Smart solutions for comfort and safety

Controls
SAIA®PCD operating system
Breaking the boundaries of PLC based controller technology

SAIA®PCD – the versatile controller for factory and

building automation
■ The open architecture of the SAIA®PCD operating system will, in the future as
in the past, allow the seamless integration of the latest technologies, such
as Ethernet-TCP/IP, web servers, etc. This guarantees the greatest possible
security of investment.
■ The same operating system, from the smallest control device up to a multiproces-
sor system, minimizes programming expenses and allows easy portability.
■ The operating system manages modular program structures in BLOCTEC and
GRAFTEC, which guide the user during the editing of efficient, reusable, well
documented programs. The “connoisseur’s” PCD thereby achieves unrivalled
maximum performance levels.
■ The comprehensive instruction set includes the traditional PLC instructions
based on IEC 1131-3, and also high-level instructions with various addressing
modes, e. g. for data and text manipulation or PID control.
■ A crucial strength of the SAIA®PCD operating system is its ability to run in parallel
up to 6 communications channels with different protocols, for example: single
character, PROFIBUS FMS/DP, LONWORKS® etc. and including open protocols
like Ethernet-TCP/IP and web server.
■ The SAIA®PCD operating system ensures reliable management and rapid access
to contents of user memory up to 1 MByte in size. This can be divided up by
the user as required into sectors for program, text and data blocks.

Efficient project planning, programming and commissioning

■ The user-friendly PG5 tool for project management and programming has been
precisely matched to the PCD operating system. Each of the different editors
has powerful commissioning and diagnostic tools.
■ Comprehensive software libraries offer fully developed solutions that are easy
to adapt, expand or integrate within function blocks.
■ The operating system also supports access for remote diagnosis, telemaintenance
and firmware updates via modem or Ethernet-TCP/IP.

Edition 26/354 E3
 PCS1
PCD1
PCD2
PCD4
Optimum interaction of operating system, hardware PCD6
and programming tools

Saia-Burgess Controls has over 20 years of experience in Reliability built in

the field of PLC technology and is among the established
The demands placed on an operating system used to control
pioneers of the PLC industry. As the first PLC supplier to
processes and machines are high. The SAIA®PCD operating
offer programming tools under Microsoft Windows and to
system has the following distinctive features:
develop CPUs based on 32-bit microprocessors, Saia-Burgess
Controls can demonstrate comprehensive expertise in the ■ High stability and robust function
fields of programming tools, CPU hardware and operating Perfect operation under all operating conditions, safety
systems for programmable controllers. shut-down when faults arise.
■ Hardness of real-time capability
High level of functionality - all included Deterministic time response and computable reaction
times, due to sequence control with direct access to inputs/
The SAIA®PCD operating system is impressive in its func-
outputs.
tionality, which elsewhere might only be obtainable with
additional hardware and software. For example, widely ■ Constant product life-cycles and reproducibility
used communications protocols and the free ASCII drivers Control solutions based on the SAIA®PCD operating system
are all integral parts of the operating system and can be can be (re)produced, even after many years – without
used without additional expense. This operating system also software updates, service packs or new hardware com-
supports telemaintenance and teleservice by modem from ponents.
a home base.
■ Maintainability
Programming and test functions that do not interrupt the
process or mechanical sequence being controlled, ensure
that care and maintenance meet practical requirements
– even when production is in full swing.
■ Perfect match
Specially tailored for PCD controllers, the SAIA®PCD ope-
rating system makes efficient, optimum use of hardware
resources.

Operating system start-up

At start-up, power supply logic checks RUN
all system voltages and enables the
SAIA®PCD controller to start the operat-
Assignment of
ing system. After extensive hardware PGU and field bus
and software checks, the operating sys- interfaces
System initialization with
tem switches to RUN mode and pro- definition instructions
cessing of the user program begins. Prepare jump table for
processing levels
Check consistency of user
programs
Optimum interaction

Compare firmware checksum

Check system memory
(RAM)
Check hardware peripherals

Supply ready

How the interpreter works

Signals from a wide range of sensors are connected to in- The CPU consecutively processes instructions in user me-
put modules and processed by the user program in the mory. Program and function blocks are called conditionally
CPU. The results are passed to the output modules and as required.
the actuators connected to them are activated accordingly.
When the last instruction in the program has been executed,
processing starts again from the beginning. This cyclic
processing is typical of all PLCs compatible with EN 61 131-1.

