User Manual for HE-QX451, HE-QX551, HE-QX651, HE-QX451-16, HE-QX551-16, HE-QX651-16, HE-BP41, HE-BP43 HEQX451C105, HEQX551C105, HEQX651C105 HEQX451C103, HEQX551C103, HEQX651C103 HEQX451C000, HEQX551C000, HEQX651C000 QX OCS MAN0798-04-EN
MAN0798-04-EN PREFACE PREFACE This manual explains how to use the QX OCS Modules. Copyright (C) 2006 Horner APG, LLC., 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved.
PREFACE MAN0798-04-EN LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG,LLC. ("HE-APG") warrants to the original purchaser that the QX OCS module manufactured by HEAPG is free from defects in material and workmanship under normal use and service.
MAN0798-04-EN PREFACE Table of Contents VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU ................................... 8 CHAPTER 1 : SAFETY / COMPLIANCE .................................................................................................... 9 1.1 Safety Warnings and Guidelines .................................................................................................... 9 1.2 Grounding ....................................................................................
PREFACE MAN0798-04-EN 8.4 I/O Specifications.......................................................................................................................... 37 8.5 QX Register Mapping ................................................................................................................... 38 8.5.1 PWM Examples....................................................................................................................... 38 8.
MAN0798-04-EN PREFACE 16.3 CsCAN Network ........................................................................................................................ 91 16.3.1 CsCAN Network Troubleshooting Checklist............................................................................ 91 16.4 Removable Media ..................................................................................................................... 92 16.5 Technical Support Contacts..............................................
PREFACE MAN0798-04-EN VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU The following map is provided to show you the major types of tasks needed to be performed and the key chapters in this manual you need to refer to for information and help. Directions: Major tasks are listed at the top of the map with the key chapters listed beneath that you need to consult in order to perform the tasks. FIRST STEP of ANY TASK: DATASHEET Each QX and BP unit is sent with a datasheet in the box.
MAN0798-04-EN CH. 1 CHAPTER 1: SAFETY / COMPLIANCE 1.1 Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections. WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly recommended to fuse the voltage measurement inputs.
CH.1 1.2 MAN0798-04-EN Grounding Grounding is covered in various chapters within this manual. 1.3 For grounding specifications and testing for a good ground, refer to page 21. For panel grounding, refer to page 19. CE Compliance To check for compliance and updates, visit our website at: http://www.heapg.com/Pages/TechSupport/ProductCert.
MAN0798-04-EN CH. 2 CHAPTER 2: INTRODUCTION 2.1 Visual Overview The QX OCS provides flexible options allowing you to choose the functionality you need. A QX Base can be used alone or it can be used with a Back Pack I/O Interface (BP) and/or a Video Capture Option board Note: After September 2006, the QXxxx base models are loaded with Back Pack capable firmware. For QX models without preloaded Back Pack firmware, use QXxxx-16 models. See Table 2.1.
CH.2 MAN0798-04-EN Continued Other Products Commonly Used with Color QX (Back Pack Options Required) Allows four channels of NTSC or PAL video to be connected to a QX. HE500VIM400 Requires Cscape Software. Plastic SmartStack Provide a wide variety of I/O options for the QX. Require little space and are easy to Modules install. Fiber Optic Extension Extends a high-speed QX backplane enabling SmartStack I/O Modules to be System mounted several meters from the QX.
MAN0798-04-EN 2.2 CH. 2 Connectivity to the QX The QX has tremendous capabilities for connecting to a variety of devices. In some cases, the use of a BP or VIM400 is required. The diagram below shows some examples of devices that can be used with the QX.
CH.2 b. MAN0798-04-EN CsCAN Network When used with a Back Pack option, the QX has the feature of CsCAN peer-to-peer networking. (CsCAN is pronounced “see-scan”). CAN-based network hardware is used in the controllers because of CAN’s automatic error detection, ease of configuration, low-cost of design and implementation and ability to operate in harsh environments. Networking abilities are built-in to the QX and require no external or additional modules.
