance schedule).

the devices connected to any safety outputs do not have mechanically-linked contacts.

CAUTION

EQUIPMENT INCOMPATIBILITY

Read and thoroughly understand all device and software documentation before attempting any component substitutions or other changes related to the application examples provided in this document.

Failure to follow these instructions can result in injury or equipment damage.



When applying this training and before using electrical control and automation equipment after design and installation, the application and associated functional safety system must be subjected to a start-up test by qualified personnel to verify correct operation of the equipment. It is important that arrangements for such testing be made and that enough time is allowed to perform complete and satisfactory testing.

Start-up and Test

CAUTION

EQUIPMENT OPERATION HAZARD

Verify that all installation and set up procedures have been completed.

Before operational tests are performed, remove all blocks or other temporary holding means used for shipment from all component devices.

Remove tools, meters and debris from equipment.

Failure to follow these instructions can result in injury or equipment damage.

Verify that the completed system, including the functional safety system, is free from all short circuits and grounds, except those grounds installed according to local regulations. If high-potential voltage testing is necessary, follow the recommendations in equipment documentation to help prevent injury or equipment damage.



Operation and Adjustments

Regardless of the care exercised in the design and manufacture of equipment or in the selection and ratings of components, there are hazards that can be encountered if such equipment is improperly installed and operated.

In some applications, such as packaging machinery, additional operator protection such as point-of-operation guarding must be provided. This is necessary if the hands and other parts of the body are free to enter the pinch points or other hazardous areas where serious injury can occur. Software products alone cannot protect an operator from injury. For this reason, the software cannot be substituted for or take the place of point-of-operation protection.

WARNING

UNGUARDED MACHINERY CAN CAUSE SERIOUS INJURY

Do not use this software and related automation equipment on equipment which does not have point-of-operation protection.

Do not reach into machinery during operation.


Ensure that appropriate safeties and mechanical/electrical interlocks related to point-of-operation protection have been installed and are operational before placing the equipment into service. All interlocks and safeties related to point-of-operation protection must be coordinated with the related automation equipment and software programming.

Note:

Coordination of safeties and mechanical/electrical interlocks for point-of-operation protection is outside the scope of the examples and implementations suggested in this training documentation.

It is sometimes possible to adjust the equipment incorrectly and may produce unsatisfactory or unsafe operation. Always use the manufacturer instructions as a guide to functional adjustments. Personnel who have access to these adjustments must be familiar with the equipment manufacturer instructions and the machinery used with the electrical equipment.


Course Overview

Course Objectives

By the completion of this training course you will:

Be able to create a new SoMachine project

Be able to connect to a Controller

Be able to create a simple Programmable Organisation Unit

The SoMachine training course is an integral part of the complete Schneider Electric curriculum. This course is designed for:

Target Audience

Users who are new to SoMachine


Course Overview (cont.)

The training course will take one day to complete. The following program outlines the topics that will be covered on each day:

Course Program

Day Topics

1 Introduction to SoMachine

SoMachine at a Glance

Project Management

Controller I/O Configuration

Controller Programming


Conventions Used in this Manual

Objectives These are the skills you will achieve by the end of each chapter. An overview providing a brief synopsis of the topic begins each section. Often, examples are given to illustrate the conceptual overview.

Example -

The SoMachine configuration environment consists of several toolbars, browser windows and programming editors. This chapter introduces the user to the configuration environment using an example project with pre-defined elements.

Exercises After a concept is explained you will be given exercises that practise the skills you just learned. These exercises begin by explaining the general concept of each exercise and then step-by-step procedures are listed to guide you through each procedure.

Example -

Paste a genie from a library in the Include project onto a test page called Utility.

1 Run the Milk_Upgrade project then trigger and view some alarms.

i. Use the following template settings:

User Input Whenever information is to be typed into a field or dialog box it will be written in this font:

Example -

KETTLE_TEMP/25

Note that some exercises will show a fragment of information already typed into a SoMachine screen and then ask students to add extra lines of configuration. In this instance, the previously entered material will be given to the student as pale grey italic text:

KETTLE_TEMP/25

OVEN_TEMP/5


Conventions Used in this Manual (cont.)

Hints & Tips This heading will provide you with useful or helpful information

Example -

Hints & Tips

To go to the next field, use the mouse cursor or press the TAB key.

Note A note will refer to a feature which may not be obvious at first glance but something that always should be kept in mind.

Example -

Note:

Any events named GLOBAL are enabled automatically when events are enabled.

Text separated by the double arrow symbol “»” indicates that you are to select a menu

Menus and Menu Options

Example -

File » New…

Open a menu “File” then select the menu option “New…”

Horizontal and Vertical Tabs

Text written this way indicates the Horizontal then the (Vertical) tab you are to select.

Example -

Appearance (General)


Conventions Used in this Manual (cont.)

See Also Text written in this way indicates further references about the current topic.

Example -

See Also:

For further information about Templates, see SoMachine Help - Using Page Templates.

This heading describes topics that are covered in more advanced courses. Further Training

Example -

Further Training:

Trend Table Maths is a topic in the SoMachine Customisation and Design Course.

Caution This heading describes situations where the user needs to be careful.

Example -

CAUTION

UNINTENDED EQUIPMENT OPERATION

Verify that all installation and set up procedures have been completed.

Failure to follow these instructions can result in equipment damage.

Chapter 2: SoMachine at a Glance

Overview

SoMachine is a professional, efficient and open OEM software solution that develops, configures and commissions the entire machine in a single environment including logic, motor control, HMI and related network automation functions.

