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OEM BL2500 User Manual

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Z-WORLD SINGLE BOARD COMPUTER
BL2500
PLC
EMBEDDED
USER'S MANUAL

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Summary of Contents for OEM BL2500

  • Page 1 Z-WORLD SINGLE BOARD COMPUTER BL2500 EMBEDDED USER’S MANUAL...
  • Page 2 © 2006 OEM Technology Solutions Pty Ltd. All rights reserved worldwide. This document is the property of OEM Technology Solutions Pty Ltd and may not be copied, used or disclosed in whole or in part except with the prior written permission of OEM Technology Solutions Pty Ltd or if it has been furnished under contract with another party, as specified in that contract.

  • Page 3: Table Of Contents

    GETTING STARTED ..........................7 INTRODUCTION ........................7 SOFTWARE INSTALLATION ....................7 2.2.1 Installing ISaGRAF Workbench V3.50 ..............8 2.2.2 Installing EMBEDDED PLC Board Support Package (BSP) for BL2500 ....8 LICENSING THE ISAGRAF WORKBENCH................8 2.3.1 Adding the software license..................9 2.3.2 Adding a hardware license (optional) ................9 BL2500 CONNECTIONS ......................10...
  • Page 4 6.2.2 Loading Shortcuts....................53 FAQ AND TROUBLESHOOTING ....................54 KNOWN ISSUES ........................54 7.1.1 BL2500 with Rabbit 3000 Microprocessor Revision 0 (IL1T) ......... 54 7.1.2 BL2500 with Large Sector Flash ................54 7.1.3 ISaGRAF Floating Point Arithmetic ................ 54 7.1.4 Reading/writing 32-bit integer/real analog variables via Modbus ......
  • Page 5 PLC BL2500 User’s Manual EMBEDDED LIST OF TABLES Table 1: Main Features of the EMBEDDED PLC Firmware Kernel V1.04 on the BL2500 ......2 Table 2: EMBEDDED PLC BL2500 Serial Port Configuration ..............38 Table 3: BL2500 Electrical, Mechanical and Environmental Specifications..........61 LIST OF FIGURES Figure 1: Power Supply Connection......................10...
  • Page 6 PLC BL2500 User’s Manual EMBEDDED This page is intentionally left blank OEM Technology Solutions Page iv...

  • Page 7: Introduction

    HVAC and vending machines. The BL2500’s compact board size of 100 x 100 mm is easily mountable in standard 100 mm DIN rail trays. External connections via polarized locking industry standard Molex® type connectors enable rapid assembly with wire harnesses.

  • Page 8: About This Manual

    PLC application using the ISaGRAF Workbench. • Chapter 4, Hardware Reference: Provides a detailed description of the I/Os and communication ports present in the SBC BL2500 and how to configure them in order to work with PLC. EMBEDDED...

  • Page 9: Embedded Plc Application Kit

    Chapter 9, About Indusoft: A brief description of Indusoft Web Studio and how can be used in conjunction with PLC. EMBEDDED PLC APPLICATION KIT EMBEDDED PLC BL2500 Application Kit contains the hardware and software needed to use the SBC EMBEDDED BL2500 with PLC system. It contains: EMBEDDED •...

  • Page 10: Reference Documents

    Some terms may vary according to the operating system (type, language and version) you are using. 1.7 REFERENCE DOCUMENTS [1] 019-0120 · 041215-H – Coyote (BL2500) C-Programmable Single-Board Computer with Ethernet User's Manual, 2002-2004 Z-World Inc. [2] ISaGRAF Version 3.5 User’s Guide, 1994 – 2004 ICS Triplex ISaGRAF Inc.
  • Page 11 PLC BL2500 User’s Manual Introduction EMBEDDED SRAM Static Random Access Memory Structured Text TCP/IP Transport Control Protocol/Internet Protocol Universal Serial Bus OEM Technology Solutions Page 5...
  • Page 12 PLC BL2500 User’s Manual Introduction EMBEDDED This page is intentionally left blank OEM Technology Solutions Page 6...

  • Page 13: Getting Started

    (Coyote) via the ISaGRAF Soft Logic package. This chapter will help you to quickly install the necessary software to run a PLC sample application on the BL2500 target using the ISaGRAF Workbench. This chapter contains also important information about licensing your product.

  • Page 14: Installing Isagraf Workbench V3.50

    ISaGRAF versions. 3. Once all the ISaGRAF files have been copied, the following group is added to your Programs group: 2.2.2 Installing PLC Board Support Package (BSP) for BL2500 EMBEDDED Use the following procedure to install...