MAN0798-04-EN 2.3.3 CH. 2 Video Capture Option (VIM400) The Video Capture Option (VIM400) permits you to integrate security, view machinery in remote locations, or incorporate a machine vision monitor with the control system. The VIM400 allows four channels of NTSC or PAL video to be connected to a QX OCS. By using the Video Object in Cscape software, video can be displayed on OCS screens in various sizes.
CH.2 2.6 MAN0798-04-EN Useful Documents and References The following information serves as a general listing of Horner controller products and other references of interest with their corresponding manuals numbers. Visit our website (see page 92) to obtain user documentation and updates. The following information serves as a general listing of Horner controller products and other references of interest and their corresponding manuals numbers.
MAN0798-04-EN CH.3 CHAPTER 3: MECHANICAL INSTALLATION 3.1 Initial Mechanical Installation Note: Prior to mounting, observe requirements for the panel layout design and adequate clearances on page 18. Initially, it is important to refer to the data sheet sent with the product in the box. The datasheet covers model-specific information related to QX and Back Pack models such as: a. b. c.
CH. 3 3.2. MAN0798-04-EN Mounting Orientation 001OCS001 NOTE: There are NO orientation restrictions on the QX. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad. Figure 3-2 – Orientation of QX 3.3 Factors Affecting Panel Layout Design and Clearances Warning: It is important to follow the requirements of the panel manufacturer and to follow applicable electrical codes and standards.
MAN0798-04-EN b. CH.3 Grounding Warning: Be sure to meet the ground requirements of the panel manufacturer and also meet applicable electrical codes and standards. Panel box: The panel box needs to be properly connected to earth ground to provide a good common ground reference. Panel door: Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference. c.
CH. 3 3.3.1 MAN0798-04-EN Panel Layout Design and Clearance Checklist: The following list provides highlights of panel layout design factors. ____Meets the electrical code and applicable standards for proper grounding, etc.? ____Meets the panel manufacturer’s requirements for grounding, etc.
MAN0798-04-EN CH. 4 CHAPTER 4: ELECTRICAL INSTALLATION 4.1 Initial Electrical Installation Initially, it is important to refer to the data sheet sent with the product in the box. The datasheet covers model-specific information related to QX and Back Pack models such as: a. b. Ports and Connectors Wiring and Pin-outs Visit our website (see page 92) to obtain updates to datasheets and user documentation. 4.
CH. 4 4.5 MAN0798-04-EN QX Primary Power Port Table 4.1 – Primary Power Port Pins Signal Pin Description V+ Input power supply voltage V- Input power supply ground Frame Ground Note: Power Supply Voltage Range is from 24VDC ±10%.
MAN0798-04-EN CH. 5 CHAPTER 5: CAN COMMUNICATIONS Note: See the latest edition of Horner’s CAN Networks Manual (MAN0799) by referring to our website (page 92). 5.1 Overview QX models with either a BP41 or BP43 attached provide a CAN networking port, which is implemented with a 5-pin connector, labeled CsCAN. Like the MJ1 serial port, the CsCAN port can be used for QX BPxx programming by connecting it to the CAN port of a PC running Cscape.
CH. 5 5.4 MAN0798-04-EN Cscape Programming via CAN The CsCAN port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via PCI card or USB), and the PC CAN port is connected to the QX BPxx CsCAN port, Cscape can access the QX BPxx for programming and monitoring. In addition, the QX BPxx supports single-point-programming of all QX BPxx and other OCS/RCS devices that are connected to a CAN network.
MAN0798-04-EN CH. 6 CHAPTER 6: COMPACTFLASH 6.1 General Chapter Six provides an overview of the CompactFlash feature in QX OCS models and Cscape Software. Note: For detailed information regarding Removable Media (RM) function blocks and parameters, refer to the help file in Cscape Software. 6.2 Compact Flash Overview All QX OCS models provide a slot for a CompactFlash memory card.