Introduction


Introduction to SoMachine .................................................... 2-2

System Requirements ............................................................ 2-3

Features of SoMachine .......................................................... 2-4

The SoMachine Interface ...................................................... 2-6

Home Screen ......................................................................... 2-7

General Functions Menu ....................................................... 2-9

Project Work Flow .............................................................. 2-11

Show Existing Machine....................................................... 2-13

Properties Screen ................................................................. 2-17


Introduction to SoMachine

OEM Solution Software

One Machine Environment

SoMachine in Flexible Machine Control


System Requirements

Before the Installation of SoMachine

Before installing SoMachine the computer that will be used as the Server needs to be configured. SoMachine has been designed for machines with the following specifications:

Hardware Requirements

The computer equipment may need to be upgraded to run SoMachine Version 3.0, as the minimum hardware requirements have changed:

Description Minimum Specification Recommended

Processor Pentium V, 1.8 GHz, Pentium M, 1.0 GHz or equivalent

Pentium V, 3.0 GHz, Pentium M, 1.5 GHz or equivalent

Random Access Memory (RAM)

2 GB 3 GB

Available Disk Space

3.5 GB including the memory space for the software installation, temporary space for execution and space for saving applications

4 GB

Drive DVD Reader DVD Reader

Display Resolution: 1024 x 786 pixels Resolution: 1280 x 1024 pixels

Peripherals Mouse or compatible pointing device

USB interface

Web Access Web registration requires internet access system

Software Requirements

SoMachine Component Minimum System Software

Operating System The SoMachine software supports 1 of the following operating systems:

Microsoft Windows XP Professional Service Pack 2 and Service Pack 3

Microsoft Windows Vista Home Basic

Microsoft Windows Vista Service Pack 1


Features of SoMachine

Standard Languages

SoMachine includes, as standard, 6 IEC (International Electrotechnical Commission) languages which are compliant with IEC 61131-3. Depending on requirements, the application may use any mixture of these different languages.

Function Block Diagram (FBD)

Sequential Functional Chart (SFC)

Structured Text (ST)

Instruction List (IL)

Ladder (LD)

Continous Function Chart (CFC)

User Created Function Blocks (FBs) Controller Programming Services

User Created Functions

Data Unit Type (DUTs)

On-line changes

Watch windows

Graphical monitoring of variables (trace)

Breakpoints, step-by-step execution

Simulation

Visualization for application and machine set-up

Graphics libraries containing more than 4000 2D and 3D objects. HMI Based Services Simple drawing objects (points, line, rectangles, ellipses, etc …)

Preconfigured objects (button, switch, bar graph, etc …)

Recipes (32 groups of 256 recipes with max. 1024 ingredients)

Action tables

Alarms

Printing

Java scripts

Multimedia file support: wav, png, jpg, emf, bmp

Variable trending

Embeded devices configuration and commissioning Motion Services CAM profile editor

Sample application trace

Motion and drive function blocks libraries for inverters, servos and steppers

Visualization screens


Features of SoMachine (cont.)

User access and profile Global Services Project documentation printing

Project comparison (control)

Variable sharing based on publish/subscribe mechanism

Library version management

Master: Integrated Fieldbus Configurators

- CANopen

- CANmotion

- Modbus Serial Line

- AS-interface

Connectivity:

- Profibus-DP

- Ethernet IP

- Modbus TCP

General: Application Libraries - PLCopen function blocks for Motion control

Segment Solutions:

- Packaging function blocks

- Conveying function blocks

- Hoisting function blocks


The SoMachine Interface

To start SoMachine: How to Start SoMachine

Select the SoMachine item from the Windows start menu:

Start » Programs »Schneider Electric » SoMachine » SoMachine

or

Double click the SoMachine icon on the desktop


Home Screen

Navigation within SoMachine is intuitive and highly visual. The GUI is optimised in such a way that the appropriate tools become available as you enter different development stages of your project. The user interface ensures nothing is overlooked, and suggests the tasks to be performed throughout the project development cycle. The workspace has been streamlined, so that only that which is necessary and relevant to the current task is featured, without any superfluous information.

Visual Graphical User Interface

Main Selection Screen

After successful startup SoMachine displays the main selection screen with the open Home screen that provides access to the functions.

1 General Functions Menu

2 Hide/View Handle

3 Task Selection Pane

4 Work Area

5 Online Help

6 Language Selection Menu

7 Information Pane


Home Screen (cont.)

Tasks of the Home Screen

The task selection pane on the left-hand side of the main selection screen groups the SoMachine functions in folders according to the tasks that can be performed.

Tasks of the Home Screen Commands Provided

Show existing machine This folder provides commands for opening an already existing SoMachine project

Browse for existing project Locate a project previously created in SoMachine

Create new machine This folder provides commands for creating a new SoMachine project either from scratch or by using a template project

Machine workflow This folder provides commands that are especially dedicated to commissioning a machine. Further commands that are beyond commissioning tasks are not available from this folder

Learning Center This folder provides further information on SoMachine. This information includes:

a quick overview

an eLearning

examples


General Functions Menu

To gain access to the General Functions Menu: How to Gain Access to the Menu Click the SoMachine icon that is always visible in the upper left corner of the

SoMachine window.


General Functions Menu (cont.)

The General Functions Menu provides the following commands:

Command Description

Home Execute this command to return to the Home screen, that is the main selection screen.

Save Execute this command to save the changes to the current project.

Save As Execute this command to save the current project to a different location or under a different name. A standard Windows Save Project dialog box is displayed that allows users to browse to the new folder and / or enter the new file name.

Save/Send archive

Execute this command to create an archive file of the SoMachine project that is currently open and:

to save the archive file to a connected drive by using the Save button of the Project Archive dialog box

or

to create a temporary archive file that is attached to an empty e-mail by using the Send button of the Project Archive dialog box. This e-mail is automatically created by SoMachine if the Messaging Application Programming Interface (MAPI) is correctly installed.

Preferences Execute this command to define:

the Preferred Path where SoMachine projects are saved

the Online Polling Interval (ms) that is the time span that has to elapse between 2 attempts to poll the connected devices

Advanced Options including Autosave

Help Execute this command to open the SoMachine online help.

About Execute this command to open the About dialog box that provides information about the currently installed SoMachine.

Exit Execute this command to close SoMachine.

Tasks of the General Functions Menu


Project Work Flow

Optimised Project Development

The SoMachine user interface is optimised to be intuitive and highly visual. With the help of the navigation tabs a project workflow is ensured and nothing will be overlooked.