2
 PCS1
PCD1
PCD2
PCD4
Structure of operating system, hardware and PCD6
programming environment

The SAIA®PCD operating system is the link between the modules, working in fine coordination, guarantee that PLC
programming tools (or user programs written with them) function and communications run perfectly, while allowing
and the controller hardware. It ensures perfect controller access to onboard functions (fast counter, interrupt inputs,
function – as specified by the programming. etc.) of the PCD1/2 hardware. Finally, the BIOS establishes
a connection to the CPU hardware and I/O module drivers
The top position is occupied by the user program, which
allow the smooth operation of I/O modules
may be written with different methods and editors. This
is executed at the appropriate processing level. Individual
PROGRAMMING

R PROGRAM
USE
SOFTWARE

GRAM LIBR
PRO
(PG5)

D AR
PC Y
A IL HM
UPL I
LA/F CO
P
KO
RUCTION
N

ST
FI
GU

N
C

RA
SYSTEM

FTE
RATING

SE
(FIRMWARE)

TOR

CTEC COMM
OPE-

IL
GRA

LO
T

S
B

UN
GRAFTEC

ICATION

PCD
KERNEL
HARDWARE

PCD PROCESSOR (CPU)

INTELLIGENT FUNCTION FIELD BUS CONNECTION

SERIAL DATA PORTS
MODULES (COUNTING, ANALOGUE AND DIGITAL (PROFIBUS DP/FMS,
(RS 232, RS 422, RS 485, TTY)
MEASURING, MOTION INPUT/OUTPUT MODULES LONWORKS®,
AND SAIA®S-BUS
CONTROL, MODEM, ETC.) ETHERNET-TCP/IP)

PROCESS AND OPERATION (HMI)

After the operating system With a BLOCTEC program,

start-up, the entire kernel instructions are processed
BLO
environment is checked and EC CT cyclically.
AFT EC
adjusted to the functions
GR GRAFTEC is used for event-
required by the user.
Uniform structure

RPRETER driven process sequences and

The central processing unit INTE provides fast reaction times.
divides its capacity among
The SASI instruction con-
I

three functional units:

SAS

Coun

figures communications
The interpreter, which channels.
ters

processes user program

Character

START-UP In character mode it is

COMMU

instructions.
mode

possible to transmit and

S
UPT

The communications receive individual

processor, which serves characters.
ents
NI

RR

up to six communications
CA

Text mode regulates the

TE

lem

channels, depending on IO
Tex de

IN
T

N
mo

output of information
ee

requirements.
t

blocks.
m
Ti

The interrupt unit, S-

Bu SAIA®S-Bus is the PCD’s
which registers timing and s proprietary field bus.
counting events and processes Sta
field ndard XOB
exception events according to Standard field buses are supported
buses
predefined rules (XOBs). by powerful drivers implemented in
the system.
Integrated program structures and routines

Processing levels
Processing levels are produced by organization purpose of this cold-start block is to execute the pro- Supply on/
blocks, which are called automatically by the operat- cess initialization that is needed for the application.
ing system in RUN mode. The event-controlled XOB It is followed by cyclical organization blocks COB0…
Start-up
blocks have the highest priority, with XOB16 being COB15 and sequential blocks SB0…SB31, which deal
called when the controller is switched on or after a with progressive process sequences.
“Restart Cold”, after which it cannot be repeated. The

XOB16
Program structure in BLOCTEC
With structured programming the user program is Cyclic organization block COB
broken down into small, self-contained program and In a BLOCTEC structure, the COB organization block
E(nd)XOB16
function blocks, with each block forming part of the defines the sequence in which the program will be
overall program. This structure saves time and costs processed. It contains calls to the program and func-
when writing a program. In addition, a structured tion block subroutines. When the called block has
program makes error detection easier during com- been processed, the program returns to the COB and COB 0
missioning or maintenance. continues from there. When the last instruction in a
COB has been processed, the processor starts on the
first instruction in the next COB.
COB 0 PB 5 FB 7 PB 27 C(all)PB
CPB 5 CFB 7 ..... Program block PB
CFB
A PB contains operations which belong together be- C(all)SB
EFB EPB cause of their functionality. For practical reasons, any
process to be controlled should always be divided into
CPB 9 PB PB 17 its mechanical or electrical functional units. Each of
EPB ..... these units will be assigned to a PB. E(nd)COB 0
CPB 5 EPB EPB
Function block FB
FB 2 Frequently recurring functions are programmed in
CFB 2 FBs. They can be viewed as subroutines and contain
CFB 15
frequently used, elementary processing sequences.
EFB Since they can be used in many applications, FBs
COB1
are often stored in a library. Instances of FBs can be
..... E(nd)COB1
CFB 15 called with different parameters.
FB 15