  • Page 15: Adding The Software License

    User Code 2 into the ISaGRAF License Registration Form that comes in the Application Kit and send the completed form to OEM Technology Solutions by fax (Fax Number: +61 2 9966 9429). 6. OEM Technology Solutions will send you the ISaGRAF software license within two business days of receiving the completed Form.

  • Page 16: Bl2500 Connections

    2.4.1 Connect a Power Supply 1. Connect the AC adapter to header J2 on the BL2500 as shown in Figure 1. Match the friction lock tab on the friction-lock connector to the back of header J2 on the BL2500 as shown. The friction-lock connector will only fit one way.

  • Page 17: Figure 2: Ethernet Connections

    Figure 2: Ethernet connections When your PC is connected directly to the BL2500 via an Ethernet connection, you need to set (or change) the TCP/IP parameters of your computer in order to establish a proper connection with the BL2500.

  • Page 18: Connect An Rs232 Cable (Optional)

    PLC is configured to Use RS232, connect a serial cable to a COM port of the PC and to the RS232 port E of the BL2500. The RS232 cable must follow the diagram shown in Figure 3. A serial cable is not provided in the PLC Application Kit.
  • Page 19 PLC BL2500 User’s Manual Getting Started EMBEDDED If you are using RS232, on the PC-PLC link parameters window select COM port and press Setup button. Select the baud-rate (19200 to 600) depending on the current value of the Target PLC.

  • Page 20: Where Do I Go From Here

    PLC BL2500 User’s Manual Getting Started EMBEDDED 2.6 WHERE DO I GO FROM HERE? The next chapter describes how to run the other sample applications and step-by-step instruction on how to create a simple PLC application. The ISaGRAF User’s Manual and the ISaGRAF Workbench on-line help contain a complete description of the Workbench features and capability, as well as a complete PLC programming languages reference.

  • Page 21: Running Sample Applications

    • Sample applications pre-configured to use BL2500 I/O boards. These applications can be simulated or downloaded to the BL2500 Target PLC and requires that the Target is connected to physical I/Os: b25qld: Demo with Quick LD programming. b25rota: Rotation of 2 BL2500 on-board LEDs (DS3 and DS4) and 2 digital outputs.
  • Page 22 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 2. Double-click on the sample application (for example, rfdemo) to open the Programs Manager window. 3. On the Programs Manager window, select Debug → Simulate (or press Simulate button the toolbar). The Debugger, I/O simulation and Debug program windows are displayed.

  • Page 23: Running Applications That Use Internal Variables Only

    PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 3.2 RUNNING APPLICATIONS THAT USE INTERNAL VARIABLES ONLY The Target PLC and your PC must be connected through Ethernet, RS232 or RS485. Use the following procedure to run any sample application that uses only internal variables: 1.

  • Page 24: Running Applications That Use Bl2500 Inputs And Outputs

    7. Repeat this procedure for the rfstack application. 3.3 RUNNING APPLICATIONS THAT USE BL2500 INPUTS AND OUTPUTS 3.3.1 Creating I/O connectors PLC Application Kit comes with a bag of cables, connectors and crimp terminals in order EMBEDDED to connect to the I/Os of the BL2500.

  • Page 25: Downloading And Running The Isagraf Application

    SpotLight window is displayed. 4. The Digital inputs IN00 and IN01 of the BL2500 are wired as the Left and Right switches on the b25qld application. The BL2500 on-board LED DS3 is the output of the light. The BL2500 digital inputs IN02 and IN03 move the window’s screen to the left and right respectively.