CH. 6 c. MAN0798-04-EN Rename RM csv This function allows renaming a file on the CompactFlash card. changed. d. The data in the file is not Delete RM csv This function allows deleting a file on the CompactFlash card. 6.4 Configuring Removable Media Manager graphical object in Cscape The Removable Media Manager is a graphical object that allows viewing filenames, size and dates of files, and directories on a CompactFlash card.
MAN0798-04-EN 6.6 CH. 6 System Registers used with CompactFlash %SR175 Status – This shows the current status of the CompactFlash interface. Possible status values are shown in the table: 0 1 2 3 4 5 Table 6.2 – CompactFlash Status Values CompactFlash interface OK Card present but unknown format No card in slot Card present, but not supported Card swapped before operation was complete Unknown error %SR176 Free Space – This 32-bit register shows the free space on the ComapactFlash card in bytes.
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MAN0798-04-EN CH. 7 CHAPTER 7: SMARTSTACK I/O 7.1 General Chapter Seven provides preliminary configuration procedures, which are common to all SmartStack Modules. Note: Because the configuration parameters are different for each SmartStack Module, refer to the data sheet that is sent with the product and is specific to the selected module. 7.2 Configuration Procedures Note: SmartStack Modules use Cscape Software for configuration. 1. From the Main Menu, select Controller|I/O Configure.
CH. 7 MAN0798-04-EN Selecting a Different Controller To select a different controller, ensure that the CPU Slots tab is pressed. Then, click on the slot or the Config button. The Configure Controller screen appears. Figure 7-2 – Selecting a Controller To select a different controller, click on the Type list box and scroll down to select the desired controller. Then press OK. If satisfied with the controller now selected, press Base # tab at the top of the screen. Then, go to Step 3.
MAN0798-04-EN 3. CH. 7 The following screen appears. In this configuration example, I/O modules are going to be selected and configured for Base 2. Any Base can be selected. It is not necessary to select bases in a specific order. The Main base contains the slots directly located on the back of the NX. Figure 7-3 – Main Base Screen appears with QX and BP43 Upon pressing the Base 2 tab, the following screen appears.
CH. 7 MAN0798-04-EN Double-click on a slot or press the Config button located next to the slot. The following screen appears. Select a tab at the top of the screen, and then select an I/O module. (For this example, the DIQ612 is going to be selected.) Press OK. Figure 7-5 – Selecting an I/O Module 4. The following screen appears. Figure 7-6 – Base 2 with an I/O Module Selected The description and properties of the I/O module are provided. If satisfied with the selections, press OK.
MAN0798-04-EN 5. CH. 7 The Module Configuration Screen appears. Two tabs are available for selection: Figure 7-7 – I/O Map Tab a. I/O Map Tab The I/O Map describes the I/O registers assigned to a specific I/O module. Although there are no userdefined parameters, the I/O Map can be viewed after the SmartStack module is configured to review the registers. • • Model number Description • • • • Type: Starting Location: Ending Location: Number: Provides the part number.
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MAN0798-04-EN CH. 8 CHAPTER 8: HIGH SPEED I/O (HSC / PWM) 8.1 Overview A QX base used with a BP43 provides High Speed I/O. The High Speed I/O includes both a High Speed Counter (HSC) and a Pulse Width Modulation (PWM) functionality for a variety of standard and complex applications as shown in Table 8.1. Table 8.1 – High Speed I/O Applications and Procedural Overview Input Functions Counter Counter Application How? 1 2 1. Choose up to 2 input functions.
CH. 8 8.2 MAN0798-04-EN Glossary Accumulator Clear Disable Encoder Frequency Input Latch (strobe) Marker Polarity Preload (load) Quadrature Totalizer 8.3 Register used to accumulate or store up a sum or count of many items or events. A special function to zero out the value in a specific register. (Not used with Frequency Counter.) A special function to trigger counter to stop.