ECOB ..... COB2

EFB

E(nd)COB 2

Program structure in GRAFTEC

COB15
GRAFTEC enables structured programming for se-
IST 0
quential processes (also referred to as “sequential E(nd)COB15
TR 0 function charts”). Its characteristic features are link-
ST 1 ages or conditions, actions, branches, junctions and
synchronisations.
TR1 TR 2 TR 3
In a sequential block (SB), the user program is sub-
ST 2 ST 5 ST 7 ST 8 ST 9 divided into events called ‘transitions’ (TRs) and ac-
TR 4
TR 9 TR11 TR13 TR15 tions called ‘steps’ (STs). This makes programming
ST 6 ST 10 ST 12 ST 14 in GRAFTEC very simple, and programs retain their
ST 3
TR10 TR12 TR14 TR16
clarity even for complex tasks.
TR 5 TR 6 TR 7
ST 11 ST 13 ST 15 Since every step is dependent on a transition, the
ST 4 operating system processes only the pending transi-
TR 17
TR 8
tions. This procedure allows very fast reaction times
ST 16 when an awaited event occurs.
TR 18

4
 PCS1
PCD1
PCD2
PCD4
PCD6

Operating system routines

1 ms
Operating system Most operating system functions run in the background during the PCD’s
cyclical operation. The main tasks are:
t
routines
– processing time function elements, error messages and the real-time
clock
– managing communications with external devices
– monitoring program cycle times, power supply and battery states
– processing interrupts, e. g. for counting functions
– managing and recording particular events
– time-dependent activities, e. g. delayed output switching
So that it can look after these background tasks, the CPU provides a small
time window once every millisecond.

Event controlled exception block XOB

Cyclic XOB XOBs are called by the PCD operating system using interrupts, i. e.: when the
SAIA®PCD is started up, when an interrupt input is activated, or whenever
t 14, 15
any irregularity is detected in hardware or software.

Integrated program structures and routines

In the XOBs, the programmer is largely at liberty to define the reaction of
the system and the measures to be taken. However, if a fault occurs in the
system that has not been programmed with an appropriate XOB exception
block, the CPU error lamp turns on and the user program will continue (if
the fault permits).
Every error is entered in an error log with the date, time, error type and
the relevant line of the program. If the same error recurs, its frequency is
Acyclic XOB registered (rather than entering it again every time). This log (history) can
be read at any time by the programming tools.
17, 18, 19, 20, 25
t Each XOB is called for a specific event:

XOB Description Priority XOB Description Priority

14 Cyclic XOB 3 5 No response from I/O module 1
15 Cyclic XOB 3 7 System overload 3
8 Invalid opcode 4
17 S-Bus XOB interrupt request 3
9 Too many active tasks
18 S-Bus XOB interrupt request 3
(GRAFTEC) 1
19 S-Bus XOB interrupt request 3
Error handling XOB 10 PB/FB nesting depth overflow 1
STOP 20 Interrupt input INB1 3
11 COB supervision time
0, 1, 2, 4, 5, 7, 8, 9, 25 Interrupt input INB2 3
exceeded 3
t 10, 11, 12, 13, 16, 30 0 Power down 4 12 Index register overflow 1
1 Power down in extension rack 2 13 Error flag set 1
2 Low battery 2 16 Executed on PCD start-up 1
4 Parity error on main bus 30 RIO connection
(PCD6 only) 1 master↔slaves 1

Working with several COB organization blocks

COB0 COB 1 COB2 Organization blocks COB0…COB15 are mainly used to structure an large user
program. By monitoring the cycle time of each COB, it is possible to ensure
COB0 COB 1 COB2 that the program runs without trouble. If an unforeseen event interrupts
its course, a subsequent COB can be activated to instigate the appropriate
N(ext)COB safety measures. This interruption can also be triggered deliberately when
specific functions must be processed at precise, cyclical intervals, e. g. PID
E(nd)COB
N(ext)COB0 E(nd)COB1 E(nd)COB2 control.

