1. Manuals
  2. Brands
  3. Automationdirect.com Manuals
  4. Control Panel
  5. OP-640
  6. Manual

Automationdirect.com OP-640 Manual

Operator panel
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
OP-640
Operator Panel
Manual Number OP-640-M

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the OP-640 and is the answer not in the manual?

Questions and answers

Related Manuals for Automationdirect.com OP-640

Summary of Contents for Automationdirect.com OP-640

  • Page 1 OP-640 Operator Panel Manual Number OP-640-M...
  • Page 2 1--800--633--0405. This publication is based on information that was available at the time it was printed. At Automationdirect.comä we constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or publications at any time without notice and without any obligation.
  • Page 3 Manual Revisions If you contact us in reference to this manual, be sure and include the revision number. Title: OP--640 Operator Panel User Manual Manual Number: OP--640--M Issue Date Effective Pages Description of Changes Original 9/99 Original Issue...
  • Page 4 EU Information This product is manufactured in compliance with European Union (EU) Directives and carries the CE mark. The following information is provided to comply with EU documentation requirements. NOTE: Products with CE marks perform their required functions safely and adhere to relevant standards as specified by EU directives provided they are used according to their intended purpose and that the instructions in this manual are adhered to.

  • Page 5: Table Of Contents

    Table of Contents Chapter 1: Getting Started Introduction ............... . . 1- -2 The Purpose of this Manual .
  • Page 6 Table of Contents Physical Specifications ............. 2--11 Environmental Specifications .
  • Page 7 Table of Contents Application Worksheets ............4--3 Computer System Requirements .

  • Page 8: Chapter 1: Getting Started

    Getting Started In This Chapter..— Introduction — Conventions Used — OP-640 Overview — Frequently Asked Questions...

  • Page 9: The Purpose Of This Manual

    You can also check our online resources for the latest product support information: Internet -- the address of our Web site is www.automationdirect.com If you still need assistance, please call us at 1--770--844--4200. Our technical support group will be glad to work with you in answering your questions. They are available Monday through Friday from 9:00 A.M.

  • Page 10: Chapters

    1- -3 Getting Started Chapters The main contents of this manual are organized into the following five chapters: Introduces the physical and functional characteristics. Getting Started Discusses pushbuttons, lamps and the LCD display. Also provides introduction to planning your system. Shows how to prepare for system installation, including Installation and specifications and mounting instructions.

  • Page 11: Op- -640 Overview

    1- -4 Getting Started OP- -640 Overview Plan your System Let’s look at the OP--640 operator panel and its individually-supported features. As you continue through this manual, try to relate the examples to your Operator Panel application. The application worksheets located in Appendix A will be helpful during the design and configuration of your system.

  • Page 12: Pushbuttons

    1- -5 Getting Started Many applications require operator Pushbuttons panel pushbuttons for controlling the machine or process. These pushbuttons are used as input signals to the PLC which start and stop a machine or process. Configure these pushbuttons as momentary or alternating to best fit F4 F5 your operator interface application.

  • Page 13: Frequently Asked Questions

    1- -6 Getting Started Frequently Asked Questions Q. What is required to get started using the OP- -640 in my application? A. You must read this manual and understand the OP-panel requirements and application concepts. You must have programming knowledge for the PLC product you’re using, the PLC serial communications capabilities which are available, as well as hook-up and connecting cable data.
  • Page 14 1- -7 Getting Started Q. My module will occasionally fail when I power up my system. Why does this happen? A. Normally this is caused by an inadequate power supply corrupting the memory. When determining the size of a power supply be sure to include ALL sources of energy consumption and also account for the surge these devices require.

  • Page 15: Chapter 2: Installation And Specifications

    Installation and Specifications In This Chapter..— Connecting a Power Supply — Preparing Panel for Configuration — Preparing Panel for Communications — OP--9001 Multi--panel Configurations — Choosing Connecting Cables — Connecting Cable Details — Labeling the Lamps and Pushbuttons —...