MAN0798-04-EN CH. 8 Table 8.2 – I/O Port Pins (HSC / PWM) (Orange Connector) Pin Signal 1 2 3 4 5 TTL In1 TTL In2 TTL In3 TTL Out1 TTL Out2 Description HSC 1 / 5 V Input 1 (See Note*) HSC 2 / 5 V Input 2 (See Note*) HSC 3 / 5 V Input 3 (See Note*) HSC 1 / 5 V Output 1 (See Note*) HSC 2 / 5 V Output 2 (See Note*) Ground 6 0V (For best performance, use separate supply and isolated ground.
CH. 8 8.5 MAN0798-04-EN QX Register Mapping Note: Unlike a typical OCS, you can assign registers for the high speed feature in the QX. Table 8.
MAN0798-04-EN CH. 8 8.6 Cscape Configuration for HSC / Frequency Measurement 8.6.1 Preliminary Configuration Procedures Note: Although the example configuration in this section shows how to configure the QX551 BP43, it applies to any QX controller using HSC. 1. From the main menu in Cscape, software, select Controller|I/O Configure. 2. Ensure that the desired controller is selected. -In this case, a different controller is shown than the one that is desired. Continue with Step 2.
CH. 8 MAN0798-04-EN 3. If satisfied with the controller now selected, click the High Speed Counter slot or the Config button next to it. Note: In this example configuration, Ethernet is not used, but it is available for use. 4. The Module Configuration screen appears with two tabs at the top: Press the HSC Setup tab. 8.6.2 Configuration Procedures Two HSC counters are available that have the following functions depending upon configuration: Counter #1 – Totalizer (32-Bit) or Frequency Counter.
MAN0798-04-EN CH. 9 CHAPTER 9: SYSTEM SETTINGS AND ADJUSTMENTS 9.1 System Menu - Overview The QX controller has a built-in System Menu, which lets the user view System Settings and make adjustments. To start the System Menu, press the SYSTEM keys at the same time (or set %SR3 to 1), which will display the Main Menu, as shown in Figure 9-1. Then use the ↓ and ↑ keys to select a Main Menu item and press Enter to display the item’s Sub-Menu.
CH.9 9.2 MAN0798-04-EN System Menu – Navigation and Editing As mentioned above, pressing the front panel SYSTEM key starts the System Menu. Then, either press ESC to exit the System Menu, or use the ↓ and ↑ keys to select an item and press Enter to display the item’s Sub-Menu. A Sub-Menu generally shows a list of System Settings and their values. After opening a Sub-Menu, if any of its System Settings are editable, the first System Setting that can be edited is highlighted.
MAN0798-04-EN CH. 9 Set Contrast The Set Contrast Sub-Menu displays, however for the QX line there are no adjustments available on this sub-menu. View OCS Status The View OCS Status Sub-Menu displays up to 17 System Settings. The OCS Net Use (%) and All Net Use (%) System Settings only appear for QX models that have a BPxx attached. Only the Mode System Setting is editable. Model: QXx51 or QXx51BP4y Mode: Scan Rate(mS): Idle DoIo Run 0.0 0.1 to 999.
CH.9 MAN0798-04-EN Fault = One or more power-on self-tests failed View OCS Diags The View OCS Diags Sub-Menu displays up to 10 System Diagnostics, all of which are not editable. The Net Errors, Network State, Network ID and Dup Net ID System Diagnostics only appear for QX models that have a BPxx attached. The first two System Diagnostics are critical. If any of them indicate a Fault condition, the QX will not enter or remain in Run mode, and the problem must be investigated and corrected.
MAN0798-04-EN CH. 9 View I/O Slots If BPxx is not installed, the View I/O Slots Sub-Menu displays 4 System Settings, none of which are editable. If BPxx is installed, the View I/O Slots Sub-Menu displays 6 System Settings, only one of which is editable.
CH.9 MAN0798-04-EN View Protocols The View Protocols Sub-Menu displays three System Settings, none of which are editable. As mentioned earlier, MJ1 (Port 1), MJ2 (Port 2), and CN1 (Port 3) serial ports support downloadable protocols. To assign a downloadable protocol to an QX serial port, select the Protocol Config item in Cscape’s Program menu and then setup a protocol for Port 1, Port 2, or Port 3 (or all of them).