E(nd)COB0 E(nd)COB1 E(nd)COB2

5
System resources

All SAIA®PCD control devices have the same internal data Assignment of system resources is static and they are acces-
structure. Only the number of inputs and outputs varies sible to the user, who can read and change them when the
depending on the chosen system. The porting of entire user controller is either stopped or in operation. This procedure
programs or their functions is made easy by this compa- makes commissioning easier, enables effective adjustments
tibility of resources, bringing the user decisive advantages. and allows speedy error detection.
The CPU processes each resource directly at its physical
address, i. e. without a process image. This procedure saves
the unnecessary copying of data and allows instant dialogue
between the user program and the process.

Description Media code Address range Bit info Data / explanatory notes
Inputs I
0…8191 High/Low —
Outputs O
Flags F 0…8191 High/Low Non volatile as standard, however, the address range can be
partitioned into volatile/non volatile
Timers T 0…2 147 483 647 (31 bits)
0…1599 High/Low
Counters C T/Cs use the same address range.
T/C partition can be adjusted (standard: T 0…31/C 32…1599)
Timers are volatile and Counters are non-volatile.
Timebase selectable between 1 ms…10 s (standard 100 ms)
Registers, non volatile R 0…4095 Integer –2 147 483 648…+2 147 483 647 (–231…+231–1)
Floating point ±9.22357 × 1018…±5.42101 × 10–20
ASCII 1…4 ASCII characters
Binary 32 bits
Text block X — All ASCII characters
0…3999
Data block DB — Up to 383 × 32 bits (= 383 register contents) per data block
X RAM — X/DBs use the same address range. X/DBs in the
4000…7999
DB RAM — address range 4000…7999 are always in RAM, i. e. they
can be written to by the user program. DBs 4000…7999
can contain up to 16 383 elements.
Constant K Constant 0…16 383 — 14 bits
Constant ± 2 147 483 647 — 32 bits
K constants can be of a variety of types:
decimal (e. g. –3456), hexadecimal (e. g. A45Fh),
binary (e. g. 11011y) or ASCII (e. g. ‘STOP’ ⇒ 32 bits =
4 characters, 14 bits = 1 character)
Time constants can be loaded into a time function
element (T) and have a special format:
T#nnnMS or S (e. g.: T#250MS corresponds to 250 ms,
regardless of the chosen time base)
Semaphore — 0…99 — Latching of parts of the program when there is access
by two or more CPUs to the same media
Index register — 0…16 — 1 per COB or XOB
Real-time clock R 0…4095 — hh/mm/ss, week/day of week, month/day of month, year
BLOCTEC structure
Organization blocks COB 0…15 — COBs are main parts of the program. Every application
Exception blocks XOB 0…30 — consists of at least one COB (the number is not
Program blocks PB 0…299 — important). The operating system processes all available
Function blocks FB 0…999 — blocks consecutively and repeats this cyclically.
PBs and FBs can be nested in up to 7 levels.
GRAFTEC structure
Sequential blocks SB 0…31 — —
Steps ST 0…1999 —
Transitions TR 0…1999 —
Parallel branches — 0…31 —

6
 PCS1
PCD1
PCD2
PCD4
PCD6

Status Flags Addressing modes

Various instructions not only write a result to a medium The performance of the PCD instruction set is very substan-
(register, counter, etc.) but also set 4 status flags (arithmetic tially affected by the addressing modes available, as most
status) according to the result. These can be tested by the of the 100+ commands allow elements to be addressed in
user program. The 4 status flags are: four different ways:
P (Positive) Direct: Element address specified directly.
Will be set if the result of an arithmetic instruction is positive.
Indirect: The address is stored in a register.
N (Negative)
Indexed: The content of the index register is added to the
Will be set if the result of an arithmetic instruction is negative.
element address.
Z (Zero)
Indirect, indexed: A combination of indirect and indexed.
Will be set if the result of an arithmetic instruction is zero.
Example of indexed addressing:
E (Error)
SEI 10 ; Index = 10
Will be set if an instruction cannot be executed.
SETX O32 ; Output 42 is set

