Renu Electronics FlexiLogics series User Manual
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Renu Electronics FlexiLogics series User Manual

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Atul Deshpande
February 12, 2025

temp not reached at set point it stop before 10 degree with reaspective set point manual PID

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1 comments:
Mr. Anderson
February 12, 2025

The Renu Electronics FlexiLogics series may not reach the set temperature and stop 10 degrees before the set point when using manual PID due to improper tuning of the PID parameters. If the proportional, integral, and derivative gains are not correctly set, the system may not provide enough corrective action to reach the desired temperature. Additionally, external factors such as environmental conditions, incorrect sensor placement, or insufficient heating capacity may also affect the performance. Checking and adjusting the PID settings, ensuring proper wiring and grounding, and verifying environmental conditions may help resolve the issue.

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Summary of Contents for Renu Electronics FlexiLogics series

  • Page 1 User’s Manual FlexiLogics...
  • Page 2 This manual is a publication of Renu Electronics Pvt. Ltd. and is provided for use by its customers only. The contents of the manual are copyrighted by Renu Electronics; reproduction in whole or in part, for use other than in support of Renu Electronics equipment, is prohibited without the specific written permission of Renu Electronics.
  • Page 3 Revision History: Revision Number Document Number Date Description Rev 1.00 UMAN\FL\0110 21-01-2010 First Release Rev 1.01 UMAN\FL\0110 10-09-2010 FlexiLogics features revised Rev 1.02 UMAN\FL\0110 10-09-2010 FlexiLogics manual revised for images & other corrections Rev 1.02A UMAN\FL\0110 12-01-2011 Timings of ON/OFF pulse width is corrected on Pg. 85, 86, 88 &...
  • Page 4 NOTE : Renu Electronics Pvt. Ltd. is dedicated to providing complete customer service and customer satisfaction. If you have any comments or criticisms about how to improve the product features/reliability, please make a note of the problem/improvement and notify us.

  • Page 5: Table Of Contents

    1.1.1 FlexiLogics Basics 1.1.2 Hardware Requirements Features FlexiLogics Overview 1.3.1 What is a FlexiLogics series unit? 1.3.2 How FlexiLogics Works? Specifications of FlexiLogics Series 1.4.1 Comparison between basic models (FL010 & FL011) 1.4.2 Comparison between basic models (FL050 & FL051) 1.4.3...
  • Page 6 Table of Content Input (XW), Output (YW) and configuration (MW) Register allocation SPECIAL INPUT AND OUTPUT Special I/O Function overview High Speed Counter Design 5.2.1 Single Phase Counter 5.2.2 Single Phase speed - counter 5.2.3 Quadrature bi-pulse counter 5.2.4 Interrupt Input Function 5.2.5 Pulse Output Function 5.2.6...

  • Page 7: Introduction

    Introduction INTRODUCTION In this chapter..♦ Purpose of this manual FlexiLogics Basics Hardware Configuration ♦ FlexiLogics Features ♦ FlexiLogics Overview What is FlexiLogics series unit? How FlexiLogics works? FlexiLogics Specifications Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 8: Purpose Of This Manual

    Microsoft® Windows based configuration Software. This Manual explains the operation of the FlexiLogics Series and how to implement available features using the FlexiSoft Software. This manual will help you to install, configure and operate your FlexiLogics product.

  • Page 9: Hardware Requirements

    Introduction 1.1.2 Hardware Requirements The following basic PC hardware configuration is needed to configure and operate your FlexiSoft Configuration Software. Minimal PC configuration for Windows2000 / XP: DEVICE RECOMMENDED Processor 800MHz Pentium processor OR euivalent processor Operating System Microsoft Windows 2000 with SP4 Microsoft Windows XP Professional / Home Edition with SP2 256MB Hard Disk Space...

  • Page 10: Features

    Introduction Features Expansion Models: The following are the digital expansion models: -> 16 points DC input -> 16 points DC output (NPN Type) -> 16 points DC output (PNP Type) -> 16 points DC output (Relay Type) -> 8 DC inputs + 8 DC outputs (NPN type) ->...

  • Page 11: Flexilogics Overview

    The FlexiLogics family is designed to offer practical PLC features in a compact and expandable design, and at the same time offer a simple-to-use philosophy. An external powered FlexiLogics series base models by itself can be used as a complete PLC system with optional built-in I/O points, or the system can be expanded with the addition of up to eight I/O modules.
  • Page 12 Introduction Application Examples1: FlexiLogics PLC base unit As shown above, FlexiLogics base unit can be connected to another PLC as well as to HMI. Thus can be worked with two different protocols at a time. Application Examples2: SCADA FlexiLogics PLC base unit As shown above, FlexiLogics base unit can be connected to SCADA as well as HMI.