  • Page 26: Creating A New Plc Application

    5 IEC 611131-3 PLC programming languages (FBD, LD, ST, IL and SFC) and Flow Chart that later you will download to the BL2500 Target PLC. The Target PLC must be connected to physical I/Os. It also assumes that the Target is connected to the PC either via Ethernet or serial port. To create (or modify) PLC applications the ISaGRAF Workbench must be licensed.
  • Page 27 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 7. Select Tools menu → Quick declaration. Enter Numbering from 1 to 2, Symbol name SW and Attributes = Input as shown in figure below. Press OK button. 8. On the Dictionary window, the SW1 to SW2 variables are listed.
  • Page 28 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 11. Save the current dictionary by selecting File menu → Save. Close the Dictionary window. 12. On the B25TEST1 – Programs window double-click on FBtest1 program. Press Insert variable button on the toolbar and click on the working area. On the Select variable window select SW1 and press OK button.
  • Page 29 Select bl25di board (BL2500 Digital Inputs) and press OK button. The bl25di I/O board is placed in Slot 0. Double-click on Channel 1. On the Connect I/O channel window press Connect button several times until all the free variables are connected.
  • Page 30 BLUE or RED colour depending on its current state, FALSE or TRUE respectively. If the digital input IN00 of the BL2500 is short circuited, SW1 is FALSE and LED DS3 will be turned ON as well as the state of LED1 in the Programs window will change. The PLC program implements a Boolean XOR operation on SW1 and SW2 with the result set on the LED1.

  • Page 31: Using Quick Ladder Diagrams

    Integers/Reals tab. Double-click on DA1 variable and set its value to 1.5 V (any value in the 0 – 3.3 V range). Connect a multimeter between DA1 and AGND of the BL2500 and check that the voltage is 1.5 V.
  • Page 32 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 6. Follow Steps 6 to 11 in Section 3.4.1 to create and populate the application’s Dictionary with SW1 and SW2 Boolean input variables (connected to Channel 1 and 2 of the bl25di I/O board respectively);...

  • Page 33: Using Structured Text

    PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 19. To stop the monitoring of the PLC application, close the Debugger window. The programs and dictionary windows in debug mode will be closed. 3.4.3 Using Structured Text 1. Open the ISaGRAF Project Management by double-clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu →...
  • Page 34 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 6. Follow Steps 6 to 11 in 3.4.1 to create and populate the application’s Dictionary with SW1 and SW2 Boolean input variables, and LED1 Boolean output variable. 7. On the B25TEST3 – Programs window double-click on STtest1 program.

  • Page 35: Using Instruction List

    PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 3.4.4 Using Instruction List 1. Open the ISaGRAF Project Management by double-clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu → Programs → ISaGRAF 3.5 → Projects. On the Projects Management window, select File menu →...

  • Page 36: Using Sequential Function Chart

    PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 14. Save the program by selecting File menu → Save. Press OK button on the Update diary window. Close the ILtest1 – ST Program window. 15. Follow Steps 17 to 25 in 3.4.1 to compile the application and download it to the Target PLC.
  • Page 37 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 5. Select File menu → New. On the New program window enter the name of the program (for example, SFCtest1); a brief comment; select the Language to SFC; select Begin Style and press OK button. The SFCtest1 program is displayed in the B25TEST5 –...
  • Page 38 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 10. Double-click on Transition 2 and write the expression not(SW1 XOR SW2); on the Transition GT2 ST/LD editor that is displayed. 11. Double-click on Step 2 and write the action LED1(S); on the Step GS2 that is displayed. Add the action LED2(R);...

  • Page 39: Using Flow Chart

    PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 3.4.6 Using Flow Chart 1. Open the ISaGRAF Project Management by double-clicking on the ISaGRAF Projects icon on your Desktop or selecting Start menu → Programs → ISaGRAF 3.5 → Projects. On the Projects Management window, select File menu →...
  • Page 40 PLC BL2500 User’s Manual Running Sample Applications EMBEDDED 11. Select the Insert a Repeat-Until button and place it in between the “Begin” symbol and the “SW1 = SW2” test symbol. Press Delete to just leave the flow line connector behind 12.

  • Page 41: Hardware Reference

    The Figure 4 shows the signal names and connectors of the BL2500. The BL2500 are equipped with five 1 × 10 friction-lock connector terminals (J1, J3, J9, J11, and J12) where pin 9 is removed to polarize the connector terminals, a 2 × 5 RS-232 signal header, a 2 × 5 programming header, and an RJ-45 Ethernet jack on the Rabbit core module.

  • Page 42: Digital Outputs

    ±40 V. IN14 is protected over a range of -36 V to +5 V. 4.2 DIGITAL OUTPUTS The BL2500 has eight digital outputs, OUT0-OUT7, each of which can sink up to 200 mA. Figure 6 shows a wiring diagram for using the digital outputs in a sinking configuration.

  • Page 43: Analog Output

    0 V and 3.3 V rails out of the Rabbit 3000 microprocessor, and the gain resistors used in the circuit have a 1% tolerance. For these reasons, each BL2500 needs to be calibrated individually, with the constants held in software, to be able to rely on an absolute accuracy. The BL2500 has this calibration support.