Accumulator (A = ACCU) Configuration memory

The accumulator is used for the continuous storage of an
All PCD systems contain an area of memory that keeps
intermediate result obtained from the instruction that has
important data from being lost, independently of data protec-
just been processed. The following instructions can be used
tion by battery:
to read the (logical) result of the last operation:
– SAIA®S-Bus settings
STH I 33
– Modem configuration
This instruction copies the state (1 or 0) of input 33 to
– CPU manufacturing data
accumulator.
– 5 register contents (PCD1) or 50 register contents (PCD2 to
OUT O 49 PCD6), which can be written with the SYSWR instruction
This instruction reads the state of the accumulator and and read with SYSRD.
writes it to output 49.
Apart from being read and set by means of instructions, the Flexible user memory
accumulator can also be given the state of a status flag:
User memory can be partitioned into sectors

Data blocks (DB)

CMP R 33 for code, text and data blocks according to the
R 34 requirements of the user program. There are
This instruction compares the contents of registers 33 and instructions for transferring data between dif-
34. If their values are the same, status flag Z (zero) is set. ferent resource types, e.g. flags, registers, tim-
ers, counters, data blocks.
ACC Z
This instruction copies the state of status flag Z (zero) to – 1 register (32 bits) takes 4 bytes in a
the accumulator. data block, or several bytes in a text
(e. g. “2147483647”)
rakters (TX)
Text cha-

– 1 text character occupies 1 byte

Convenient text output – 1 program line occupies 4 bytes
The SAIA®PCD operating system is capable of storing large
quantities of text (up to 8000 texts) that, for example, is
Program

to be transmitted to a display or a printer. The text can

(P)

contain strings, control characters and PCD data or symbol

references, which allows design freedom.
Character strings are written in quotation marks, control
System resources

characters (e. g. line space) in brackets and PCD data is pre-

ceded by a $ sign (e. g. Contents of register 296 ⇒ $R0296). Configuration of a PCD system with the PG5
programming tool
The PCD operating system permits a wide variety of opera-
tional possibilities. The user can configure the system’s PCD
type, memory size and communications interfaces, using
the PG5’s hardware configurator.

7
 PCS1
PCD1
PCD2
PCD4
Instruction set of the SAIA®PCD PCD6

IEC 1131-3 Instruction set

®
The SAIA PCD programming languages are based on the The instruction list language includes 113 instructions.
international IEC 1131-3 standard. This standard defines The SAIA®PCD complements usual instruction set of a tra-
a set of basic instructions, which have been extended by ditional PLC with a number of high-level instructions, saving
the addition of more powerful SAIA-specific instructions. long sequences of instructions or time-consuming function
Programming structures defined by IEC 1131-3 can also blocks. Programs written with the SAIA®PCD need less space
be created by specific instructions in the SAIA®PCD. This in memory and are easier to understand.
allows the user to obtain the best from a controller, saving
All data are memory-oriented. The logical linkages of bit
valuable development time.
instructions are stored in an accumulator. All word, integer
and floating point operations are executed as fast, register-
to-register instructions.

Logical operations (1 bit) Communications instructions

Read or link element states ¹): Interface assignment: SASI
STH, STL, ANH, ANL, ORH, ORL, XOR
Handling single characters and intelligent text output:
Set elements or set accumulator: SRXD, STXD/STXT
OUT, OUTL, SET, RES, COM, ACC, DYN
Handling control lines: SICL, SOCL
Set elements with delay:
Control of telegram traffic for PCD data:
SETD, RESD
SRXM, SRXMI, STXM, STXMI
¹) Elements = inputs/outputs, flags, timer/counter states or individual bits
from a register Establishing a connection and diagnostics: SCON

Word instructions (register operations)

Program structure and control instructions
Load, increment, decrement registers, counters and timers:
LD, LDL, LDH, DSP, INC, DEC for BLOCTEC: COB/ECOB, PB/EPB, FB/EFB (parameters
can be supplied to FBs), XOB/EXOB
Index register handling: SEI, INI, DEI, STI, RSI
for GRAFTEC: SB/ESB, IST, ST/EST, TR/ETR
Read and write multiple bits (up to 32) or digits from and
to registers: Relative, direct and indirect jumps: JR+, JR-, JPD, JPI
BITI, BITIR, BITO, BITOR, DIGI, DIGIR, DIGO, DIGOR Call program and function blocks (BLOCTEC) and sequential