  • Page 13: How Flexilogics Works

    Introduction 1.3.2 How FlexiLogics Works? The FlexiLogics follows a specific sequence and the sequence is as shown below: START Initialize Watchdog Check for Initialize serial and Valid USB ports Firmware Wait till Firmware Download. Flash Error and RUN led at 1 sec interval Soft restart Check for Initialize serial and...
  • Page 14 Introduction CPU Watch- dog reset Soft restart Check for type of restart Power On Reset Clear All PLC registers Clear All PLC registers expansion module except keep memory, information and event history Restore Keep memory data, Event History Initialize USB Set internal configuration according application.
  • Page 15 Introduction Main Loop Start Start counting Main Loop Scan Time Error Down Self Diagnosis ERROR MODE STOP Position Read RUN/STOP HALT MODE Switch RUN Position Update PLC mode from software Hold Mode Halt Mode Mode HOLD HALT MODE check RUN Mode or Switch position change from Stop to RUN If power On System bit is ‘1’...
  • Page 16 Introduction Update local, expansion. Scan Local and expansion inputs Execute Global Tasks Feed the CPU watch-dog Start counting ladder scan time Execute main Ladder Stop counting ladder scan time Execute First Scan operations (1. Initialize special inputs and outputs. 2. Load Digital filter constant.) Update High speed counter registers...
  • Page 17 Introduction HALT MODE Feed Watch-dog Turn OFF all Outputs and RUN Led Respond to the monitor query (if any) on USB. Stop counting main loop scan time Set Power On system bit to ‘1’ Main Loop Start ERROR MODE Feed Watch-dog Set the state of output as per ‘ERROR STATE OUTPUT CONDITION’...
  • Page 18 Introduction HOLD MODE Read Local and Expansion Inputs Update Local, Expansion and PWM outputs Respond to the monitor query (if any) on USB. Stop counting main loop scan time Main Loop Start Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 19 Introduction Power-Up Self Diagnosis IO Mismatch 2. CPU Watchdog reset Log event in Event History Set Error down mode flag Return RTC error 2. Retentive data loss Log event in Event History Return Return Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 20 Introduction Self Diagnosis IO BCC error Log event in Event History Set Error down mode flag Return 1. User watchdog error 2. Scan time over error Log event in Event History Return Return Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 21: Specifications Of Flexilogics Series

    Introduction Specifications of FlexiLogics Series The FlexiLogics series models possess powerful programmable logic features. User can implement logic, specific to application using standard Ladder programming. FlexiLogics models need +24VDC power from an external supply. Models included in the FlexiLogics Series are as follows:...

  • Page 22: Comparison Between Basic Models (Fl010 & Fl011)

    Introduction 1.4.1 Comparison between basic models (FL010 & FL011) Functional Specific. FL010 FL011 Case FlexiLogics Case Open PCB with DIN rail Mounting Ladder Program 8K Steps 8K Steps Memeory Expansion I/O capacity Maximum 8 expansion None modules Expansion Bus SPI (1MHz) SPI (1MHz) Local I/Os 16 ( 8 IN / 8 OUT).

  • Page 23: Comparison Between Basic Models (Fl050 & Fl051)

    Introduction 1.4.2 Comparison between basic models (FL050 & FL051) Functional Specific. FL050 FL051 Case FlexiLogics Case Open PCB with DIN rail Mounting Ladder Program 8K Steps 8K Steps Memeory Expansion I/O capacity Maximum 8 expansion None modules Expansion Bus SPI (1MHz) SPI (1MHz) Local I/Os 32 ( 16 IN / 16 OUT )

  • Page 24: Specification For Basic Models

    Introduction 1.4.3 Specification for Basic Models FL010 Power Supply 24VDC, 330mA Input per channel 24 VDC, 5mA & 20mA (for CH0 & CH1) Output per channel 230V / 2A or 24VDC / 2A for Relay, 0.5A at 24VDC for transistor Approvals CE, UL Memory...
  • Page 25 Introduction Wiring Diagram for Digital I/Ps and O/Ps of model FL010: 1. Wiring diagram for testing digital inputs: Note: X0 and X1 are high speed input 24VDC Closing Swx will turn on respective inputs Wiring for transistor type outputs: Transistor type O/P LOAD Internal...
  • Page 26 Introduction Wiring for output connections: *L1 to L6 are A.C. Load. Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 27: Fl011

    Introduction FL011 Power Supply 24VDC, 330mA Input per channel 24 VDC, 5mA & 20mA for High Speed inputs (CH1 & CH2) Output per channel 24VDC; 0.5A Approvals CE, UL Memory Total Program Memory 8K Steps User Data Input Registers 400 Words / 6400 pts. (Max.*) Outout Registers 400 Words / 6400 pts.

  • Page 28: Fl050

    Introduction FL050 Power Supply 24VDC, 150mA Input per channel Output per channel Standards CE, UL Memory Total Program Memory 8K Steps User Data Input Registers 400 Words / 6400 pts. (Max.*) Outout Registers 400 Words / 6400 pts. (Max.*) Data Registers 4096 words Retentive Registers 1400 words (EEPROM)

  • Page 29: Fl051

    Introduction FL051 Power Supply 24VDC, 150mA Input per channel 24 VDC, 5mA & 20mA for high speed inputs (CH1 & CH2) Output per channel 24VDC; 0.5A Standards CE, UL Memory Total Program Memory 8K Steps User Data Input Registers 400 Words / 6400 pts. (Max.*) Outout Registers 400 Words / 6400 pts.

  • Page 30: Specification For Expansion Models

    Introduction 1.4.4 Specification for Expansion Models FLD1600 Digital Inputs 16 Normal Inputs, 8 points per Power Rating (Back Plane) common. Bidirectional type. Voltage Rating 3.75 VDC derived from Input per channel 5mA, 24VDC base model Output per channel Current Rating Upto 80mA Input Impedance 5.4K ohm...