After starting a project the user is asked to fill in the Properties with useful information for project identification.

After defining the scope of the project the user creates a Configuration with at least one controller. The graphical configuration screen makes it easy to establish the hardware with additional modules, e.g. an additional controller, an HMI or fieldbus communication.


Project Work Flow (cont.)

Optimised Project Development (cont.)

The Program tab opens the project for programming and application development. All CoDeSys functionalities are available in this area.

The Commissioning tab provides online access to the controller and the connected devices for monitoring device status and the user is able to download the application(s) or update the firmware.


Show Existing Machine

The Show existing machine task allows users to open an existing project. Commands of the Task

The Task includes the following commands:

Browse for existing project

Extract archive

The work area provides quick access to the four SoMachine projects that have been opened most recently.

How to Open an Existing Project

To open an existing project:

Double click the project's thumbnail in the Work area

or

Select the project in the Work area and click the Open button in the Project Information pane. The project will open at the Properties screen for assigning further information.


Show Existing Machine (cont.)

To Browse for an existing project: How to Browse for an Existing Project Click the Show existing machine item in the Task pane, then click Browse for

existing project item in the Task pane

Search the directory tree in the left pane for the folder that contains the existing project then double click the project icon in the Work area

or

Select the project in the Work area and click the Open button in the Project Information pane


Exercise - Browse for an Existing Project

1 Open an Example Project.

i. Launch SoMachine.

ii. When the Home screen appears click the Show existing machine item in the Task pane, then click Browse for existing project item in the Task pane

iii. Search the directory tree in the left pane for the folder that contains the existing project examples. If the default path has been installed this will be

C:\Program Files\Schneider Electric\SoMachine\CoDeSys\ NewGUI\Learning Center\Examples\en

iv. Select the folder 04-Traffic lights.

v. Double click the Traffic lights.project thumbnail.


Exercise - Browse for an Existing Project (cont.)

vi. When the project is opened SoMachine will display the project in the General Properties tab.

2 Return to the Home screen.


Properties Screen

Additional Project Information

The Properties screen allows users to enter additional project information. The textual and graphical information entered here is optional. As this information is always displayed in the information pane for the project selected in the work area, it helps to identify the individual projects, avoiding the need to open them. This screen is only displayed after a project has been opened.

The Properties screen provides the following tasks:

General

Description

Custom Information


Properties Screen (cont.)

The task selection pane on the left-hand side of the properties screen groups the SoMachine functions in folders according to the tasks that can be performed.

Tasks of the General Screen

Tasks of the Properties Screen

Commands Provided

General Task The General task allows users to save the project file to a different location or under a different name and provides the option to add author information. The work area provides the following sections:

File Information

Author Information

File Information The section File Information displays the name of the project file and the folder it is saved in. To save the project to a different location or under a different name, click the Save as button, navigate to the preferred folder, and save the project file.

Author Information The section Author Information provides entry fields for optional information the author considers relevant. The entries are displayed in the section Project Information on the right side of the screen.

To save the information entered in the Properties screen, click the SoMachine icon and select Save from the General Functions Menu

Description Task The Description task allows users to add an image to the project. This optional customer image helps users to identify the project



The Description task allows users to add an image to the project. This optional customer image helps users to identify the project.

Description Task

The work area provides the Add button to add a preferred Customer Image to the SoMachine project and displays the Configuration View corresponding to the settings in the Configuration screen. After an image has been added to the project Change and Remove buttons are provided.



The Custom Information task allows users to customise project information that they may consider relevant. The screen provides entry fields for custom information as well as a button to add attachments to the project.

Custom Information Task

Many actions have more than one way of being invoked. For example, a typical action will be invoked by:

Methods of Using the Interface

Click a tool on a toolbar

Select a menu item from the main menu

Use a keyboard shortcut

Right click inside a window and select an item from a context sensitive menu

This manual, frequently demonstrates only one method of performing an action. This is not because this is necessarily best method, but because it is too time consuming and unnecessary to show all possible methods. Your instructor will encourage the use of a variety of methods.


Exercise - Examine the User Interface

1 Create a new project based on one of the existing examples.

i. Use the Windows Explorer to create a new folder named C:\Class.

ii. Return to the Home screen and click the Learning Center item in the left pane.

iii. Click the Examples item from the expanded menu.

iv. Double click the 04-Traffic lights thumbnail then the Traffic lights.project thumbnail.

v. When the Save Project As dialog appears save the project as MyTraffic then click the Save button.

vi. Save the project as MyTraffic in the C:\Class directory.


Exercise - Examine the User Interface (cont.)

2 Examine the interface using an example project.

i. The new project opens at the Properties screen.

ii. Click the Configuration tab then select the device in the Work area to display the description in the Information pane.



iii. Select the Program tab.

3 Navigate the Devices pane.

i. If the tree branches are closed they may be expanded by clicking the plus (+) sign next to each object. Double click the Library Manager item. This opens the Library Manager Editor which displays all the defined libraries in this PLC.



4 Examine the objects in the Example project.

i. Double click the Visualization object.

ii. The toolbars are context sensitive. When the Visualisation is the focus window a graphic editor toolbar will appear underneath the main toolbar.

iii. Click the Library Manager tab and the graphic toolbar will disappear.



5 Run the project.

i. Select Online » Simulation from the menu to place the project into Simulation mode.

ii. Select Online » Login to log in to the simulator.

iii. Since there is no program in the simulator, the following message will appear. Click Yes.

iv. The operator interface shows that the program is connected.



v. Select Online » Start to start the controller.

vi. Type the name of one of the countries into the input field and press ENTER.

vii. Click the Start/Stop Sequence button.



viii. Double click the Light_Sequences (FB) POU in the Devices tree to open the POU. Observe the values changing.

ix. Examine all of the objects in the Devices pane.

6 Shutdown the runtime.

i. Select Online » Stop.

ii. Select Online » Logout.

iii. Select Online » Simulation to disable Simulation Mode.


Chapter 3: Project Management

Overview

SoMachine allows the user to perform fundamental tasks such as creating, exporting and importing projects. There are also other project management tools such as archiving which create a highly compressed version of the project.

