Programming Manual

PacDriveTM
System

PDM_UserMan_us
Article number: 17130061-001
Edition: 10.2003
Impressum

Imprint
© All rights reserved to ELAU AG, also in case of patent right
applications.
No part of this documentation and the related software and firm-
ware may be reproduced, rewritten, stored on a retrieval system,

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transmitted or translated into any other language or computer lan-
guage without the express written consent of ELAU AG.
Any possible measure was taken to ensure the that this product
documentation is complete and correct. However, since hardware
and software are continuously improved, ELAU makes no repre-
sentations or warranties with respect to the contents of this product
documentation.

Trademarks
PacDrive is a registered trademark of ELAU AG.
All other trademarks mentioned are the exclusive property of their
manufacturers.

ELAU AG ELAU Inc.

Dillberg 12 4201 W. Wrightwood Ave.
D-97828 Marktheidenfeld Chicago, IL 60639
Phone: 09391/606-0 Phone: 773 342 8400
Fax: 09391/606-300 Fax: 773 342 8404
eMail: [email protected] [email protected]
PD_UserMan_00_us.FM

Internet: www.elau.de www.elau.com

page 2 Programming Manual ELAU AG

 Contents

Contents
1 On this manual 9
1.1 Introduction ............................................................................................ 9
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1.2 Symbols, Signs and Forms of Depiction .............................................. 10

2 General Safety Notes 11

2.1 Basics .................................................................................................. 11
2.2 Depiction of Safety Notes .................................................................... 12
2.3 Use as Directed ................................................................................... 13
2.4 Selection and Qualification of Staff ...................................................... 14
2.5 Residual Risks ..................................................................................... 14
2.5.1 Installation and Handling ..................................................................... 15
2.5.2 Protection against Touching Electrical Parts ....................................... 16
2.5.3 "Safely Separated Low Voltages" ........................................................ 17
2.5.4 Potentially Dangerous Movements ...................................................... 18

3 System Overview 19
3.1 Drive Concepts of Packaging Machines .............................................. 19
3.2 Structure of the PacDrive™ Automation System ................................. 21
3.3 Concept ............................................................................................... 22
3.4 Components ........................................................................................ 23

4 The Basics of IEC-61131 25

4.1 Programmable Logic Controls ............................................................. 25
4.2 IEC-61131 ............................................................................................ 28
4.2.1 The Programming Model ..................................................................... 29
4.2.2 The Communication Model .................................................................. 31
4.2.3 Program Organization Units POU ........................................................ 43
4.2.4 The Programming Languages ............................................................. 49
4.2.5 Operators ............................................................................................. 71
4.2.6 Operands ............................................................................................. 87
4.2.7 References .......................................................................................... 92
4.3 Special Features of the PacDrive ........................................................ 93
4.3.1 General Function ................................................................................. 93
4.3.2 Data Types of the Control Configuration ............................................. 94
4.3.3 Size of Programs and Variable Ranges ............................................... 94

5 Programming Guidelines 95
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5.1 The Concept of Mapping ..................................................................... 95

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5.1.1 The Structure of Packaging Machines ................................................. 95

5.1.2 The Automation System ....................................................................... 96
5.1.3 From Problem Definition to Solution ..................................................... 97
5.1.4 Method for Solving a Defined Problem ................................................. 98

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5.2 The Structure of a Project .................................................................... 99
5.2.1 Program Organization with Tasks ........................................................ 99
5.3 ELAU Program Structure .................................................................... 109
5.3.1 ELAU Functions and Function Blocks ................................................ 112
5.3.2 Parameter Transmission .................................................................... 113
5.4 Designator Names .............................................................................. 114
5.5 Upper and Lower Case ...................................................................... 116
5.6 Valid Characters ................................................................................. 116
5.7 Create a PacDriveTM project .............................................................. 116
5.7.1 Problem Definition .............................................................................. 116
5.7.2 Hardware ............................................................................................ 118
5.7.3 Configuration ...................................................................................... 119
5.7.4 User Program ..................................................................................... 122
5.7.5 Observe & Operate ............................................................................ 128
5.7.6 Document and Save a Project ............................................................ 130
5.8 Expansion of the Example by Positioning Functions .......................... 131
5.8.1 Problem Definition .............................................................................. 131
5.8.2 Hardware ............................................................................................ 133
5.8.3 Configuration ...................................................................................... 134
5.8.4 User Program ..................................................................................... 136
5.8.5 Observe & Operate ............................................................................ 138
5.8.6 Document and Save the Project ......................................................... 142