  • Page 31: Fld0016P (Pnp Type Transistor Output)

    Introduction FLD0016P (PNP Type transistor output) Power Supply 24VDC, 300mA Digital Inputs Input per channel Digital outputs 16 PNP type Transistor output. 4 Output per channel 0.5A, 24VDC per output points per common Rated load 500mA max for PNP and NPN type transistor output Power Rating (Back Plane) General...

  • Page 32: Fld0016N (Npn Type Transistor Output)

    Introduction FLD0016N (NPN Type transistor output) Power Supply 24VDC, 300mA Digital Inputs Input per channel Digital outputs 16 NPN type Transistor output. 4 points per common Output per channel 0.5A, 24VDC per output Rated load 500mA max for PNP and NPN type transistor output Power Rating (Back Plane) General...

  • Page 33: Fld0016R (Relay Type Output)

    Introduction FLD0016R (Relay Type output) Power Supply 24VDC, 300mA Digital Inputs Input per channel Digital outputs 16 Relay (Form A) output. 4 points per common Output per channel 230V, 2A / 30 VDC, 2A per output Rated load 230V / 2A, 30VDC / 2A Power Rating (Back Plane) General Voltage Rating...

  • Page 34: Fld0808R (Relay Type Transistor Output)

    Introduction FLD0808R (Relay Type transistor output) FLD0808P (PNP Type transistor output) FLD0808N (NPN Type transistor output) Digital Inputs 8 Normal inputs 4 points per common. Power Rating (Back Plane) Bidirectional type. Voltage Rating 3.75 VDC derived from Digital outputs 8 Relay (Form A) outputs. 4 points per base model common.
  • Page 35 Introduction Wiring Diagram for FLD0808R: 1. Wiring diagram for testing digital inputs: 24VDC Closing Swx will turn on respective inputs 2. Wiring diagram for output connections: *L1 to L8 are A.C. Load. Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 36 Introduction Wiring Diagram for FLD0808P: 1. Wiring diagram for testing digital inputs: 24VDC Closing Swx will turn on respective inputs 2. Wiring diagram for output connections: Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 37 Introduction Wiring Diagram for FLD0808N: 1. Wiring diagram for testing digital inputs: 24VDC Closing Swx will turn on respective inputs 2. Wiring diagram for output connections: Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 38: Fla0800L

    Introduction FLA0800L Power Rating (Back Plane) Analog Inputs 8 input channels Voltage Input 0 - 10 V Digital Side: Power derived from expansion slot connector Current Input 4- 20 mA Voltage Rating 3.75 VDC derived from Analog Outputs base model Isolation Isolation between analog and Current Rating...
  • Page 39 Introduction Wiring Diagram of input connection for FLA0800L: 1. Voltage Mode connections:: AIN1 AGND AIN2 AGND AIN3 AGND AIN4 AGND AIN5 AGND AIN6 AGND AIN7 AGND AIN8 AGND 2. Current mode connections: 4 to 20 mA 4 to 20 mA AIN1 AGND AIN2...

  • Page 40: Fla0800R

    Introduction FLA0800R Analog Inputs 8 input channels Power Rating (Back Plane) RTD PT100 Digital Side: Power derived from expansion slot connector Analog Outputs Voltage Rating 3.75 VDC derived from Isolation Isolation between analog base model and digital section. No Current Rating Upto 80mA interchannel isolation.
  • Page 41 Introduction Wiring Diagram of input connection for FLA0800R: PT1000 Input Channel 0 AIN1 Input Channel 1 AIN2 AIN1 AGND AIN2 AGND Input Channel 2 AIN3 AIN3 AIN4 AGND Input Channel 3 AIN4 AIN5 AGND AIN6 AGND AIN7 Input Channel 4 AIN5 AIN8 AGND...

  • Page 42: Fla0004

    Introduction FLA0004 Analog Inputs Power Rating (Back Plane) Analog Outputs 4 Output channels Digital Side: Power derived from expansion slot Voltage 0 - 10 V (Min Load 1000 ohm) Voltage Rating 3.75 VDC derived from Current 4 - 20 mA(Max load 500 ohm) base model Isolation Isolation between analog and digital...
  • Page 43 Introduction Wiring Diagram of input connection for FLA0004: 1. Current Output Connection Diagram: Iout AGND AGND AGND Iout AGND AGND AGND Iout AGND Iout AGND 2. Voltage Output Connection Diagram: Vout AGND AGND AGND Vout AGND AGND AGND Vout AGND Vout AGND Doc No: UMAN\FL\0110...

  • Page 44: Fla0402U

    Introduction FLA0402U Power Rating (Back Plane) Analog Inputs 4 Universal Input Channels Voltage Input 0 - 10 V Digital Side: Power derived from expansion slot Current Input 0-20mA, 4-20mA Voltage Rating 3.75 VDC derived from RTD PT100 (alpha1, alpha2) base model Thermocouple(TYPE B,R,S,E,J,K,N,T.) Current Rating...
  • Page 45 Introduction Wiring Diagram of input connection for FLA0402U: 1. Current Input Connection Diagram: CS11 IN1+ AGND CS11 CS21 IN1+ AGND Improper Connection for current: IN2+ CS21 AGND IN2+ AGND AGND CS31 CS31 CURRENT IN3+ AGND IN3+ CS41 AGND IN4+ AGND CS41 IN4+ AGND...
  • Page 46 Introduction 3. RTD Input Connection Diagram: 3 WIRE RTD CS11 IN1+ AGND CS11 CS21 IN1+ AGND IN2+ CS21 AGND IN2+ AGND CS31 CS31 IN3+ AGND IN3+ CS41 AGND IN4+ AGND CS41 IN4+ AGND AGND 4. Thermocouple Input Connection Diagram: CS11 IN1+ AGND CS11...
  • Page 47 Introduction Wiring Diagram of output connection for FLA0402U: 1. Current Output Connection Diagram: CS11 IN1+ AGND CS21 IN2+ AGND CS31 IN3+ AGND CS41 IN4+ AGND Iout AGND AGND R < 500 Ω 2. Voltage Output Connection Diagram: CS11 IN1+ AGND CS21 IN2+ AGND...