Introduction

The implemented project management principle allows users to browse the existing projects quickly getting the relevant information without the need to open them before selection.

The user can create a new project, starting from several means: using Tested Validated and Documented Architectures, using the provided examples, using an existing project or from scratch. There is quick access to the most recently-used projects.


New Projects.......................................................................... 3-2

Create New Machine ............................................................. 3-3

Start with Empty Project ....................................................... 3-4

Start with Standard Project.................................................... 3-8

Archive Projects .................................................................. 3-12


New Projects

The first step when configuring SoMachine is to create a new project. The project is where all information is stored.

First Step in the Configuration

SoMachine facilitates project creation by providing different project templates.

The project templates are categorised in four groups:

Project Template Group Description

Empty Projects Empty project, empty library and projects with a predefined controller

Generic Implementations Generic project shells, including controller, HMI, field devices and functions - tested, validated and documented

Conveying Implementations

Project shells dedicated to conveying, including controller, HMI, field devices and application functions - tested, validated and documented

Packaging Implementations Project shells dedicated to packaging, including controller, HMI, field devices and applied functions - tested, validated and documented

Configure Projects

SoMachine provides tools that assist users in creating new projects quickly and easily.

It provides for project startup:

a variety of preferred implementations. A dedicated TVDA Finder tool (Tested Validated Documented Architectures) assists users in selecting the preferred implementation that best suits individual projects.

a variety of application projects for conveying, hoisting, and packaging that provide basic configurations for these applications.

some examples that provide basic projects for making yourself familiar with SoMachine.

Once the project is created, SoMachine provides extensive possibilities to add textual and graphical information to each project file. This additional information enables users to distinguish projects avoiding the need to open them when they have to select the suitable project out of those that are available on the computer.

For easy configuration of the project, SoMachine provides a graphical configuration editor that allows users to add and configure the requested devices in a comfortable way.


Create New Machine

Create New Machine Commands

The Create new machine menu allows users to create a new project either from scratch or by using a project template.

It includes the following commands:

Start with empty project

Start with standard project

Start with TVD architecture

Start with application

Start with existing project

Start with example


Start with Empty Project

The Empty Project Command

The Start with empty project command allows users to create a new project from scratch without any preconfigured devices or settings. The command opens a Save Project As dialog box where users can browse to the destination folder and assign a name to the new project.

To create an empty project:

Click the Start with empty project menu item

How to Create an Empty Project

When the Save Project As dialog opens browse for a location using the Save in: field

Create a name for the project in the Filename: field then click Save.


Exercise - Create a New Empty Project

1 Create a new Empty Project.

i. Click the Create new machine item in the left pane.

ii. Click the Start with empty project item from the expanded menu.

iii. When the Save Project As dialog appears use the Save in: field to navigate to the C:\Class folder. Use the File name: field to name the project Empty.project then click the Save button.


Exercise - Create a New Empty Project (cont.)

iv. When the project is created SoMachine will display the project in the General Properties tab.


Exercise - Create a New Empty Project (cont.)

2 Examine the project settings.

i. Click the Configuration tab. There are no devices selected.

ii. Click the Program tab. The Devices pane is also empty. When a device is added to the project the devices pane will be populated with standard references.



Start with Standard Project

The Standard Project Command

The Start with standard project command allows users to create a new project on the basis of a specified PLC. SoMachine provides a variety of PLCs that can be used as templates to create individual projects.

To create a standard project:

Click the Start with standard project menu item

How to Start with a Standard Project

Select the device from the Device: drop down list then click the Create Project button.


Exercise - Create a New Standard Project

1 Create a new project based on a specific PLC.

i. At the Home screen click the Create new machine item in the left pane.

ii. Click the Start with standard project item from the expanded menu.

iii. Select the device TM238LFDC24DT from the Device: drop down list. Change the default name of the POU Name: to MyPOU. Click the Create Project button.


Exercise - Create a New Standard Project (cont.)

iv. When the Save Project As dialog appears use the Save in: field to navigate to the C:\Class folder. Use the File name: field to name the project Standard.project then click the Save button.

2 Examine the project settings.

i. Open the Configuration tab. Select the controller to display the description in the Information tab.


Exercise - Create a New Standard Project (cont.)

ii. Open the Program tab. Select each of the objects in the Devices pane to view the objects that have populated this pane. Compare this with the Devices pane in the Empty project.

3 Save the project.


Archive Projects

A project Archive is a very compressed version of the project. The compression rate can result in a file that is more than one fiftieth the size of the project file. Archiving is similar to exporting except that it saves the compiled application. The consequences of this is that the user cannot archive a project until a successful compile can be completed. Until this is possible it is necessary to export.

Save the Compiled Project

Archive Properties

A project Archive is saved with the extension .ProjectArchive. The ProjectArchive file contains:

The PLC binary

The Upload information, i.e. Comments and Animation tables

The Operator Screens

To create an archive:

Select File » Project Archive » Save/Send Archive… from the main menu. Enter desired path for the archive file when prompted.

How to Create an Archive

Note:

Archiving is possible only if the project was compiled and when the Upload information has been included, when it contains at least the comments.


Exercise - Archive Projects

1 Archive the project.

i. Open one of the previous projects. Select File » Project Archive » Save/Send Archive … from the main menu.

ii. Select the following information then click the Save... button.

iii. Save the file as .projectarchive.

iv. Open Windows Explorer and compare the size of the two files .project and .projectarchive.

v. Which file is larger? ______________________________

vi. Why? _________________________________________

Chapter 4: New Project Creation

Overview

The Configuration screen is only displayed after a SoMachine project has been opened.

Introduction

The screen consists of a graphical configuration editor that provides necessary functions to perform the entire hardware and network configuration of the machine. The configuration settings performed here will also be available in the controller and Vijeo Designer Program screen


The Configuration Screen...................................................... 4-2

Display Manager ................................................................... 4-4

Add a Device to a Project...................................................... 4-5

Add an Expansion Module to a Device................................. 4-8


The Configuration Screen

The graphical Configuration Editor provides necessary functions to perform the entire hardware and network configuration of your machine in a graphical way.