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CH.9 MAN0798-04-EN If the Removable Media Manager displays files or directories, as in the last example above, there are several options available: Del DelAll Format SavPgm Esc = Delete the highlighted file or directory = Delete all files and directories = Format the Compact Flash card = Save QX application to DEFAULT.PGM = Cancel current operation (back up one screen) If a directory name is highlighted, pressing Enter will switch to that directory showing its files and subdirectories.
MAN0798-04-EN CH. 9 Selecting Backup/Restore Data displays the following screen in: Backup Restore Clear Backup Exit = Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS. = Copies the backed up data from onboard FLASH to the battery backed RAM. = The backup data will be erased from the onboard FLASH. = Goes back to previous menu.
CH.9 MAN0798-04-EN Enable AutoLoad No Yes = Does not load AUTOLOAD.PGM automatically when application program is absent or corrupted. = Loads AUTOLOAD.PGM file automatically from RM when application program is absent or corrupted. Clone Unit ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in Battery backed RAM of an OCS into the RM (refer Removable Media Chapter 6 for details on using RM).
MAN0798-04-EN CH. 9 Selecting Make Clone brings up the screen below for the user: After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM CLONE.DAT Application file File having all unit settings and register values from Battery Backed RAM Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”.
CH.9 9.4 MAN0798-04-EN Touch screen calibration The touch screen is calibrated at the factory and rarely needs modification. However, if actual touch locations do not appear to correspond with responding objects on the display, field adjustment is available. To access the field adjustable touch screen calibration dialog, press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to figure 9.2 should appear.
MAN0798-04-EN CH. 10 CHAPTER 10: USER INTERFACE 10.1 Overview This chapter presents the user interface (or operator view) of the QX and some of the model specific characteristics of the QX as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the CSCAPE graphics editor. For instructions on creating screens and using the graphics editor, refer to the graphics editor help file. The following aspects are discussed: • • • • • • • • • • 10.
CH.10 MAN0798-04-EN Multiple objects are provided for displaying data such as virtual panel lights, push buttons, numeric value displays, bar graphs, meters, graphs and animated bitmaps. On the QX, these graphical objects (through ladder manipulation of attribute bits) can change color, flash or change visibility to attract operator attention. On objects that accept user input, the input is provided by touching the object or alternately changing an OCS register (i.e. Function key registers).
MAN0798-04-EN CH. 10 Figure 10-2 – Alpha-numeric Keypad Once the desired value is entered, the Enter key moves that value into the object (and the corresponding OCS register) and the alpha-numeric keypad disappears. Alternately, pressing the ESC key any time before the Enter key cancels the operation, leaves the objects current value unchanged, and the alphanumeric keypad disappears. Note: Each numeric entry object has a configured minimum and maximum value.
CH.10 MAN0798-04-EN ASCII Object When editing an ASCII value, each press of the same key generates a different value. For example, the [1 _QZ] key generates the following sequence: , Q, Z, q, z, 1, The digit keys (except zero) sequence the corresponding 3 alphabetical characters first in upper case followed by the same 3 characters in lower case followed by the corresponding numeric digit. Thereafter, continued presses of the same key repeat the sequence.
MAN0798-04-EN CH. 10 labeled Back or Previous to indicate to the operator that it is possible to transverse back to a previous screen. Figure 10-4 – Screen Jump Object (configured to return to previous screen) Note that changing the current displayed screen though use of a display coil in ladder logic clears the screen jump queue. 10.5 Beeper Acknowledgement The QX contains an internal beeper that provides an audible acknowledgment when an operator touches a graphic object that accepts touch input.
CH.10 MAN0798-04-EN The alarm object is generally used to enunciate alarms to the operator. While the display characteristics of this object is configurable, it is generally displayed as a button that changes colors to indicate the highest state of the alarm(s) in the alarm group it is monitoring. The following indicates the priority of the alarm states and the default colors associated with these states.