  • Page 48: Hardware

    Hardware HARDWARE In this chapter..♦ Unpacking the unit ♦ Managing Electrostatic Discharge ♦ CE Compliance ♦ Environmental rating ♦ Environmental Consideration ♦ Safety Precautions ♦ Installation Instructions ♦ Wiring Diagram ♦ Communication Port ♦ Communication Cables Doc No: UMAN\FL\0110 Rev.

  • Page 49: Unpacking The Unit

    Check that the container includes the Mounting DIN rail slider, locking connector, and a silica gel bag. The silica gel bag is enclosed to absorb the moisture in the packing. Renu Electronics will not accept responsibility for shortages against the packing list unless notified within 30 days. The unit and its accessories were inspected and tested by Renu Electronics before shipment.

  • Page 50: Safety Precaution

    Hardware Safety Precaution General Information: 1. FlexiLogics has been designed and manufactured for use in an industrial environment. However, the FlexiLogics is not intended to be used for systems which may endanger human life. Consult REPL if you intend to use the FlexiLogics for a special application, such as transportation machines, medical apparatus, aviation and space systems, nuclear controls, submarine systems, etc.
  • Page 51 Hardware Wiring: CAUTION Turn off power before wiring to minimize the risk of electrical shock. Exposed conductive parts of wire can cause electrical shock. Use crimp-style terminals with insulating sheath or insulating tape to cover the conductive parts. Also close the terminal covers securely on the terminal blocks when wiring has been completed.

  • Page 52: Installation Instructions

    Hardware Installation Instructions The FlexiLogics should be mounted on a din rail plate. A din rail sliders and locking connectors are provided with each FlexiLogics unit for proper installation. Environmental Considerations: Make sure that the unit is installed correctly and that the operating limits are followed (see Specifications for FlexiLogics).
  • Page 53 Hardware FlexiLogics unit with DIN rail slider Front View Rear View Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 54 Hardware Steps to mount the unit on DIN rail plate FIG-1 FIG-2 FIG-3 FIG-1 Pull up the sliders provided with the FlexiLogics towards outward direction. FIG-2 Rest the unit on the DIN rail plate FIG-3 Pull down the slider again so that unit can fix up with the DIN rail plate Doc No: UMAN\FL\0110 Rev.
  • Page 55 Hardware Steps to lock the expansion module with the FlexiLogics base FIG-1 FIG-2 FIG-3 FIG-1 Lock connector provided with FlexiLogics unit FIG-2 Two slots to grip the locking connector are provided on the case highlighted by RED circle. Insert a big leg of locking connector highlighted by RED rectangle.

  • Page 56: Wiring Diagram

    Hardware Wiring Diagram If wiring is to be exposed to lightening or surges, use appropriate surge suppression devices. Keep AC, high energy and rapidly switching DC wiring separate from signal wires. Connecting high voltages or AC power mains to the DC input will make unit unusable and may create an electrical shock hazard to personnel.
  • Page 57 Hardware 2. COM2 Port Details: BATTERY USB Device: 1. USB Device, compliant with USB 2.0 specification, self powered device. 2. Connector used: Standard USB Type B Female connector. Ethernet: 1. Fully compliant with IEEE 802.3 / 802.3u standards. 2. 10/100 Mbps support. 3.

  • Page 58: Communication Cables

    Hardware 2.10 Communication Cables Programming cable for FlexiLogics units (IBM-H-005-00): FlexiLogics SIDE PC SIDE 2 mtr. R.H.S. VIEW FRONT VIEW Pin 1 Pin 8 (Left side) (Right side) DB9 FEMALE PINOUTS 8 PIN MODULAR CONNECTOR PINOUTS Signals Pin# Pin# Signals SG &...
  • Page 59 Hardware FlexiLogics TO Toshiba T1 PLC (RC-P-019A-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS 8 Pin MINIDIN MALE PIN-OUTS (Unit End) (PLC End) 5 (Connect to shield ) short pin 4 & 7 at PLC end FlexiLogics TO Toshiba T2 PLC (RC-P-019B-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS DB9 MALE PIN-OUTS...
  • Page 60 Hardware FlexiLogics TO Mitsubishi FX PLC (RC-P-008A-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS 8 Pin MINIDIN MALE PIN-OUTS (Unit End) (PLC End) SG & SHIELD FlexiLogics TO Aromat FP0 Series PLC (RC-P-015A-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS 5 PIN MINIDIN MALE (Unit End) PIN-OUTS (PLC End) SG &...
  • Page 61 Hardware FlexiLogics to Microsmart PLC (RC-P-025B-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS 8 PIN MINIDIN MALE (Unit End) PIN-OUTS (PLC End) 6 & 7 (shield connect to only PLC end) FlexiLogics TO TSX17 PLC (RC-P-017-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS DB15 MALE PIN-OUTS (Unit End) (PLC End) 4 &...
  • Page 62 Hardware FlexiLogics TO OMRON CQM(RC-P-006B-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS DB9 MALE PIN-OUTS (Unit End) (PLC End) SHIELD Shield wire to DB9 pin no.1 only for PLC end FlexiLogics TO Siemens Step-7 Micro PLC(RC-P-029-00) 8P8C(RJ45) MALE PIN-OUTS PIN SIGNALS DB9 MALE PIN-OUTS (Unit End) (PLC End) 4 &...