  • Page 16: Power Supply Connections

    2- -2 Installation and Specifications Connecting a Power Supply Power Supply An external power supply is adapted to supply operating voltage to the OP--640 unit. Connections The power supply must deliver a range between 8 to 30 VDC, and provide a minimum of 5 watts continuous power to the units.

  • Page 17: Preparing The Panel For Configuration

    2- -3 Installation and Specifications Preparing the Panel for Configuration RUN/PGM The RUN/PGM Switch must be set to PGM (ON) before downloading from the PC to the panel. The TERM switch should remain off. Switch NOTE: You must cycle power to the panel to activate the new switch settings. TERM Set to PGM Configuration...

  • Page 18: Preparing The Panel For Communications

    2- -4 Installation and Specifications Preparing the Panel for Communications RUN/PGM The RUN/PGM Switch must be set to RUN after loading the configuration program. The TERM switch should remain off. Switch NOTE: You must cycle power to the panel to activate the new switch settings. TERM Set to RUN OP- -9001 Multi-Panel Configurations...
  • Page 19 2- -5 Installation and Specifications Choosing Connecting Cables OptiMate Cables Family Family Depending on which PLC you are Port Port Cable Cable (or other device) (or other device) using, you may require as many as DirectLOGIC DL05: D0--05 DL05: Both ports OP--2CBL cables.

  • Page 20: Connecting Cable Details

    2- -6 Installation and Specifications Connecting Cable Details Connecting Cable The OP--640 connecting cable may vary depending on the CPU used. Refer to the previous page to confirm the proper cable is chosen for connecting to your PLC. OP--2CBL RJ12 RJ12 DB15 RJ12 (PLC)

  • Page 21: Labeling The Lamps And Pushbuttons

    2- -7 Installation and Specifications Labeling the Lamps and Pushbuttons Labeling the In any manufacturing environment it is important to have legible labels on the Lamps and Pushbuttons pushbuttons. Labeling the OP--640 panel is a relatively simple process that involves removing the bezel and sliding a label transparency into a pocket in the panel overlay.
  • Page 22 2- -8 Installation and Specifications Select OP- -640, and Configure Panel. Select Labels. The OP--640 Label Template appears. Type in the label text for the five pushbuttons and the three lamps. Press OK to save the labels.

  • Page 23: Templates For Manually Creating Labels

    2- -9 Installation and Specifications OP640 LABEL TEMPLATES Printer Lamp Template: Pushbutton Template: 5. Print label on transparent film. Start Setup Next Prev. Stop 6. Cut out the block of labels and Transparent insert them in the panel. Sheet Pocket for Lamps Pocket for Pushbutton Bezel...

  • Page 24: Dimensions For Mounting

    2- -10 Installation and Specifications Dimensions for Mounting Cutout Area Example panel mounting 6.20” 0.50” 0.20” 5.80” 0.75” 0.16” DIA, Dimensions in Inches 1.15” four places...

  • Page 25: Panel Specifications

    2- -11 Installation and Specifications Panel Specifications Physical Specifications Weight ........12 ounces Panel Fasteners .

  • Page 26: Chapter 3: Understanding The Features

    Understanding the Features In This Chapter..— Learning the Features — Status and Control Registers — Messages — Displaying Messages — Pushbuttons and Lamps — Memory Mapping Process — DirectLOGIC User Memory Overview — Mapping Operation — Mapping Example (DL05/105/DL205/D3--350/DL405) —...
  • Page 27 3- -2 Installation and Specifications Learning the Features In this section, the subject of how to use the OP--640 features is described. The details for using pushbuttons and messages are covered. We recommend that you study this chapter before attempting to configure and use the OP-panel. As you proceed through this chapter, relate the topics discussed with how your operator panel may be implemented.

  • Page 28: Status And Control Register Overview

    3- -3 Installation and Specifications Status and Control Registers Status and Control The OP-panels communicate to the PLC through user defined PLC data registers. Register Overview The starting or “Base” register is assigned during panel configuration and automatically occupies fourteen consecutive 16--bit data registers. In this manual the registers are identified as M+0, M+1, M+2, thru M+13.