Configuration Screen Interface

1 General Functions Menu

2 Hide/View Handle

3 Task Selection Pane

4 Work Area

5 Online Help

6 Display Manager

7 Information Pane


The Configuration Screen (cont.)

Task Selection Pane

The Task Selection pane of the Configuration tab lists the devices that may be added to the configuration in the graphical configuration editor grouped by type into Logic Controller, HMI Controller, and other categories of devices.

When a new project is created from scratch, the work area of the graphical Configuration Editor will be empty. The work area will display a prompt for the user to drag a device from the list in the left pane into this empty area.


Display Manager

To simplify the use of the graphical Configuration Editor a Display Manager is provided at the bottom of the pane.

Functions of the Display Manager

The display manager contains the following functions:

Display Manager Item Description

Zoom The Zoom slider controls the magnification of the graphical configuration editor

100% The 100% button returns the display of the elements in the graphical configuration editor to their original size

Show All The Show All button displays the elements available in the graphical configuration editor

Reroute The Reroute button redraws the connecting lines between the items

Reroute On Drop Activate this function to redraw the connecting lines between the items with every new device that is dragged into the graphical configuration editor

Coll All The Coll All button collapses the subdevices that are expansion modules

Exp Last The Exp Last button expands the subdevices (expansion modules) of the last device that was selected

Exp All The Exp All button expands all subdevices that are expansion modules


Add a Device to a Project

To add a device: How to Add a Device

Select the device in this list and drag it to the work area. Notice the device description on the right, designed to help you make the correct selection.

When the device has been added to the work area a graphical representation of the device is displayed.


Add a Device to a Project (cont.)

How to Search for a Device

To assist in finding the suitable device icon, SoMachine provides a Search function.

To search for a device:

Enter the name of the device in the text box surrounded by asterisks and click the Search button.

SoMachine will return a list of devices meeting the search phrase that was entered or will display a message indicating that no devices were found.


Exercise - Add a Device to an Empty Project

1 Use the Configuration Screen to add a device to an empty Project.

i. Return to the Home Screen and open the Empty.project created in Exercise - Create a New Empty Project (page 3-5).

ii. Open the Configuration Screen.

iii. Use the Search function to locate the controller TM238LFDC24DT. Enter the name of the device into the Search field then click the Search button.

iv. Drag and Drop the controller TM238LFDC24DT into the work area.

v. When the device has been added to the work area a graphical representation of the device is displayed.

2 Save the project and return to the Home Screen.


Add an Expansion Module to a Device

To add an expansion module to a device: How to Add a Digital Expansion Module

Click the Add Expansion hot spot on the device.

Select a module from the Add object dialog then click Add and close. Notice the Information panel displays information on the selected device. This helps the user to select the correct device


Exercise - Add an Expansion Module

1 Use the Configuration Screen to add an expansion module to a device.

i. Return to the project created in Exercise - Add a Device to an Empty Project (page 4-7).

ii. Open the Configuration screen where the device created in the previous exercise will be displayed.

iii. Click the Add Expansion hot spot on the device.

iv. When the hot spot is clicked the Add Object dialog will open.


Exercise - Add an Expansion Module (cont.)

v. Click the (+) next to the Digital Expansion Modules branch then the Inputs branch and select the TM2DA18DT module. Notice that when the module is selected the Information pane give a description of the module

vi. Click the Add and close button to add the module to the device

2 Save the project.

i. Open the Devices tab and click the Save Project button.

Chapter 5: Controller Programming

Overview

Over a period of ten to fifteen years PLC Programming languages developed independently from each other. Control applications developed their own proprietary languages based on Ladder programming, C, BASIC and many others. Since all of these languages were different the people who needed to use these languages had to spend a great deal of time learning each language.

Introduction

During the early 1990s the International Electrotechnical Commission (IEC) developed a standard for all PLCs called IEC 61131. IEC 61131-3 (Part 3) was developed in 1993. This part of the standard is concerned with the PLC programming languages.

SoMachine is able to use the five IEC standard languages. These are Sequential Function Chart (SFC) language and four inter-operable programming languages:, Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST) and Instruction List (IL). SoMachine is also able to use the programming language Continuous Function Chart (CFC)

SFC is mainly used to control highly sequential processes, like repetitive machine operations. This is properly referred to as a state machine. It can also be used as a supervisory control mechanism.


Program Screen ..................................................................... 5-2

Tasks...................................................................................... 5-8

PLC Program Execution........................................................ 5-9

POU Program Creation........................................................ 5-10

Gateway Configuration ....................................................... 5-16

Task Configuration.............................................................. 5-17

PLC Simulator ..................................................................... 5-21

CoDeSys Program Languages............................................. 5-26

Watchdog Mechanisms ....................................................... 5-36

Structuring an Application .................................................. 5-37

The POU Function............................................................... 5-38

Sample Project..................................................................... 5-44

Global Variables.................................................................. 5-47


Program Screen

The Program screen is displayed when a SoMachine project is opened. It provides access to the CoDeSys programming environment. Any configuration settings that were already performed in the Configuration screen are displayed in the Devices view and can be modified, deleted and / or added here. Any changes performed in this view will also be available in the Configuration screen.

Devices Window

The Devices window consists of four main nodes. Configuration screens are accessed by double clicking on the node in the device tree. The four main nodes are:

Area Description

Controller PLC type and PLC configuration

Program All parts of the PLC’s program

Embedded Functions functions built into the M238

I/O (fast & normal I/O),

HSC high speed counter,

PTO and PWM (pulse train output, pulse width modulation)

Communication Communication ports to external devices

Advantys

CAN devices

Servo & Stepper drives

etc. …


Program Screen (cont.)

Gateway In order to connect to a M238 controller, a Gateway must be defined and set to be the active path. The Gateway is defined in the Communications tab in the Controller section of SoMachine.