  • Page 63: Before You Begin

    Before you begin BEFORE YOU BEGIN In this chapter..♦ Installing FlexiSoft ♦ Starting FlexiSoft Configuration Software ♦ Launching Ladder Text Editor ♦ Creating Sample Ladder Application Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 64: Installing Flexisoft Configuration Software

    Before you begin Installing FlexiSoft configuration software: To install FlexiSoft configuration Software: 1. Open Microsoft® Windows. 2. Select Run and Pop up window appears. Type the path for installing the Setup. This will install FlexiSoft Configuration Setup Software. 3. When you click on OK, Welcome window appears on the screen. Click on Next. Select the destination folder where setup will install the files.
  • Page 65 Before you begin 5. Click on “NEXT”, installation starts. A dialog box indicating the status of progress of installation will display. Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 66 Before you begin A screen is displayed to inform you when installation is completed. This procedure installs FlexiSoft Software in start menu (in selected folder). Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 67: Steps For Starting Flexisoft Software

    Before you begin Steps for starting FlexiSoft Software 1. Click the Start button in Windows OS. 2. Select Programs. 3. Select “FlexiSoft”. 4. Select FlexiSoft setup exe. 5. Select New Application either from Tool station or from File Menu. 6. Select the model and product type that you would like to set by clicking on picture of the product in the list.

  • Page 68: Procedure To Launch Ladder In Flexisoft

    Before you begin Procedure to launch ladder in FlexiSoft Launch FlexiSoft setup software on your PC. Below shown welcome screen will display. To launch a ladder application either choose Project -> New option or click on New application icon. Choose FlexiLogics unit and define “Project Configuration” window with the information required. Click “OK”.
  • Page 69 Before you begin A ladder Text Editor appears as shown below: Now here you can create your ladder Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 70: Creating Sample Ladder

    Before you begin Creating sample ladder After launching Ladder Text Editor, you can create a ladder here. Steps are shown below: Step-1: Here in the example, “NO” instruction is taken. Define its address and name from the “Instruction Properties” window seen to the left side of the application window.
  • Page 71 Before you begin Complete the rail using “Horizontal Link” command, then put “Output” command. User can also directly put “Output” link to the last right side point of the rail. This will complete the command. as shown below: For output command also, define tag address and name from the “Instruction Properties” window seen to the right side of the application window.
  • Page 72 Before you begin Note: Do not forget to put “END” command whenever ladder application is over. After completing ladder, Compile it as shown below: Following screen will appears if compilation is successful. Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 73: Configuration

    Configuration CONFIGURATION In this chapter..♦ Configuring unit using FlexiSoft ♦ Tag Database ♦ Memory Allocation of Registers Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 74: Configuring Unit Using Flexisoft

    Configuration Configuring unit using FlexiSoft Before creating any application or connecting FlexiLogics base unit to any system, user have to configure the unit unsing FlexiSoft. 1. Connect the unit to the PC. 2. Power-On the unit. 3. Launch FlexiSoft software. “Welcome” screen will seen. Press “New” from the application window or Project ->...
  • Page 75 Configuration 5. Press “OK”. “Project Configuration” window will pop-up as shown below: Doc No: UMAN\FL\0110 Rev. No.: 1.02B...
  • Page 76 Configuration In this dialoge box section: Point 1: You can define project name or can keep “Untitle” as default. Point 2: You can define path for the project to be saved. Point 3: You can mention any special note; if required. Point 4: You can define author name.

  • Page 77: Tag Database

    Configuration Tag Database This is the central database for the tags that need to be used in the application. Once the tags are defined (as register or coils) and their attributes selected, the tags can be used in the application, tasks, etc. This screen helps you to define Tags associated with defined Nodes.
  • Page 78 Configuration Default System Tags Note: Please do not attempt to modify read only system tags in the ladder. This could affect the functionality of the product. System Registers / Coils: Register / Coil Tag Name Read / Write Description SW0003_14 COM1 Status Read Only 0 = Communication Error;...
  • Page 79 Configuration SW046 Ladder Scan Time Read only Value is multiple of 0.1 mSec S0034 Ladder Instruction Error Read/Write Set if Division by zero operation is performed in Status the ladder instruction and for invalid conditions or operands in case of conversion instructions. Configuration Words and coils Register / Coil Tag Name...
  • Page 80 Configuration M00021 Clock/calendar illegal Read Only ON when clock/calendar data is illegal value warning M00022 Retentive data invalid warning Read Only ON when retentive data in RAM are invalid M00027 Watchdog timer error Read Only ON at error state M00029 I/O mismatch error Read Only ON at error state...