MAN0798-04-EN CH. 10 in the alarm object. If not enabled, the Clear buttons are grayed and do not respond to touch. Once view operations are complete, simply touch the Esc button to remove the pop-up alarm viewer. Note that OCS registers %SR181 and %SR182 are available for ladder use, which indicate presence of unacknowledged or acknowledged alarm (respectively). The screen designer may implement these registers to switch screens or active the beeper to attract the operator’s attention. 10.
CH.10 MAN0798-04-EN Figure 10-8 – Removable media viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry. If more entries exist than can fit on the page, a scroll bar is displayed on the right side that also indicates the current relative position. File operations are accomplished by pressing the appropriate button at the bottom of the removable media viewer.
MAN0798-04-EN CH. 10 Figure 10-9 – Example application segment for safe removal of removable media 10.9 OK and Run Status Since the QX does not provide external LEDs for the Ok and Run status of the configuration and ladder logic engine (respectfully), an optional pop-up may be enabled to warn the user that one of these two status indications has changed. When enabled in the system menu, a status change is indicated as shown in figure 10.10.
CH.10 10.10 MAN0798-04-EN Screen Saver The QX screen backlight life is typically 5 years when in continuous use. If the application does not require interaction with the QX for long periods of time, the backlight life can be extended by using the screen saver function. When enabled through the system menu, the backlight is shut off (screen goes black) after a specified time of no touch activity on the screen.
MAN0798-04-EN CH. 11 CHAPTER 11: REGISTERS 11.1 QX Resources 11.1.1 Overview This section defines the resource limits that a programmer needs to know when writing a program using the QX. The QX combines operator interface (display and keypad), local and remote I/O (analog and digital), networking, and controller, into a single product. In addition, the QX has graphical capabilities.
CH. 11 MAN0798-04-EN 11.1.3 Resource Definitions System Registers System Registers (%S and %SR) are used to store general QX status information. This information is used internally, and is also available to the operator via the System Menu, using the QX display and keypad. The System Registers are also available for User Screens and can be accessed by Ladder Code. %S Registers %S Registers are 1-bit memory locations containing system status information, which are implemented as shown in Table 11.
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CH. 11 Register %SR164.3 %SR164.4 %SR164.5 %SR164.6 %SR164.7 %SR164.8 %SR164.9 %SR164.10 MAN0798-04-EN Name %SR164.11 %SR164.12 %SR175 %SR176177 %SR178179 Compact Flash %SR181 ALM_UNACK %SR182 %SR183 %SR184 %SR185 %SR186 %SR187 ALM_ACT SYS_BEEP USER_BEEP SCR_SAVER SCR_SA_TM NET_USE %SR188 NET_MIN %SR189 NET_MAX %SR190 %SR191 %SR192 NT_TX_AVG NT_TX_MIN NT_TX_MAX Compact Flash Compact Flash Table 11.
MAN0798-04-EN CH. 11 HMI Registers HMI Registers (%K and %D) give the user access to the QX keypad and display. %K Registers A %K Register is a non-retentive 1-bit memory location (contact), used to store the state of a function key on the QX keypad. If the function keys are set for momentary mode, a function key’s associated %K register will be ON as long as the function key is pressed.
CH. 11 MAN0798-04-EN %QG Registers A %QG Register is a retentive 1-bit memory location, which is normally used to store a digital state to be sent as global data to another node on the network. %AIG Registers A %AIG Register is a retentive 16-bit memory location, which is normally used to store a global analog value obtained from another node on the network.
MAN0798-04-EN CH. 12 CHAPTER 12: CSCAPE CONFIGURATION 12.1 Overview QX hardware is programmed with a Windows-based PC application called Cscape (HE500OSW232). Please see the on-line help provided with Cscape for additional details. 12.2 Cscape Status Bar When the QX is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen. The Cscape Status Bar can be used to determine if communications have been established between the QX and the Cscape program.