  • Page 29: Register Definition

    3- -4 Installation and Specifications Register Definition The following describes the function of each of the registers shown in the table. S Register M+0 -- When a number from 1 to 160 is placed in this register, the predefined message associated with that number will be displayed on the top line of the LCD display.

  • Page 30: Messages

    3- -5 Installation and Specifications Messages Through the OP--WINEDIT software, up to 160 predefined messages can be Displaying entered and stored in the OP--640. These messages are 20 characters long and can Messages on the include a field for the display of numeric data. LCD Screen Any predefined message can be displayed on either the top or bottom line.

  • Page 31: Displaying Messages

    3- -6 Installation and Specifications Displaying Messages The logic required to display the configured message is quite simple. Simply put the message number (1--160) in memory location M+0 for the top line message, M+1 for the second line message, M+2 for the third line message, or M+3 for the bottom line message.
  • Page 32 3- -7 Installation and Specifications Dynamic Message You may program message numbers 1--160 to be used as dynamic messages. One Operation numeric field per line is allowed. Dynamic messages may be displayed on either the top or bottom display lines. The maximum number of digits which may be displayed is five if binary data format is used, four if BCD is used, and eight if BCD double is used.

  • Page 33: Dynamic Message Operation

    3- -8 Installation and Specifications Dynamic Message In this example, if the PLC’s input signal X4 is Top Line ON, the 16 bit integer (K10) value is placed in Selects message# Word register V2000 (M+0) selecting message for Top line #10 to be displayed on the top line.

  • Page 34: Displaying Data With A Decimal Point

    3- -9 Installation and Specifications Bottom Line Dynamic Message Register Function Value Remember, your ladder logic Top line message selection program must select the bottom line Second line message selection message being displayed by placing Third line message selection an integer value between 1 and 160 Bottom line message selection (message #) in register M+3.

  • Page 35: Displaying Floating Point Numbers

    3- -10 Installation and Specifications Example: BCD Double When placing a BCD double number in the display registers, the first register numerically 92345678 in the sequence of two registers (M+4, M+6, M+8 or M+10) will contain the four least significant digits of the number. The second register in the sequence (M+5, M+7, M+9 or 9234 must be in M+11) contains the data for the four most...

  • Page 36: Pushbuttons And Lamps

    3- -11 Installation and Specifications Pushbuttons and Lamps The OP--640 has five user-defined pushbuttons. Pushbuttons may be used to begin events or tasks within the PLC, such as start/stop control. This section describes concepts of how to monitor and control the pushbuttons on your OP-panel. Pushbutton The OP-panel pushbutton inputs are monitored for ON/OFF conditions in your PLC Operation...

  • Page 37: Pushbuttons Using Direct Access To Status Register Bits

    3- -12 Installation and Specifications Pushbuttons Using The DirectLogic D2--250/D3--350/D4--450 CPUs and the Allen-Bradley SLC 5/03 Direct Access to and 5/04 support instructions which provide individual status bits access. This is called Bit-of-Word capability. For example, in the previous example, the ladder Status Register Bits logic for the D2--250/D3--350/D4--450 monitors the first bit of the status word directly.

  • Page 38: Lamp Flash

    3- -13 Installation and Specifications Lamp Flash The lamp flash examples shown here are using DirectLOGIC PLC address references. The equivalent instructions for other PLC products supported are shown in Chapter 5. In this example, C2 represents the pushbutton No.3 (F3) via the mapping process. When alter- nating pushbutton No.3 is pressed internal Con- trol Relay C21 and C24 are energized ON.
  • Page 39 3- -14 Installation and Specifications OP-Panel User Let’s examine the different address conventions for DirectLOGIC and Allen-Bradley. For example, the DirectLOGIC address references are octal, and Memory the Allen-Bradley is decimal. The DirectLOGIC DL05/DL105/DL205/D3--350/DL405 OP-panel address uses V-memory registers which are 16-bit registers. The D3--330/340 CPUs use reference assignments with 8-bit registers.
  • Page 40 3- -15 Installation and Specifications DirectLOGIC User Memory Overview D2- -250 D3- -350 D4- -450 D4- -440 D0- -05 D1- -130/D2- -230 D2- -240 D4- -430 V-Memory V-Memory V-Memory V-Memory V-Memory V-Memory V1200 V1400 V1400 V1400 V2000 V2000 V2377 V3777 V7377 V40600 V40600...