Instruction set of the SAIA®PCD

Logical linking of registers: AND, OR, NOT, EXOR blocks (GRAFTEC): CPB, CPBI, CFB, CSB

Shift operations: SHIU, SHID, SHIL, SHIR

Special instructions
Rotate operations: ROTU, ROTD, ROTL, ROTR
Read and write the real-time clock: RTIME, WTIME
Register transfer: MOV, PUT, GET, TFR, TFRI, COPY
Partitioning of volatile/non-volatile flags, and counters/timers:
DEFVM, DEFTC
Integer and floating point calculations Definition of timebase and of write-protected memory:
Basic arithmetic operations: ADD, SUB, MUL, DIV DEFTB, DEFWPR, DEFWPH
Square root, compare operations: SQR, CMP Call special function
Basic arithmetic operations: The CSF instruction allows frequently occurring or complex
FADD, FSUB, FMUL, FDIV, FSQR, FCMP user routines can be executed directly by the CPU in its
native code. The benefits are fast processing and economies
Trigonometric operations: FSIN, FCOS, FATAN of programming time.
Other, higher mathematical operations: FEXP, FLN, FABS
Format conversion: IFP, FPI Read, write and compare system data
The special SYSRD, SYSWR and SYSCMP instructions give the
user access to internal system data. Typical applications are:
Analogue value processing and PID command
Analogue value input and output: BITI, BITIR, BITO, BITOR – Access to the local configuration memory on EEPROM
(see page 7)
Call PID control algorithm: PID – Time and date manipulations
– Accurate time measurement in milliseconds
– Access to XOBs or triggering an XOB
– Reading all communications definitions
– Writing and reading the flash-card

8
 PCS1
PCD1
PCD2
PCD4
Communication PCD6

The PCD operating system allows 6 communications chan- The following example shows how three register contents
nels to be run with different protocols for the physical and can be represented differently.
logical connections.
Without formatting 123456
Connections –7890

Modem

Andere
TCP/IP
RS 232
RS 422
RS 485

FTT 10
5
Mode/Standard Defined field length 123456
0–7890
Character and text mode X X X – X – – 000005
Open data mode – – – X – – – All zeroes displayed 00123456
SAIA®S-Bus X X X X X – – –0007890
PROFIBUS FMS/DP – – X – – – – 00000005
LONWORKS® – – – – – X – Field length and decimal point 123.456
EIB ¹) – – – – – – X 0–7.890
000.005
Belimo MFT – – – – – – X
Decimal point only 1.23456
M-Bus ¹) – – – – – – X
–0.789
Modbus X X X X X – – 0.05
¹) These standards are supported by additional modules.

SAIA®S-Bus
Assigning a serial interface S-Bus is a proprietary field bus, included in every PCD
The SASI instruction tells a communications channel what operating system, which the user can utilize at no additional
definition will be used for the serial connection: cost. S-Bus is characterized by the following:

UART Baud rate, character length, parity, stop bits, – high transmission reliability, due to CRC16 error detection
timeout – high speed data transfer using binary protocol
MODE Character/text, S-Bus, PROFIBUS – supports remote data transmission and diagnostics via
DIAG Flags and registers modem and the OPC standard or Ethernet-TCP/IP
– drivers also available for many process management
systems
Protocols
S-Bus can be used to produce master/slave networks, and
Character mode also multi-master networks with the integral gateway func-
This mode allows single characters to be transmitted and tion. For details see technical information 26/370.
received via a register. When mode C is selected, it automati-
cally manages the handshaking control signals. PROFIBUS FMS/DP
PROFIBUS is an internationally accepted open field bus
Mode Effect standard and is supported by the PCD operating system in
MC0 Without control lines and without control characters two application-specific versions.
MC1 With control lines RTS and CTS
MC2 With control characters XON and XOFF – PROFIBUS FMS for communications tasks at field and
MC3 With echo (e. g. for operator devices) cell level
MC4 With transmission reversing for RS 485 – PROFIBUS DP for exchanging data with field devices
and decentralized peripherals
Example: "UART: 9600, 7, E, 1;"
"MODE: MC1;" The PG5 programming package includes a configurator
"DIAG: F100, R4000;" for PROFIBUS networks, which considerably simplifies the
definition of bus parameters, communications relationships
The user program is notified of the results of communication:
and objects.
receipt of a character, readiness to send, error diagnostics
and completion of a job. The 512-character send and receive
LONWORKS®
buffers can match data exchange with the sequence of the
user program. PCD systems can be used as host nodes in LONWORKS® net-
Communication