CH. 12 12.3 MAN0798-04-EN Establishing Communications The main method for communicating between Cscape and an QX is RS-232 serial. The QX can communicate with Cscape using USB to serial adapters, Ethernet, CAN (CsCAN) or modems. For communications other than RS-232 serial, please refer to the manual that ships with the adapter hardware being used for programming. Start by configuring Cscape to use the correct communications port.
MAN0798-04-EN CH. 13 CHAPTER 13: FAIL – SAFE SYSTEM 13.1 Overview The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: • • Battery power loss Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive EMI event.
CH. 13 13.2 MAN0798-04-EN Settings To use the fail – safe feature, the user needs to do the following: 1. Backup the current Battery-Backed RAM Register contents in On-Board Flash memory using System Menu options. 2. From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 3. Place the Removable Media with AUTOLOAD.PGM in the device. 4. Set the ‘Enable AutoLoad’ option in the device to YES. 5.
MAN0798-04-EN CH. 13 Figure 13-3 – Backup Registers Restore OCS Data: When initiated, this will allow the user to manually copy the backed up data from the onboard FLASH to the Battery-Backed RAM. A restore operation will be automatically initiated if a backup has been previously created and on powerup the Battery-Backed RAM registers fail their check. The following process will be followed for restoring data: • The controller will be placed in IDLE mode.
CH. 13 MAN0798-04-EN Figure 13-4 – Restore OCS Data %SR164.3 is set to 1 only when an automatic restore operation is performed - not on a manual one. This bit is reset to 0 when a new backup is created. Restoring of data can be manually performed by selecting RESTORE option from the Backup / Restore Data menu. This will cause the controller to reset. Clear Backup Data: When initiated, the backup data will be erased from the onboard Flash and no backup will exist. %SR164.4 and %SR164.
MAN0798-04-EN CH. 13 Figure 13-5 – Clear Backup Data Exit: Goes back to the previous screen.
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MAN0798-04-EN 13.4 CH. 13 AutoLoad Figure 13-7 – AutoLoad Menu This system menu option allows the user to specify whether the OCS automatically loads the application AUTOLOAD.PGM located in Removable Media. When the AutoLoad setting is enabled (set to YES), it can either be manually initiated or automatically initiated at power-up. The automatic initiation will happen only in the following two cases: • When there is no application program in the OCS and a valid AUTOLOAD.
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MAN0798-04-EN 13.5 CH. 13 AutoRun Figure 13-9 – AutoRun Menu This system menu option, when enabled (YES), allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation. When the AutoRun setting is disabled (NO), the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation. %SR164.5 can be set by putting the system into RUN mode automatically, once an AutoLoad has been performed or an Automatic Restore has occurred.
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MAN0798-04-EN CH. 14 CHAPTER 14: CLONE UNIT 14.1 Overview ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in Battery backed RAM of an OCS into the RM (refer Removable Media Chapter 6 for details on using RM). It can then be used to clone a different OCS (exact same model). This feature can be used for: • • 14.2 Replacing an OCS by another unit of the same model. Duplicating or “clone” units without a PC.
CH. 14 MAN0798-04-EN 3. Make/Create Clone option enables user to duplicate / Clone application file, all unit settings and all register values from Battery Backed RAM. Selecting Make Clone brings up the screen below for the user: Figure 14-3 – Clone Unit Confirm Screen After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM CLONE.
MAN0798-04-EN CH. 14 4. Once the cloning is successful, OCS gives a message as below: Figure 14-5 – Cloning Status Make / Create clone can also be triggered by setting %SR164.9 bit to “1” from Ladder program or graphics. Once the operation is completed, this bit is made zero by the firmware. When Make clone operation is triggered by this SR bit, it does not ask the user for confirmation for making clone. The success / failure of the operation is also not notified on screen to the user.
CH. 14 MAN0798-04-EN 2. Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. Figure 14-7 – Clone Unit Menu after Cloning 3. User needs to confirm Load Clone as shown below: Figure 14-8 – Load Clone Confirm Screen 4. After confirmation, all unit settings and register values will be loaded from Removable media to the Battery backed RAM (Regardless of AutoLoad settings) and then OCS resets for the settings to take effect.