  • Page 44: Communication Interfaces

    The BL2500 can be used in an RS-485 multidrop network spanning up to 1200 m (4000 ft), and there can be as many as 32 attached devices. Connect the 485+ to 485+ and 485- to 485- using single twisted-pair wires as shown in Figure 9.

  • Page 45: Ethernet Port

    When using more than 10 BL2500s in a multidrop network, or when you need the full common-mode immunity per the RS-485 specification, leave the 681 W bias resistors in place on the master BL2500, and leave the 220 W termination resistors in place on the BL2500 at each end of the network.

  • Page 46: Led Indicators

    PLC BL2500 User’s Manual Hardware Reference EMBEDDED 4.6 LED INDICATORS PLC Kernel running on the BL2500 uses three LEDs to indicate status: EMBEDDED • DS1 (yellow). When this LED is flashing every second, it indicates that the Target PLC is licensed and active.

  • Page 47: Software Reference

    PLC BL2500 User’s Manual Software Reference EMBEDDED 5. SOFTWARE REFERENCE 5.1 MORE ABOUT ISAGRAF 5.1.1 Project Manager The ISaGRAF methodology begins with the preparation of a detailed project specification. This step is common to all PLC programming techniques and is usually the result of a thorough analysis of the project and consultation between the integrator and the user.

  • Page 48: Iec 61131-3 Language Editors

    PLC BL2500 User’s Manual Software Reference EMBEDDED 5.1.5 IEC 61131-3 Language Editors In February 1993, responding to the need for standards to reduce training costs and guaranteed portability, the IEC issued the IEC 61131-3 standard: a specification of five PLC programming languages that can be freely mixed to define automation and control procedures.

  • Page 49: Isagraf Software Reference

    EMBEDDED 5.2.1 I/O Boards ISaGRAF I/O board library for the BL2500 is included as part of the BL2500 BSP to make it easy to communicate with the BL2500 supported inputs and outputs. These I/O boards are described in the following sub-sections.
  • Page 50 5.2.1.4 BL2500 Analog Input Board Name: bl25ai Description: Monitors AD0 Analog Input of the BL2500 (10-bit resolution over 0-3.3V range) Number of Channels: Connection Terminals: AD0 – Connection for positive signal channel 1 AGND – Connection for negative signal channel 1 Channel Value Correspondence: Analog REAL type variable: Voltage input in the range 0 –...

  • Page 51: Isagraf C Functions

    5.2.1.5 BL2500 Analog Output Board Name: bl25ao Description: Controls DA1 Analog Output of the BL2500 (10-bit resolution over 0-3.3V range) Number of Channels: Connection Terminals: DA1 – Connection for positive signal channel 1 AGND – Connection for negative signal channel 1 Channel Value Correspondence: Analog REAL type variable: Voltage output in the range 0 –...

  • Page 52: Isagraf C Function Blocks

    5.2.3.1 SET_TIME set_time Trigger minute dOfWeek result Arguments: if Rising edge, sets the time and date of the BL2500 Trigger Year (1900 - 2050) Month (1 - 12) Day of month (1 -31) Hour (0 - 23) Minute (0 - 59)
  • Page 53 PLC BL2500 User’s Manual Software Reference EMBEDDED OEM Technology Solutions Page 47...

  • Page 54: Loading Or Upgrading The Firmware Kernel

    PLC Firmware Kernel to the Rabbit-based Target EMBEDDED EMBEDDED such as the SBC BL2500. The Firmware Kernel, once loaded into the Target, requires a license key to run. The PLC Utility does not check for an existing license key before loading the Kernel.

  • Page 55: Loading And Licensing The Firmware Kernel

    4. After loading is completed a message dialog box is displayed. Follow the instructions in the same order: Connect DIAG cable → Reset Target → Press OK. There are two ways to reset the BL2500: unplugging the power supply and then plugging it again (also known as a power cycle);...

  • Page 56: Configuring The Firmware Kernel

    BL2500 LED status see Section 4.6. 6.1.4 Configuring the Firmware Kernel If you purchased an PLC Application Kit, the BL2500 comes pre-configured for Use Modbus EMBEDDED TCP and the following TCP/IP values: IP address = 192.168.1.100, Netmask = 255.0.0.0, Default gateway = 192.168.1.1.