Other configuration items in the Controller section include:

Item Description

Applications Displays list of applications on the PLC

PLC Settings Name of application running IO, output behavior when in STOP mode

Services Set time in PLC. Firmware rev, Boot version

Real time in the PLC can be set

Status Status of PLC and expansion bus

Information Information about connected PLC model



The Program Section contains several items: Program Section

Application

- All parts of the PLC’s program

GVL (Global Variable List)

- Declaration of global variables. Variables visible between all programs in project.

- 3 GVL lists per project is the maximum allowed

Library Manager

- Add optional libraries to current project or create your own custom library

- Libraries provide the following items that are executed in the runtime system of the automation device:

Functions and function blocks

Datatype definitions

Global variables

Visualization objects

Programs (PRG) and Functions(FUN)

- Named POU (Program Organizational Unit). User created program sections or functions in the current project. May be created in any of the six IEC supported languages.

Task Configuration

- Controls the execution of the programs in the project. MAST – created by system when you start a new project



Embedded Functions

IO

- Configuration of the M238’s internal I/O. The M238 has 6 discrete inputs, 8 fast inputs, 6 discrete outputs, 4 fast outputs

HSC

- Configuration of the built-in high speed counter. The HSC function can execute fast counts of pulses from sensors, encoders, switches, etc. The HSC is independent of the M238 scan time.



PTO_PWM Embedded Functions (cont.) - Configuration of the pulse train output or pulse width modulation outputs.

The PTO function provides a square wave output for a specified number of pulses and a specified cycle time.

The PTO function can be implemented in two different modes:

- one train of pulses

- a pulse profile (multiple trains of pulses).

Two PTO channels are available on the Modicon M238 controller. Each PTO channel is associated to 2 fast outputs and 1 standard input:

PWM uses a square wave whose duty cycle is modulated resulting in the variation of the average value of the waveform.

Two PWM channels are the maximum possible.



Communication

Depending on the M238 model, there are either:

- One serial port, no Can Master or

- Two Serial ports, one Can Master

By default, the TM238LFDC24DT device is preconfigured as follows:

- Serial Line 1: Modbus manager

- Serial Line 2: SoMachine - Network manager

Serial1/Serial2 – RS232/485, RTU/ASCII

- Program download, HMI interface, other services are possible

CANbus

- connect remote CANopen devices

16 remote devices are possible


Tasks

Task Basics A Task is a group of sections and subroutines, executed cyclically or periodically for the MAST task, and periodically for the FAST task (cyclic task with a periodicity smaller than that of the MAST task).

Task Configuration allows the definition of one or several tasks to control the execution of an application program. Tasks control the execution of the application.

The M238 allows the configuration of up to seven tasks with the restrictions listed below.

There are Five types of tasks:

Cyclic (3 max) - executed on a time schedule…every 50ms

Event (2 Max) - executed on L -> H transition of trigger on event tag

Freewheeling (1 Max) – starts with program and cycles, no specific time

External Event (4 Max) – (not in menu) executed when designated “system event” is TRUE. Example - embedded input = ON or OFF or Both

See Also:

For further information about Maximum Number of Tasks for each platform, see SoMachine Help - and search for Maximum Number of Tasks.

Tasks may be triggered by: Task Triggering

a time (cyclic, freewheeling)

an internal or external event

- the rising edge of a global project variable

- an interrupt event of the controller

the combination of priority and condition determine the order that the tasks will be executed


PLC Program Execution

PLC Program Cycle

The diagram above describes a PLC Program cycle.

Local I/O - processed by the tasks which use them (Task MAST, Task Name-xxx,…).

Expansion Module I/O - processed by the MAST task only, not by other tasks if they exist


POU Program Creation

Program Organization Units (POU)

The Devices window allows users to add POUs (Program Organization Units) to the application. A POU is an object in SoMachine where programming code is written.

The different types of POU are:

POU Type Description

Program Returns one or several values during operation. All values are retained from the last time the program was run until the next. It can be called by another POU.

Function Block Provides one or more values during the processing of a program. As opposed to a function, the values of the output variables and the necessary internal variables shall persist from one execution of the function block to the next. So invocation of a function block with the same arguments (input parameters) need not always yield the same output values.

Function Yields exactly one data element (which can consist of several elements, such as fields or structures) when it is processed. The call in textual languages can occur as an operator in expressions.


POU Program Creation (cont.)

To create a POU:

Right click Application and select Add Object » POU from the menu.

How to Create a POU


POU Program Creation (cont.)

Enter a Name and an Implementation Language. How to Create a POU (cont.)

All POUs are created in this manner. When finished, they must be scheduled to run by assigning them to a Task.


Exercise - Create a POU

1 Use the Program screen to create a POU.

i. Return to the Home Screen and open the Empty.project created in Exercise - Create a New Empty Project (page 3-5).

ii. Open the Program Screen.

iii. Right click the Application node and select Add Object » POU from the menu.


Exercise - Create a POU (cont.)

iv. When the Add POU dialog opens type the name POU_ST in the Name: field then select Structured Text (ST) in the Implementation Language: field. Click the Open button when complete.

v. The Devices pane will display the new POU and the Work area will be open ready for the user to enter the new program.

vi. Click the Save Program button on the main toolbar to save the project.


Exercise - Create a POU (cont.)

2 Create a program to calculate the average of three variables.

i. Return to the Devices pane and double click the POU_ST item to open the programming editor.

ii. Create four INT variables shown between the VAR and END_VAR. These are local variables and are only usable in this POU. Be careful with the syntax.

iii. Add the code shown in the lower window. Click the Save Project

button on the main toolbar to save the POU.

3 Save the project.


Gateway Configuration

To add a USB Gateway: How to Add a USB Gateway

If the PC is connected to the controller, you can double click the controller to access the Communication Settings.

If no gateway is present, you can use the Add gateway... button to add one. You can also configure multiple gateways but only one can be active at a time. When the Set active path button is pressed, the path visualisation changes from normal to bold.

Use the Set active path button to select the active gateway. When the Set active path button is pressed, the path visualisation changes from normal to bold.


Task Configuration

To Configure a Task:

A POU_ST is added to MAST Function.