MAN0798-04-EN CH. 15 CHAPTER 15: MAINTENANCE 15.1 Firmware Updates The QX products contain field updatable firmware to allow new features to be added to the product at a later time. Firmware updates should only be performed when a new feature or correction is required. Warning: Firmware updates are only performed when the equipment being controlled by the QX is in a safe, non-operational state.
CH. 15 MAN0798-04-EN If the optional controller pop-up status is enabled when the QX detects battery failure, a pop-up status dialog is displayed on the current screen to alert the operator of the Ok status change. The operator can then invoke the system menu diagnostic sub-menu to determine the cause of the loss of Ok status. Alternately, the screen designer can also place a graphic object or audible indicator (through ladder logic) in the application (referenced to OCS register %SR55.
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MAN0798-04-EN CH. 16 CHAPTER 16: TROUBLESHOOTING / TECHNICAL SUPPORT CHAPTER 166 provides commonly requested troubleshooting information and checklists for the following topics. • • • • Connecting to the QX controller Local controller and local I/O CsCAN Network Removable media In the event that this information is not what you need, please contact Technical Support at the locations indicated at the end of this chapter. 16.
CH. 16 MAN0798-04-EN 16.1.1 Connecting Troubleshooting Checklist 1. Programming and debugging must use MJ1. 2. Controller must be powered up. 3. Assure that the correct COM port is selected in Cscape. Tools/Options/Communications Port. 4. Assure that a straight through (non null modem) serial cable is being used between PC and controller. 5. Check that a Loaded Protocol or ladder is not actively using MJ1.
MAN0798-04-EN 16.3 CH. 16 CsCAN Network For complete information on setting up a CsCAN network, refer to CAN Networks manual (MAN0799) by visiting our website (page 92) for the address to obtain documentation and updates. Network status, node ID, errors, and baud rate in the controller system menu are all in reference to the CsCAN network. These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting.
CH. 16 16.4 MAN0798-04-EN Removable Media 15.4.1 Basic Troubleshooting Description Action QX does not read card. The card should be formatted with the QX. QX will not download project file. Make sure the project file is saved as a .pgm file and not a .csp file. 16.5 Technical Support Contacts For manual updates and assistance, contact Technical Support at the following locations: North America: Tel: (+) (317) 916-4274 Fax: (+) (317) 639-4279 Web: www.heapg.com Email: techsppt@heapg.
MAN0798-04-EN INDEX INDEX %AI Registers, 67 %AIG Registers, 68 %AQ Registers, 68 %D Registers, 67 %I Registers, 67 %IG Registers, 68 %K Registers, 67 %M Registers, 67 %Q Registers, 67 %QG Registers, 68 %R Registers, 67 %T Register, 67 Accessories, 15 AutoLoad, 77 AutoRun, 79 Backup / Restore, 72 Battery Backup, 85 Replacement, 86 Warnings, 86 When to Replace, 85 Battery backed RAM, 50, 81 CAN Comm Cscape Programming, 24 I/O Expansion (Network I/O), 24 Ladder-Controlled, 24 Overview, 23 Ports, 23 Wiring, 2
INDEX MAN0798-04-EN Toubleshooting Connecting Checklist, 90 Troubleshooting Common problems, 89 CsCAN Checklist, 91 CsCAN Network, 91 August 20, 2009 Local Controller / I/O, 90 Local I/O Checklist, 90 Removable Media, 92 Visual Overview, 11 Where to Find Information, 12 Page 94 of 95 ECN # 979
MAN0798-04-EN Table of Figures TABLE OF FIGURES Figure 2-1 – Visual Overview of QX, Back Pack, and VIM400 ................................................................... 11 Figure 2-2 – Visual Overview of Types of Devices that can be Connected to QX ..................................... 13 Figure 2-3 – Pass Through Function (Available in CsCAN Networks Only)............................................... 14 Figure 3-1 – QX Front and Back Views ..........................................................