works. All standard network variable types currently speci-

Text mode fied under the LONMARK® are supported. The transmission
of “explicit messages” also allows connection to LON nodes
Text mode allows a sequence of predefined characters to be
transmitted with the same automatic features as character with proprietary communications objects. The configuration
mode. The PCD operating system can store up to 4000 texts. of a PCD host node is supported by use of the SAIA®LON
The length of each text is limited only by the amount of configurator within the PG5 programming package.
user memory. Operation of the user program is not affected
during text output. Ethernet with SAIA®S-Bus or open data mode
Texts can contain PCD data, e.g. for outputting the time, date Open data mode allows TCP or UDP data packages to be
or contents of a register to a printer or screen. Data can be exchanged with foreign systems via Ethernet. It allows very
transferred either in decimal or hexadecimal format. This flexible matching, because the specific application protocol
requires accompanying instructions to define the output is constructed with the user program.
format of data in the text.

9
 PCS1
PCD1
PCD2
PCD4
Programming PCD6

The programming unit for SAIA®PCD process controllers The SAIA®PG5 programming tools will very quickly become
is a standard personal computer running the SAIA®PG5 familiar to the user, running under Microsoft Windows
programming tools. Apart from programming, the user can and using the familiar Windows graphical user interface.
also test program sequences, optimise the process and test Programming languages are based on the international
for errors. Development and configuration programs are standard IEC 1131-3.
therefore provided, which make it much easier to realize
For details about the scope of performance of the PG5 pro-
complex process sequences and exchange data with foreign
gramming tool, see technical information 26/362.
devices.

Instruction list (IL)

Instruction list is a low-level machine language for general
purpose use. It represents the entire PCD instruction set, and
is used to implement the other forms of program representa-
tion. IL instructions are processed consecutively.

Function block diagram FUPLA (FBD)

The function block diagram is a form of graphical program- on the left side of a function box, the right side represents
ming. It uses digital engineering symbols as its instructions, the outputs or the result of the function. Depending on the
selecting them as function boxes from a comprehensive li- application, function boxes are configured with data, which
brary and connecting them by signal lines. Inputs are shown can be adjusted on-line by the programming tools.

Sequential function chart (SFC)

The sequential function chart is used to define the structures
of sequential processes. It represents the time sequence
of process execution in the form of steps (actions) and
their controlling transitions (events). The PCD operating
system provides a virtual processor for SFC programs. It
processes sequential structures efficiently, without the time-
consuming cycling of a continuous program.
Programming

Ladder diagram (LD)

The ladder diagram represents connective
networks in a similar way to the circuit path of
a relay contact plan. This programming lan-
guage is essentially limited to Boolean signals.
More complex functions can also be integrated
within a ladder diagram, but only in the form
of closed function boxes.
 PCS1
PCD1
PCD2
PCD4
Commissioning and Debugging PCD6

Connection of a programming unit

The operating system of any PCD supports at least 2 serial
ports. One of them is used to connect the programming unit
(PGU). This connection has the highest priority compared
with all other serial communications interfaces (RS485,
modem, Ethernet-TCP/IP). The programming unit not only
starts up programs for the first time, but can also be used
to execute other useful functions:
– Single-step processing of a program up to a defined halt
point, or to a specific instruction, or to an error. The PG5 debugger includes familiar functions, such as step-
– Setting, loading and modifying all elements, data and text. by-step, breakpoints, the editing of data and instructions, plus
the “synchronous data view”, which continuously displays the
– Displaying all data in a previously chosen format, with content of the accumulator, status flags, resources and the
data being continuously refreshed during operation. index register.