How to Configure a Task

Priority – Define the priority of the current task (0 is the highest priority, 31 is the lowest priority).

Type – Define the type of task

- Cyclic - execute cyclically according to the period defined.

- Event – start on rising edge of the variable associated to trigger the event

- External Event – start on rising edge of the trigger input for the event.

- Freewheeling - execute at start program. At the end of a cycle run, the task is automatically restarted in a continuous loop, after a delay that is 30%-proportional to the duration of the last task cycle. There is no cycle time defined but T#: 1...1000 ms.

Watchdog – Enable the watchdog, enter the watchdog time and the sensitivity. The Sensitivity field defines the number of times a watchdog overrun can occur before a watchdog event is generated.

POU – Add previously created POU program(s) in the task and fix the execution order of the POU in online mode. Like a segment scheduler in other =S= PLCs.


Task Configuration (cont.)

To add a POU to a Task: How to Add a POU to a Task

Double click the Task in the Devices pane to open the Configuration window in the Work area.

Click Add POU in the POUs section of the Configuration tab.

Select the POU.


Exercise - Configure a Task

1 Add a POU to the MAST Task.

i. Double click the MAST item in the Devices pane to open the MAST Configuration window in the Work area.

ii. Click Add POU in the POUs section of the Configuration tab. This will open the Input Assistant.

iii. Expand the branches of Application and select the POU_ST. Click OK.


Exercise - Configure a Task (cont.)

iv. The POUs section of the MAST Configuration tab will display the POU_ST item.

v. Check the lower left corner of the SoMachine window under the Messages section to see that the message Precompile OK has appeared.

vi. Select Build » Build from the menu.

2 Save the project.


PLC Simulator

Offline PLC Simulator

SoMachine provides an Offline PLC Simulator. Applications may be downloaded to the simulator and run offline for:

- Program development

- Program debugging

To start the simulator:

Select Online » Simulate <PLC Name> from the main menu to place SoMachine into simulation mode.

How to Start the Simulator

Select Online » Login to log in to the Simulator. Transfer the application.


PLC Simulator (cont.)

The simulation mode is indicated in the software by a red rectangle reading SIMULATION being displayed in the information line of the dialog box and by the controller in the Devices window being displayed in italics.

How to Start the Simulator (cont.)


Exercise - Start the Simulator

1 Connect the project to the Simulator.

i. Select Online » Simulation from the main menu to place SoMachine into simulation mode.

ii. Select Online » Login to log in to the Simulator.

iii. Since there is no program in the simulator, the following message will appear. Click Yes.


Exercise - Start the Simulator (cont.)

iv. The operator interface shows that the program is connected. An M238 is shown on the left and an M258 is shown on the right

2 Test the running project

i. Select Online » Start to start the Controller.

ii. Open the POU and observe its operation. Notice that all the variables currently have a value of zero.


Exercise - Start the Simulator (cont.)

iii. Enter some values into the Prepared value field for var1, var2, var3 as shown. The Prepared Value field is a queue for the variables. The values are not currently applied to the variables.

iv. Press <CTRL> + W on the keyboard or Online » Write Values from the menu to force the values into the variables. Confirm the action.

The values are written into the variables and the average is calculated.

3 Log out of the application and save the project


CoDeSys Program Languages

POU ST ST (Structured text) is similar to programming in PASCAL or C.

Note:

Multiple variable declarations of same data type is possible

POU FBD FBD (Function block diagram) is a network oriented graphical language. The components are placed in Networks (i.e., Row) so there is no free placement.


Exercise - Program a Function Block Diagram POU

1 Create a program using FBD language to calculate the average of three variables.

i. Return to the Devices pane and add a new POU program in the Function Block Diagram (FBD) language. Name the new POU POU_FBD.

ii. Create the same four INT variables that were used in Exercise - Create a POU (page 5-13).

iii. Right click to the left of Network 1 in the lower pane of the Work area and select Insert Box from the menu.


Exercise - Program a FBD POU (cont.)

iv. When the Input Assistant opens select FDB Operators from the Categories: pane then select ADD from the Items: pane. Click OK.

v. The ADD operator will be inserted into the editor. Right click the ADD block and select Insert Input from the menu.

A third input will be added to the ADD operator.



vi. Click to select the first Input then click the Ellipsis button.

vii. This will open the Input Assistant. Select var1 then click OK. In the same manner add variables var2 and var3 to the second and third inputs respectively.

viii. Right click the Output pin and select Insert Box to open the Input Assistant. Select Keywords from the Categories: pane then select DIV from the Items: pane. Click OK. Add 3 to the lower input pin (denominator).



ix. Right click the Output pin of the DIV block and select Insert Assignment.

x. Use the Input Assistant to add the avg variable. The completed program will look like this:



2 Test the program.

i. Add the new POU to the MAST task.

ii. Select Online » Login from the main menu. Since the code has changed SoMachine will prompt for the type of login. Select Login with online change then click OK.

iii. Click the Start Application button to start the program.

iv. Enter values into the variables in the same manner as before. Check the display to see whether the program is functioning correctly.

v. Select Online » Logout to log out of the program.

3 Log out of the application and save the project.


CoDeSys Program Languages (cont.)

POU IL IL (Instruction list) is an Assembler like programming language.

POU LD LD (Ladder Diagram) enables the programmer to virtually combine relay contacts and coils.


Exercise - Convert to IL and LD

1 Convert an FBD POU to Ladder Diagram (LD) language.

i. Return to the POU_FBD POU created in Exercise - Program a Function Block Diagram POU (page 5-27).

ii. Select FBD/LD/IL » View » View as ladder logic to change the POU from FBD language to Ladder Diagram language.

iii. Select FBD/LD/IL » View » View as instruction list to change the POU Instruction List language.

Note:

FBD, LD and IL formats can be converted from one format to another. SFC and CFC cannot be converted.



CoDeSys Program Languages (cont.)

POU CFC CFC (Continuous Function Chart) is similar to FBD. Unlike FDB it allows the free placement of components.

Note:

Local variables are declared in the “VAR” section.