6 Error Search Strategies 143

6.1 Method ............................................................................................... 143
6.2 LEDs ................................................................................................... 144
6.3 PLC configuration ............................................................................... 145
6.4 Message Logger ................................................................................. 146
6.4.1 Function .............................................................................................. 146
6.4.2 The Functions of a Message Logger in Detail .................................... 147
6.4.3 Filtering Messages ............................................................................. 149
6.4.4 Establish a Connection with the PacDrive Controller MAx-4 in Case of an
Error 150
6.5 Further Possibilities for Diagnosis ...................................................... 152
6.5.1 Trace .................................................................................................. 152
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6.5.2 Debugging .......................................................................................... 152

6.5.3 Check Library ..................................................................................... 152

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6.5.4 Call Hierarchy (CallStack) .................................................................. 153

7 Teleservice 155
7.1 Overview ............................................................................................ 155
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7.2 Direct Telecommunication Connection .............................................. 157

7.2.1 Principle ............................................................................................. 157
7.2.2 Selection of a Suitable Modem .......................................................... 160
7.2.3 Settings in the Project for the PacDrive Controller ............................ 162
7.2.4 Settings on the Remote PC ............................................................... 167
7.2.5 Establishing a Connection with Remote PC / PacController ............. 191
7.2.6 Trouble Shooting ............................................................................... 192
7.3 Telecommunication network over Remote PC to the PacDrive Controller
197
7.3.1 Principle ............................................................................................. 197
7.4 Telecommunication Connection via Router to Several PacDrive Control-
lers 198
7.4.1 Principle ............................................................................................. 198
7.5 Connection via Internet ...................................................................... 199
7.5.1 Direct Connection via IP Address ...................................................... 199
7.5.2 VPN (Virtual Private Network) Connection ........................................ 200
7.6 Access to the PacDrive Controller with a standard browser (not permited)
201
7.6.1 Prinzip ................................................................................................ 201

8 Networks 203
8.1 Basic Concept .................................................................................... 203
8.1.1 Peer to Peer ....................................................................................... 203
8.1.2 Client-Server ...................................................................................... 204
8.2 Topologies ......................................................................................... 204
8.2.1 The Term “Topologies“ ...................................................................... 204
8.2.2 Bus ..................................................................................................... 205
8.2.3 Star .................................................................................................... 206
8.2.4 Loop ................................................................................................... 207
8.2.5 Mixed Forms ...................................................................................... 208
8.2.6 Transmission Media ........................................................................... 210
8.3 MAC Address ..................................................................................... 211
8.4 Access Methods ................................................................................ 212
8.4.1 CSMA/CD .......................................................................................... 212
8.4.2 Token Passing ................................................................................... 213
8.5 Overview of Network Operating Systems .......................................... 214
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8.5.1 Novell NetWare .................................................................................. 214

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8.5.2 Microsoft Windows NT and Windows 2000 ........................................ 214

8.6 TCP/IP ................................................................................................ 214
8.6.1 Comparison of Reference Models ...................................................... 214
8.6.2 Important Protocols ............................................................................ 215

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8.6.3 IP Addressing ..................................................................................... 217
8.6.4 Subnet Mask ...................................................................................... 217
8.6.5 IP Address Classes ............................................................................ 218
8.6.6 Private IP Networks ............................................................................ 218
8.6.7 IP Address Assignment ...................................................................... 219
8.6.8 Name Resolution ................................................................................ 220
8.6.9 IP Host and NetBIOS Name Resolution ............................................. 220
8.7 Coupling of Networks ......................................................................... 221
8.7.1 Additional Devices for Network Coupling ........................................... 221
8.7.2 Tools for Dealing with TCP/IP Problems ............................................ 224