  • Page 41: Mapping Operation

    3- -16 Installation and Specifications Mapping Operation We explained earlier that the PLC and OP-panel must exchange data on a bit-level basis. For DirectLOGIC controllers, the OP-panel Status Register (M+12) must be mapped into internal control relays such as C0, C1, etc (and the control relays C20--C37 must be mapped into the Control Register, M+13).

  • Page 42: Mapping The Control Register

    3- -17 Installation and Specifications Mapping the Control The figure below demonstrates how the Internal Control Relays C20--C37 are Register mapped to the OP-panel control register. Notice the sixteen bits in the Internal Control Relays C20--C37 are loaded into the control register. These control relays function as outputs for the Lights.

  • Page 43: Mapping The Control Register 3

    3- -18 Installation and Specifications Mapping the Control The figure below demonstrates how the Internal Control Relays are mapped to the Register OP-panel control register. Notice the sixteen bits in the Internal Control Relays C200--C217 are loaded into the control register. These control relays function as outputs for the Lights.

  • Page 44: Chapter 4: Configuring Your Operator Panel

    Configuring Your Operator Panel In This Chapter..— Preparing for Configuration — How to Configure Your Panel...

  • Page 45: Op--Winedit Software 4

    Preparing for Configuration OP- -WINEDIT The OP--640 is configured with software running on a personal computer. This Software software is available through Automationdirect.com and is referred to as OP--WINEDIT configuration software. More about The OP--WINEDIT configuration software allows you to configure OP--panel...

  • Page 46: Step 1

    4- -3 Configuring Your Operator Panel To prepare your application, use the Application Worksheets which are provided Application in Appendix A of this manual. The example worksheets will help you configure the Worksheets OP--640 panel. The blank worksheets can be photocopied and used in planning your own applications.

  • Page 47: Step 3

    4- -4 Configuring Your Operator Panel Step 3 Open OP- -WINEDIT -- Select New System. Step 4 Start Configuring Your Panel -- Start by filling in these parameters: Select New System Select PC Port Select Single or Multiple Panel System Enter a title that you will save this configuration as.

  • Page 48: Step 6

    4- -5 Configuring Your Operator Panel You also have several ports which can be used to connect your communications cable. Some of these ports have fixed PLC address assignments, and some do not. The ports which allow configuring the PLC addresses can be set to a unique address, ranging from 1 through 90.

  • Page 49: Step 7

    4- -6 Configuring Your Operator Panel Configure the Panel Features -- These features are discussed in detail in Chapter Step 7 3, but they include: Pushbutton Configuration -- The pushbuttons can be configured as either Momentary or Maintained (alternate ON/OFF). Momentary pushbuttons remain ON as long as they are pressed, while Maintained pushbuttons retain their status (ON or OFF) until the next time they are pressed.

  • Page 50: Chapter 5: Programming Examples

    Programming Examples In This Chapter..— Examples Using DirectLogic PLCs — DL05/105/DL205/D3--350/DL405 Examples — D3--330/340 Examples — Allen-Bradleyt SLC 5103--5105 and Micrologix Examples — Troubleshooting...

  • Page 51: Register Usage

    5- -2 Programming Examples Examples Using DirectLOGIC PLCs Register Usage The OP--WINEDIT configuration software allows you to configure a panel to use a block of registers at a starting value that you define. For a DL05, DL105, DL205, D3--350 or DL405 CPU the recommended memory to use is the general purpose data words starting at V2000.