  • Page 81: Input (Xw), Output (Yw) And Configuration (Mw) Register Allocation

    Configuration Input (XW), Output (YW) and configuration (MW) Register allocation For Digital Expansion Models: The Physical Inputs and Outputs in the Expansion modules are accessed using XW and YW registers respectively. The digital inputs in the Digital Expansion Models are updated in the (Input) XW registers. The expansion model may have XW or YW registers depending on availability of the physical input/outputs for that model type.
  • Page 82 Configuration FLA0402U: Sr. No. Description Register Type Input Channel 1 Data XWxx00 Input Channel 2 Data XWxx01 Input Channel 3 Data XWxx02 Input Channel 4 Data XWxx03 Output Channel 1 Data YWxx00 Output Channel 2 Data YWxx01 Input Channel 1 Type Select MWxx06 Input Channel 2 Type Select MWxx10...
  • Page 83 Configuration Channel Type Selection Values Table: Use the following values in the Input and output channel type select register to configure the corresponding channel to particular type. e.g. If you want to configure the Input channel 3 of FLA0800L model as ( 0 – 10 V ) type, then move value 19 in MWxx16 configuration register.

  • Page 84: Special Input And Output

    Special Input and Output SPECIAL INPUT AND OUTPUT In this chapter..♦ Special I/O Function Overview ♦ Single Phase Counter ♦ Single Phase speed-counter ♦ Quadrature bi-pulse counter ♦ Interrupt input function ♦ Pulse Output Function ♦ PWM Output Function Doc No: UMAN\FL\0110 Rev.

  • Page 85: Special I/O Function Overview

    Special Input and Output Special I/O Function overview The FlexiLogics PLCs support the special I/O functions as listed below: Function name Function summary Remarks Variable input filter constant Input filter constant (ON/OFF delay time) can be set by MW10 setting is user program.

  • Page 86: High Speed Counter Design

    Special Input and Output High Speed Counter Design Configuration Registers for Special Function Inputs and PWM outputs: Register Description Register Number Configuration Register for Special inputs MW10 Configuration Register for PWM output MW11 Single Phase Counter Set Value Channel 1 MW12, MW13 Channel 2 MW14, MW15...
  • Page 87 Special Input and Output PWM Output Function Pulse Enable Flag (Device) M336 Frequency Setting Register MW22, MW23 ON duty setting register MW24, MW25 pulse width error flag M189 On duty setting error flag M190 Frequency Setting Error Flag (Device) M191 The Mode selection is done through two registers as below.
  • Page 88 Special Input and Output Configuration Register 11 (Pulse / PWM Output): MW0011 Bit 0 < P-OUT and PWM master flag > 0: No use P-OUT / PWM operation error flag 1: Use (These are not user setting items) Bit D < PWM pulse width error > 0: Normal Bit 1 <...

  • Page 89: Single Phase Counter

    Special Input and Output 5.2.1 Single Phase Counter When the count input is changed from OFF to ON, the count value is increased by 1. When the count value reaches the set value, the count value is reset to 0, and I/O interrupt program is activated (if the interrupt enable flag is ON). The count value is reset to 0 when the reset input comes ON.

  • Page 90: Single Phase Speed - Counter

    Special Input and Output 5.2.2 Single Phase speed - counter This function counts the number of changes of the count input from OFF to ON during the every specified sampling time. The count value in a sampling time is stored in the hold value register. This counter operation is enabled while the soft-gate is ON.

  • Page 91: Quadrature Bi-Pulse Counter

    Special Input and Output 5.2.3 Quadrature bi-pulse counter This function counts up or down the quadrature bi-pulse (2-phase pulses whose phases are shifted 90° each other). Counts up when phase A precedes, and counts down when phase B precedes. 1-edge count: The current value increments or decrements at the rising or falling edge of the phase B input after the phase A input has turned on.
  • Page 92 Special Input and Output The function selection is done through configuration register1 Function Register/device Remarks Phase A IP 1 (X000) Phase B IP 2 (X001) Reset input IP 3 (X002) Comparison value 1 MW12 MW13 Data range: 0 to 4294967295 Comparison value 2 MW14 MW15 Count value MW16 MW17...

  • Page 93: Interrupt Input Function

    Special Input and Output 5.2.4 Interrupt Input Function When the signal state of the interrupt input is changed from OFF to ON (or ON to OFF), the corresponding I/O interrupt program is activated immediately. Up to 2 interrupt inputs can be used. The interrupt generation condition can be selected either rising edge (OFF to ON) or falling edge (ON to OFF) for each input.

  • Page 94: Pwm Output Function

    Special Input and Output 5.2.6 PWM Output Function This function is used to output a variable duty cycle pulse train. The controllable duty cycle is 0 to 100 % (1 % units). The PWM output is enabled when the pulse enable flag is ON. While the pulse enable flag is ON, the duty cycle (ON duty) can be changed by changing the duty setting value (0 to 100).

  • Page 95: Operating Systems Overview

    Operating System Overview OPERATING SYSTEMS OVERVIEW In this chapter..♦ Operating Modes Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 96: Operating System Overview

    Operating System Overview Operating System Overview The FlexiLogics base models has three basic operation modes, the RUN mode, the HALT mode and the ERROR mode. It also has the HOLD and RUN-F modes mainly for system checking. RUN: The RUN mode is a normal control-operation mode. In this mode, the FlexiLogics base model reads input signals, executes the user pro- gram, and updates the output devices according to the user program.