System analysis, debugging and maintenance

The SAIA®PCD operating system has several integrated func- Loading updated program blocks
tions for user program analysis and maintenance. The unique download-in-run function does not just allow
individual program blocks to be updated during operation.
XOB for error handling
The operating system can simultaneously download up to
XOBs are started by the system as soon as an exceptional
five changed blocks and start them synchronously. This
event occurs. The reaction of the system to these events
has the advantage of increased reliability when loading
is user-programmable (e. g. in response to XOB2 “Battery
nested programs and complicated program modifications,
supply error”, an appropriate SMS text message could be
compared with traditional solutions.
transmitted to the maintenance engineer).
Remote diagnosis and telemaintenance
Analysis of error log
The operating system of every SAIA®PCD has an integral
Errors handled by XOBs are also logged in the history list.
modem connection. No programming of any kind is required
This can be displayed and analysed using the PG5 program-
to establish a modem connection between the controller
ming tools.
and the PG5 programming tools.
Breakpoints / step-by-step
Firmware update
“Conditional run”, which has been integrated into the operat-
The ..M170 CPU allows firmware to be updated by the PG5.
ing system, allows monitoring of system resources, accu-
This enables the user to take advantage of new features, in-
mulator, status flags or the index register. As soon as a

Commissioning und Debugging

cluding the possibility of control & monitoring via Internet/
monitored element assumes a defined value, the CPU stops
intranet with the web server.
processing the program at the current line. The program can
be executed step-by-step to allow each line to be checked
and processed individually.

Overview of user library

The PCD operating system supports a large number of pre- groups serve to connect with communications units or
coded functions. These are available as function blocks or as drivers for intelligent function modules (e.g. the servo
FBoxes, each of which fulfils a particular function. Other drives).

Alarm and maintenance Serial interfaces Control & monitoring PGU

HMI drivers
Character mode
Modem Text output Configurator
Text mode
Mobile phone, pager Text manipulation Up/Downloader
Assignment
Internet OPC Debugger
Diagnosis
DLL

PCD user program

FUPLA boxes for Drivers for Connections to
HEAVAC, electrical Servo motors Connections to SAIA®S-Bus
GENIbus, MP-Bus Stepper motors PROFIBUS FMS Ethernet-TCP/IP
EIB, BACnet Fast counters PROFIBUS DP LONWORKS®
System macros SSI interface M-Bus MODBUS
Energy management PID controllers 3964-R

Building automation Factory automation Standard field bus Other field buses
Hardware overview

Smart solutions for comfort and safety

PCS1 compact controller
– up to 20 digital inputs and up to 4 digital outputs 24 VDC plus 8 relay
outputs 4 A/250 VAC (4 “make” contacts/4 change-over relays) plus up to
16 analogue inputs (up to 4 × 0…10 V plus 12 × Pt/Ni 1000)
– user memory of 384 kBytes
– up to 4 interfaces (serial, SAIA®S-Bus, LONWORKS®)

PCD1 series
– up to 32 inputs/outputs or
up to 64 inputs/outputs if using Saia-Burgess Controls Ltd.
digital modules with 16 I/Os Bahnhofstrasse 18
– up to 140 kBytes user memory CH-3280 Murten / Switzerland
– up to 2 interfaces (serial, PROFIBUS DP, LonWorks® Telephone ++41 26 672 71 11
Ethernet-TCP/IP) Telefax ++41 26 670 44 43
E-mail: [email protected]
Homepage: www.saia-burgess.com
Support: www.sbc-support.ch
PCD2 series
– up to 128 inputs/outputs or
Saia-Burgess Controls Kft.
up to 255 inputs/outputs if using
digital modules with 16 I/Os Liget utca 1
H–2040 Budaörs
– up to 1MByte user memory
Telephone 023 / 501 170
– up to 6 interfaces (serial, Telefax 023 / 501 180
SAIA®S-Bus, PROFIBUS FMS/DP,
LONWORKS®, Ethernet-TCP/IP) E-mail: [email protected]
Homepage: www.saia-burgess.hu
Support: www.sbc-support.ch
PCD4 series
– up to 510 inputs/outputs or Your local contact:
up to 1020 inputs/outputs if using digital
modules with 16 I/Os
– up to 1 MByte user memory
– up to 6 interfaces (serial, SAIA®S-Bus,
PROFIBUS FMS/DP, LONWORKS®,
Ethernet-TCP/IP)
– up to 2 CPUs

PCD6 series
– up to 5100 inputs/outputs
– up to 1 MByte user memory
– up to 30 interfaces (serial, SAIA®S-Bus,
PROFIBUS FMS/DP, Ethernet-TCP/IP)
– up to 6 CPUs

Printed in Switzerland 26/354 E3 04. 2002 TA20 Subject to change without notice.