  • Page 57: Embedded Plc Utility Software Reference

    PLC BL2500 User’s Manual Loading or Upgrading the Firmware Kernel EMBEDDED 2. Enter the desired Modbus Slave Number (Default is 1). Select Use Modbus TCP radio button and fill the Modbus TCP configuration parameters if you want to use Modbus TCP as communication protocol.
  • Page 58 PLC BL2500 User’s Manual Loading or Upgrading the Firmware Kernel EMBEDDED 6.2.1.4 Setup → Target Configuration The configuration parameters can be changed at any time once the PLC kernel is running but EMBEDDED requires the Target to be reset (or powered cycle).

  • Page 59: Loading Shortcuts

    PLC BL2500 User’s Manual Loading or Upgrading the Firmware Kernel EMBEDDED 6.2.1.5 Setup → Kernel License This option can be used to establish connection with the target to check the current license status. If license is required the following window will appear.

  • Page 60: Faq And Troubleshooting

    DS4. If you have an SBC BL2500 with the Rabbit 3000 microprocessor revision 0 (IL1T or IZ1T) and want to use the analog features bear in mind that outputs 0 to 3, RS485 and RabbitNet can not be used.

  • Page 61: Faq

    Kernel is loaded to a Target. This means that after loading a new Kernel to a Target, a new User Reference Code is generated and you will need to contact OEM Technology Solutions or your local distributor to obtain a new license key to activate the EMBEDDED PLC Kernel.
  • Page 62 PLC supports, visit OEM Technology website or contact sales directly via phone +61 2 EMBEDDED 99669424 or email sales@oem.net.au. Q10. What does the letter C after the BL2500 in the BSP filename stand for? The ‘C’ letter in the filename BL2500C_BSP_V1.04_9-0003-006.zip corresponds to the type of the BL2500 board supported by PLC.

  • Page 63: Troubleshooting

    PLC BL2500 User’s Manual FAQ and Troubleshooting EMBEDDED 7.3 TROUBLESHOOTING 7.3.1 Common Errors Listed below are some solutions of common errors that you may encounter with PLC products. EMBEDDED 7.3.1.1 Communications If you experienced problems with the communication between the Target and either the ISaGRAF Workbench or a Modbus master check the items below: •...

  • Page 64: Before Contacting Technical Support

    Verify that the entire system has good, low-impedance, separate grounds for analog and digital signals. The BL2500 is often connected between the host PC and another device. Any differences in ground potential can cause serious problems that are hard to diagnose.
  • Page 65 PLC BL2500 User’s Manual FAQ and Troubleshooting EMBEDDED This page is intentionally left blank OEM Technology Solutions Page 59...

  • Page 66: Specifications

    PLC BL2500 User’s Manual Specifications EMBEDDED 8. SPECIFICATIONS 8.1 ELECTRICAL AND MECHANICAL SPECIFICATIONS Figure 13: BL2500 Dimensions OEM Technology Solutions Page 60...

  • Page 67: Table 3: Bl2500 Electrical, Mechanical And Environmental Specifications

    PLC BL2500 User’s Manual Specifications EMBEDDED Table 3: BL2500 Electrical, Mechanical and Environmental Specifications Microprocessor Rabbit 3000 @ 44.2 MHz Ethernet Port 10/100 Base-T Flash Memory 512K SRAM 512K (program) + 256K (data) Backup Battery 3 V lithium coin-type, 1000 mA-h, supports RTC & SRAM Digital I/O 16 inputs: 15 protected to ±36 V DC, 1 protected to +5 –...

  • Page 68: About Indusoft

    IWS applications interface with industrial I/O systems and other Windows applications in the run-time environment using ODBC, DDE, NetDDE, OPC or TCP/IP protocols. For more information about IWS contact OEM Technology Solutions (http://www.oem.net.au). 9.1 USING INDUSOFT WEB STUDIO WITH EMBEDDED...
  • Page 69 PLC BL2500 User’s Manual About Indusoft EMBEDDED You can quickly add the Modbus driver on the Workspace, define its operational parameters and define the I/O variables (tags) that will be exchanged between the PLC and the IWS application. EMBEDDED OEM Technology Solutions...
  • Page 70 PLC BL2500 User’s Manual Index EMBEDDED INDEX link setup............17 software license ..........8 SpotLight ..........13, 17 BL2500 Workbench............. 1 A/D converter ..........36 D/A converter ..........37 digital inputs ..........35 digital outputs ..........36 Modbus Ethernet port ..........39 configuration ..........
  • Page 71 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Rabbit Semiconductor 101-1108...

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