  • Page 97: Programming Information

    Programming Information PROGRAMMING INFORMATION In this chapter..♦ Devices and registers ♦ Memory allocation of XW, YW and MW ♦ Index modifications ♦ Real-time clock/calendar ♦ User Program ♦ Pragramming Language ♦ Program execution Sequence Doc No: UMAN\FL\0110 Rev.

  • Page 98: Devices Registers

    Programming Information Devices Registers Broadly two types of registers are present in PLC register database: 1. Internal PLC Registers: Implemented through buffers present in RAM of Base module. Data Registers (D). Auxillary Registers (BW/B). System Registers (SW). System coil (S). Timer Registers (T).
  • Page 99 Programming Information You can allot “ss” (slot number) from “Project Information” docker window; “IO Allocation\Local” section as shown below: Double click on each slot to assign model name When you double click on the highlighted slot section; below shown window will appear: Note: Here you have to allot slots seriallly only and if you tried to allott randomly;...
  • Page 100 Programming Information Thus, you can assign the expansion models as per your requirement as follows: In the above shown screen, you can observe that the address range for the expansion models assign for Slot 1 through Slot 4, it has taken first two digit as 01, 02, 03 & 04 serially. And last three digits will indiacate the register numbers.
  • Page 101 Programming Information System Register for Special Function Inputs and PWM outputs: Register Description Register Number Configuration Register for Special inputs MW10 Configuration Register for PWM output MW11 Single Phase Counter Set Value Channel 1 MW12, MW13 Channel 2 MW14, MW15 Count Value Channel 1 MW16, MW17...
  • Page 102 Programming Information Register Description Register Number Single Phase Speed Counter Sampling Time Channel 1 MW12 Channel 2 MW14 Hold Value Channel 1 MW16, MW17 Channel 2 MW18, MW19 Soft Gate (Device) Channel 1 M 320 Channel 2 M 328 Quadrature Bi Pulse Comparision Value1 MW12, MW13 Comparision Value2...
  • Page 103 Programming Information "Device/“register" Name Function M0016 CPU error (down) ON at error state M0017 I/O error ON at error state M0018 Program error (down) ON at error state M0019 Not Used M0020 Not Used M0021 "Clock/calendar error“(alarm)" ON when clock/calendar data is illegal M0022 "Retentive data invalid“(alarm)"...
  • Page 104 Programming Information When COM ports are configured as Modbus slaves, the internal PLC tags are mapped to the modbus addresses as given in the following table: PLC Tag description Reg. Addressing Bit Addressing Modbus address I/O register XW(400) X (6400) 440001 - 440400 YW(400) Y (6400)

  • Page 105: Memory Allocation Of Xw, Yw And Mw

    Programming Information Memory Allocation of XW, YW and MW Memory for XW, YW and MW registers for particular model is allocated by software at the time of I/O allocation. The number of XW, YW and MW for the particular model is as per the table given below: Sr.
  • Page 106 Programming Information Then the array of XW, YW and MW will be as follows: Allocated for register Modbus Slave register address FL010 (XW0000) 440001 FLD0808R (XW0100) 440002 FLD0808N (XW0300) 440003 FLD1600 (XW0400) 440004 FLD1600 (XW0401) 440005 FLA0800L (XW0500) 440006 FLA0800L (XW0501) 440007 FLA0800L (XW0502) 440008...

  • Page 107: Index Modification

    Programming Information Index Modification When registers are used as operands of instructions, the method of directly designating the register address as shown in Example 1) below is called ‘direct addressing’. As opposed to this, the method of indirectly designating the register by combination with the contents of the index register (I, J, or K) as shown in Example 2) below is called ‘indirect addressing’.
  • Page 108 Programming Information (substitutes 64 in index register I) (substitutes the data of D0035 in index register J) (substitutes the result of addition in index register K) Note: (1) The index modification is available for RW, T, C and D registers. (2) If index registers are used as a double-length register, only the combinations J×I and K×J are allowed.

  • Page 109: Real-Time Clock / Calendar

    Programming Information Real-time clock / calendar The FlexiLogics base unit is equipped with the real-time clock/calendar for day of the month, month, year, hour, minute, second and day of week. This data is stored in the special registers SW10 to SW16 by unsigned integer format as follows: D0050 Day of month...

  • Page 110: User Program

    Programming Information User program The user program is stored by each program types as shown in the following diagram and is managed by units called blocks in each program types. User program configuration Program type internal configuration (Program types) (Blocks) Block 1 Main program Sub-program #1...

  • Page 111: Sub-Program

    Programming Information 7.5.2 Sub-program # 1 If the sub-program #1 is programmed, it is executed once at the beginning of the first scan (before main program execution). Therefore, the sub-program #1 can be used to set the initial value into the registers. The sub-program #1 is called the initial program.

  • Page 112: Subroutines

    Programming Information 7.5.5 Subroutines In the program type ‘Subroutine’ total 256 numbers of subroutines can be programmed. The subroutine is not an independent program. It is called from other program types (main program, sub-program, interrupt program) and from other subroutines. One subroutine is started with the CALL instruction, and ended by the RET instruction.

  • Page 113: Programming Language

    Programming Information Programming Language The programming language of the FlexiLogics unit is ‘ladder diagram’. Ladder diagram is a language which com- poses program using relay symbols as a base in an image similar to a hard-wired relay sequence. In the FlexiLogics unit, in order to achieve an efficient data-processing program, ladder diagram which are combinations of relay symbols and function blocks are used.