  • Page 52: Dl05, Dl105, Dl205, D3- -350 And Dl405 Examples

    5- -3 Programming Examples DL05, DL105, DL205, D3- -350 and DL405 Examples The following examples assume that the OP--640 is configured for a base address of Defining the Status Register V2000. When configuring the panel, use the configuration data and messages shown in the following figure.
  • Page 53 5- -4 Programming Examples Place the following program rung in the program to copy the status register to memory location V40600 and copy V40601 to the control register. With this rung placed in the PLC program, the status and control bits will be control relays. Status register V2014 V40600...

  • Page 54: Using A Function Button

    5- -5 Programming Examples Using a Function The five function buttons will appear as control relay coils in your program (assuming Button the register copy rung shown previously is in the program). This rung turns on output Y1 when pushbutton F1 is active.

  • Page 55: Lighting A Lamp

    5- -6 Programming Examples Lighting a Lamp Lighting a lamp simply requires activating the control relay associated with the lamp. The following example will light the first lamp when relay C1 is on. Remember to place the register copy rung shown previously in the program. LAMP1 In this example, C1 represents the pushbutton No.

  • Page 56: Displaying Messages 5

    5- -7 Programming Examples Displaying The following example shows two messages being displayed. The example Messages assumes that the messages shown earlier are entered, and shows two messages that will be displayed as long as C100 is on. The second line is displaying message #4 and the bottom line is displaying message #8.

  • Page 57: Displaying Binary Numbers 5

    5- -8 Programming Examples Displaying Binary This example is similar to the previous example, except that it uses a binary number Numbers in the top display. The top line uses data display message #1, which has been configured as a binary display message. The data for the top data field is number 56432 (from V2200).
  • Page 58 5- -9 Programming Examples Displaying BCD This example is similar to the previous example, except that it uses a BCD Double Double Numbers number in the bottom line display. The bottom line uses data display message #6, which has been configured as a BCD Double display message. The data for the bottom line data field is from V3002 and V3003.

  • Page 59: Displaying Floating Point Numbers Example 1 5

    5- -10 Programming Examples Displaying This example uses a floating point number in the third line display message. The Floating Point third line uses data display message #7, which has been configured as a floating Numbers point display message. Since the data is a floating point number, it uses two 16-bit registers.
  • Page 60 5- -11 Programming Examples Displaying This example is similar to the previous one, except that it gets its value from two PLC Floating Point registers instead of a constant value. The third line uses data display message #7, Numbers which has been configured as a floating point display message. Remember, floating point numbers require two 16-bit registers and they must be read together.

  • Page 61: Displaying Messages

    5- -12 Programming Examples Example Using D3- -330/340 Example The following example assumes that the OP--640 is configured for a base address of R400/R401. When configuring the panel, enter the messages shown in the previous section for the DL05, DL105, DL205, D3--350 and DL405 examples. Displaying Messages This rung displays message #1 in the top DSTR...

  • Page 62: Interfacing To A-B Memory

    5- -13 Programming Examples Allen-Bradleyt SLC 5/03 & 5/04 and Micrologix Examples Interfacing to A-B OptiMate panels interface to Allen-Bradley SLC 5/03 & 5/04 and Micrologix PLCs via Memory integer file type N. The 5/03 and 5/04 have file type N7 as standard. Other “N” type files can be created.

  • Page 63: Flashing A Lamp

    5- -14 Programming Examples Flashing a Lamp Flashing a lamp simply requires activating the control relay to turn on the lamp and the flash control relay. This example will flash lamp L1 when input I:2/12 is active. Lamp L1 N7:13 Flash LF1 N7:13 Status Register...
  • Page 64 5- -15 Programming Examples Displaying The following example uses the configuration shown below. Messages Display Fixed...