POU SFC SFC (Sequential function chart) is used to program sequential processes.


Exercise - Program a Continuous Function Chart POU

1 Create a program using CFC language to calculate the average of three variables.

i. Create a new POU program named POU_CFC using the CFC language. Create the same program to calculate the average of three variables.

ii. The CFC language allows free placement of the components. The Inputs, Outputs and Boxes must be added to the work area by using the CFC Toolbox located to the right of the Work area.

iii. Create this POU by following the program below. Ask the instructor if additional help is needed.

iv. Save, Login, and test this POU.



Watchdog Mechanisms

A Watchdog is a device used to protect a system from specific software or hardware failures that may cause the system to stop responding.

M238 Watchdog Operation

There are two types of Watchdog in SoMachine:

Application (configured) watchdog - Each task cycle can be monitored by a watchdog timer (a maximum duration of the task cycle). This helps debugging certain application conditions (such as infinite loops, etc.) and provides a maximal duration for refreshing outputs.

A watchdog can be defined for each task.

System Watchdog - System Overload is reached when all the user tasks use more than 80% of system resources. This is computed on a 1 second window, each second.

This system overload mechanism cannot be disabled, so that system tasks can be executed properly.

In Online mode, task processing can be monitored by clicking on the task .

- Monitoring the task shows you how long the task is taking to execute

- Monitoring the actual task execution time helps determine the correct WDT setting


Structuring an Application

POU Program Structure

A POU can call other POUs (nesting)

- No limits to number of calls

- Could affect Watchdog limits if not taken into account

Program structuring is possible

- Conditional execution may be added

Watchdog issues are possible

- Called POUs can be in any language

POU calling in the application program


The POU Function

POU Function – A POU that returns a result A POU that Returns a Result

- Normally used when you need repeat the same calculation with different vars. Number crunching

- Returns the result of the calculation to the calling POU

- Arguments are passed to the function, returns a single result

Example - Function Creation

Function CalcAvg is created in ST language


The POU Function (cont.)

Function CalcAvg called from ST POU and POU running Calling Function

Values 10, 20, 15 passed to function CalcAvg. Result of 15 is returned

The same POU Function is shown in three different programming languages POU Function in Three Languages


Exercise - POU Function

1 Create a POU Function and add it to a POU Program.

i. Right click the Application node and select Add Object » POU.

ii. Name the function CalcAvg. Select Structured Text as the creation language for this function and return data type of INT


Exercise - POU Function (cont.)

iii. Create the function as shown. The function returns an Integer and has three input variables. The comments do not need to be added to the function. Save the function.

iv. Save and Build the application. Fix any errors that appear.

2 The next steps will call the function from a new program POU. Create a new POU program call the function

i. Open the POU_FBD program. Right click the left margin, and select Insert Network from the menu.



ii. Right click the left margin and add a box to the network that was just created.

iii. When the Input Assistant opens select the item Module Calls in the Categories pane. Expand the Application branch and select the function CalcAvg. Click OK.



iv. The CalcAvg function is added. Add the vars shown

v. Save, login and download this application to your controller. Test the operation by entering values into the Prepared Value fields and using the CNTRL + <W> keys to enter values into the Value field.


Sample Project

The Escalator project is a simple project that is designed to start and run an escalator. This project will be used to consolidate all of the features of SoMachine that have been demonstrated in this tutorial.

Escalator Project


Exercise - Start the Escalator Project

1 Create a new Standard Project.

i. At the Home screen click the Create new machine item in the left pane.

ii. Click the Start with standard project item from the expanded menu.

iii. Select the device TM238LFDC24DT from the Device: drop down list. Name the POU Escalator_Mgt and select Continuous Function Chart as the Implementation Language. Click the Create Project button.


Exercise - Start the Escalator Project (cont.)

iv. Save the project as Escalator in the C:\Class directory.

v. When the project is opened SoMachine will display the project in the Properties tab. Add Title, Author and Company information into the Author Information fields.

vi. Save the project.


Global Variables

A Global Variable List (GVL) is a list of variables that are available to all parts of the application. The fact that all POUs as well as other sections of the application, have access to these variables is what makes them global. A maximum of three GVL lists may be created per application

Global Variable List (GVL)

Note:

Global Variables are declared in the same manner as local variables but are located in a GVL file.


Exercise - Add Global Variables

1 Add Global Variables to the Escalator project.

i. Open the Program screen to view the Devices pane.

ii. Double click the GVL item in the Devices tree. The GVL Tab will open in the right pane.

iii. Add these variables to the project.

2 Save the project.


Exercise - Add a POU to the Escalator Project

1 Add a POU to the project.

i. The Escalator Project already contains a blank POU named Escalator_Mgt (PRG). Double click the POU to open for editing.

ii. Add these Local Variables to top pane of the POU.

iii. Add the CFC Diagram to the lower pane. Note that the comments are not necessary.

iv. Notice that the AND function block has a little circle on the lower left pin.

This is a Negated pin. To negate the pin right click the pin and select Negate from the menu.

v. Add the Escalator_Mgt POU to the MAST task.

vi. Save and build the project.

vii. Run the project in Simulation mode to test the logic.


Exercise - Add a POU to the Escalator Project (cont.)

2 Add an Action (sub program) using Ladder Logic Diagram for the Emergency Management.

i. Right click the Escalator_Mgt POU and select Add Object » Action... from the menu.

ii. When the Add Action dialog appears name the Action Emergency_Stops_Mgt and select Ladder Logic Diagram as the Implementation language. Click Open.

iii. Add this ladder logic to the Action.


Exercise - Add a POU to the Escalator Project (cont.)

3 Add an Action using Structured text for the Maintenance.

i. Right click the Escalator_Mgt POU and select Add Object » Action... from the menu.

ii. When the Add Action dialog appears name the Action Maintenance and select Structured Text as the Implementation language. Click Open.

iii. Add this code to the action.

4 Add the Actions to the POU.

i. Add boxes to the program to add the two Actions to the program.

ii. Log in to the program and test.

Training Manual En

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Transcript of Training Manual En