  • Page 114: Program Execution Sequence

    Programming Information Program execution sequence The instructions execution sequence is shown below. (1) They are executed in the sequence from block 1 through the final block which contains the END instruction (or IRET in an interrupt program). (2) They are executed in the sequence from rung 1 through the final rung in a block (or the END instruction). (3) They are executed according to the following rules in any one rung.

  • Page 115: Troubleshooting

    Troubleshooting TROUBLESHOOTING In this chapter..♦ Troubleshooting Procedure ♦ Self Diagnostic Item Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 116: Troubleshooting Procedure

    Troubleshooting Troubleshooting Procedure 1. Pay special attention during the troubleshooting to minimize the risk of electrical shock. CAUTION 2. Turn off power immediately if the FlexiLogics unit or related equipment is emitting smoke or odor. Operation under such situation can cause fire or electrical shock. 3.

  • Page 117: Power Supply Check

    Troubleshooting 8.1.1 Power Supply Check If the PWR (power) LED is not lit after power on, check the following points. Check the power connection Connection terminals are correct. The terminal screws are not loose. The terminal block is installed securely. Correct Check the power voltage 24 VDC;...

  • Page 118: Input Check

    Troubleshooting 8.1.4 Input Check If the program is running but the external input signal is not read normally, check the following points: Is the input status LED If not, check the input voltage at the changed ON/OFF according FlexiLogics’s input terminals. to the corresponding input If the voltage is not normal, check the input device operation ?

  • Page 119: Output Check

    Troubleshooting 8.1.5 Output Check If the output status monitored on the programming tool is normal but the external output device (load) is not operated normally, check the following points: Is the output status LED changed ON/OFF according to the program execution ? Check the voltage between the output terminal and its common terminal.

  • Page 120: Environmental Problem

    Troubleshooting 8.1.6 Environmental Problem If the following improper operations occur in the controlled system, check possible environmental factors. If an improper operation occurs synchronously with the operation of I/O devices: The noise generated at ON/OFF of the output device (load) may be the cause of the problem. Take necessary measures mentioned in section Precaution.

  • Page 121: Self Diagnosis

    Troubleshooting Self Diagnosis ERROR Mode :- The ERROR mode is a shut-down mode as a result of self-diagnosis. The PLC enters the ERROR mode if internal trouble is detected by self-diagnosis. In this mode, program execution is stopped and all outputs are switched off. The cause of the Error-down can be confirmed by connecting to FlexiSoft software.
  • Page 122 Troubleshooting The errors in the PLC can be categorized as below: CPU error: a. System watchdog Reset (WDT Error) If there is error in this category the CPU error flag ( MW01_0 device) sets along with corresponding device of the error. So for WDT error MW01_11 device sets. I/O Error: a.
  • Page 123 Troubleshooting No. Event Info1 Info 2 Info 3 Info 4 Special Meaning and Check at Device countermeasures Scan Scan MW01_2 The scan time has exceeded 200 Each main loop time over time MW02_1 mS (Default). (Alarm)Correct the scan program to reduce the scan time or use WDT instruction to extend the check time.
  • Page 124 Troubleshooting Device/register Name Function MW01_0 CPU error (down) ON at error state MW01_1 I/O error ON at error state MW01_2 Program error ON at error state MW01_5 Clock/calendar error(alarm) ON when clock/calendar data is illegal MW01_6 Retentive data loss/invalid(alarm) ON when retentive data in RAM are invalid MW01_11 System Watchdog error (down) ON at error state MW01_13...
  • Page 125 Troubleshooting Register / Coil Tag Name Read / Write Description S0022 COM2 failed node Read/write If this bit is set communication with the failed reconnect control nodes is detected after scan time SW0019 for port2.By default : ON S0023 COM3 failed node Read/write If this bit is set communication with the failed reconnect control...

  • Page 126: Maintenance And Checks

    Maintenance MAINTENANCE AND CHECKS In this chapter..♦ Precautions during operation ♦ Daily Checks ♦ Periodic checks ♦ Maintenanace Parts Doc No: UMAN\FL\0110 Rev. No.: 1.02B...

  • Page 127: Precautions During Operation

    Maintenance Precautions during operation When the FlexiLogics units are in operation, you should pay attention to the following points: (1) The programming cable can be plugged or unplugged while the FlexiLogics units are in operation. When you try to do it, do not touch the connector pins. This may cause malfunction of the FlexiLogics units owing to static electricity.

  • Page 128: Daily Checks

    Maintenance Daily Checks 1. Pay special attention during the maintenance work to minimize the risk of electrical CAUTION shock. 2. Turn off power immediately if the FlexiLogics unit or related equipment is emitting smoke or burning. Operation under such situation can cause fire or electrical shock. To maintain the system and to prevent troubles, check the following items on daily basis.

  • Page 129: Periodic Checks

    Maintenance Periodic Checks 1. Pay special attention during the maintenance work to minimize the risk of electrical CAUTION shock. 2. Turn off power immediately if the FlexiLogics unit or related equipment is emitting smoke or odor. Operation under such situation can cause fire or electrical shock. Check the FlexiLogics units are based on the following items every six months.

  • Page 130: Spare Parts

    Maintenance Item Check Criteria Programming tool Check that the functions of the Monitoring and other operations programming tool are normal. are available. Check that the connector and cable Not damaged are not damaged. User program Check that the T1/T1S program No compare error and the master program (saved on a floppy disk, etc.) are the same.

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