  • Page 65: Displaying Messages 5

    5- -16 Programming Examples Displaying The second line is displaying BCD message #4. The data for the data field which is Messages displayed in the second line is from location N7:54. The bottom line is displaying text Example message #8. The top and third lines use data display message #140, which has been configured as a blank text message.
  • Page 66 5- -17 Programming Examples Displaying Binary This example is similar to the previous example, except that it uses a binary number Numbers in the top line display. The top line uses data display message #1, which has been configured as a Binary display message. The data for the top line data field is a constant number, 56432 (DC70 Hexadecimal).

  • Page 67: Chapter 6: Troubleshooting

    Troubleshooting In This Chapter..— Troubleshooting — Panel Configuration Problems — Panel to PLC Communications — A- -B Panel to PLC Communications...

  • Page 68: Troubleshooting The Op- -640 Panel

    In this section, we explain how to isolate potential problems which may occur while Troubleshooting using the OP-640. If you are unable to troubleshoot and correct your problem using these procedures, please contact our technical product support team between the hours of 9:00 AM and 6:00 PM (EST) Monday through Friday.

  • Page 69: Panel To Plc Communications Problems

    6- -3 Programming Examples Panel to PLC If you experience communications difficulties between the OP-panel and PLC for a Communications period of twelve seconds, the LEDs in the corners of the five pushbuttons will flash Problems rapidly. In this case, you should check the following items: Observe the TX and RX LEDs on the rear of the panel.

  • Page 70: Allen-Bradley Panel To Plc Communications Problems

    6- -4 Programming Examples Allen-Bradley For Allen-Bradley, you must connect to Channel 0 (bottom serial port), using DF1 in Panel to PLC full duplex mode. Typically, the only change that needs to be made to channel 0 is the Communications baud rate.

  • Page 71: Appendix A Worksheets

    Appendix A Worksheets In This Appendix..— Example Application/Message Worksheet — Blank Application/Message Worksheet...
  • Page 72 A- -2 Application Worksheet PAGE: EXAMPLE WORKSHEET PUSHBUTTONS / LAMPS : (Alternate/Momentary) OP--640 Demo DESCRIPTION : Single Panel System Type OP--640 Panel Type V2000 PLC Base Register Addr PLC CONFIGURATION : DirectLOGIC PLC Family F1--130 CPU Model K Sequence Protocol PLC Address Lamp1 PLC Timout...
  • Page 73 A- -3 Application Worksheet PAGE: OP-640 APPLICATION WORKSHEET PUSHBUTTONS/LAMPS (Alternate/Momentary) DESCRIPTION : System Type Panel Type PLC Base Register Addr PLC CONFIGURATION : PLC Family CPU Model Protocol PLC Address Lamp1 PLC Timout Yellow Baud Rate Lamp2 Parity Green Data/Stop Bits...
  • Page 74 A- -4 Application Worksheet PAGE: PAGE: OP-640 MESSAGE WORKSHEET MESSAGE: Text Message Action: Data Format: Range: Action: Data Format: Range: Action: Data Format: Range: Action: Data Format: Range: Action: Data Format: Range: Action: Data Format: Range: Action: Data Format: Range:...
  • Page 75 Index Application, planning, 1--4 Frequently Asked Questions, 1--6 Back-panel, layout, 1--5 Keypad, entry, 1--6 Label Communications Cable, recommended, 2--5 creating, 2--7 installation, 2--9 Configuration preparation, 4--2 Lamp software, 4--2 example, 5--6, 5--12, 5--13 flash example, 5--6, 5--12, 5--13 Configuration Cable, 2--3 labels, 2--7 Configuring operation, 3--12...
  • Page 76 Index- -2 OP--9001, cable connectors, 2--5 Serial Port, 1--5 OP--9001 Communications Master, 2--4 Specifications, 2--11 communication link, 2--11 OP--WINEDIT environmental, 2--11 configuration cable, 2--3 NEMA rating, 2--11 configuration software, 2--3, 4--2 power connector, 2--11 installation, 4--3 storage temperature, 2--11 system requirments, 4--3 user steps, 4--3 Static Message display, 3--5...

Table of Contents