9 System Data 231

10 Time Diagrams - MotorController 233

10.1 Switching on Enable ........................................................................... 233
10.2 Lifting Enable ...................................................................................... 234
10.2.1 Ramping-down within Maximum Ramping-down Time ...................... 234
10.2.2 Stop Time Limit Exceeded, Drive Is Brought to a Controlled Stop ..... 235
10.2.3 Stop Time Limit Exceeded, Drive Brought to an Uncontrolled Stop ... 236
10.3 Error Reaction "B" .............................................................................. 237
10.3.1 Ramping down within Stop Time Limit ............................................... 237
10.3.2 Stop Time Limit Exceeded ................................................................. 238
10.4 Error Reaction "A" .............................................................................. 240
10.5 Overload Switchoff ............................................................................. 241
10.5.1 Overload Switchoff within Maximum Switchoff Time .......................... 241
10.5.2 Overload Switchoff with Transgression of Maximum Stopping Time . 243

11 Version Numbers and Compatibility 245

11.1 Version Designation in General .......................................................... 245
11.2 Compatibility EPAS-4 - MAx-4 ........................................................... 245
11.3 Compatibility MAx-4 - MC-4 ............................................................... 245
11.4 Compatibility MAx-4 - IEC-Libraries ................................................... 245

12 ENI-4 247
12.1 Function of the ENI ............................................................................. 247
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12.1.1 Multi-User Operation .......................................................................... 248

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12.1.2 Version Management ......................................................................... 248

12.1.3 Access by External Clients ................................................................ 249
12.2 Structure and Communication of the ENI .......................................... 249
12.3 Structure in the Data Storage System / ENI Explorer ........................ 250
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12.4 The ENI in EPAS-4 ............................................................................ 251

12.5 ENI Admin and ENI Control ............................................................... 254

13 Frequently Asked Questions 257

14 Glossary 259

15 APPENDIX 285
15.1 Contact .............................................................................................. 285
15.2 Further Literature ............................................................................... 286
15.3 Product Training ................................................................................ 288
15.4 Modifications ...................................................................................... 289
15.5 Index .................................................................................................. 291
15.6 Form for Error Report ........................................................................ 295
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Contents

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page 8 Programming Manual ELAU AG

 1.1 Introduction

1 On this manual

1.1 Introduction
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Before using ELAU components for the first time, you should
familiarize yourself with this operating manual.
In particular, observe the safety notes described in chapter 2.
Only persons who meet the criteria for "Selection and Qualification
of Staff" (see chapter 2.4) are allowed to work on ELAU
components.
One copy of this manual has to be available for staff working on the
components with access at any time.
This manual is to help you use the component safely and expertly
and to use it as directed.
Observe this manual. This will help to avoid risks, reduce repair
costs and down times and increase the lifetime and reliability of the
products.
You also need to observe the valid rules for the prevention of
accidents and for environmental protection in the country and place
where the device is used.
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ELAU AG PacDrive page 9

1 On this manual

1.2 Symbols, Signs and Forms of Depiction

The following symbols and signs are used in this document:

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Depiction Meaning

„ First level enumeration sign.

– Second level enumeration sign.

Action symbol: The text following this symbol inclu-

 des an instruction for action. Execute the instruction
actions in the given order, from top to bottom.
Result symbol: The text following this symbol con-
9 tains the result of an action.
If the describing text contains special terms (e.g.
Italics
parameters) these are written in italics.
If the manual contains program code, this is marked
Serif font
by Serif font.
Information symbol: This symbol marks notes and
useful tips for using the product.

Warning sign: Safety notes can be found in the rele-

vant places. They are marked by this symbol.

After this symbol, information about contents of the

chapter follows as guideline assistance.

Table 1-1: Symbols, signs and forms of depiction

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page 10 PacDrive ELAU AG

 2.1 Basics

2 General Safety Notes

This chapter contains general requirements for working safely.
Every person using ELAU components or working on ELAU
components has to read and observe these general safety notes.
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If activities involve a residual risk, you will find a clear note in the
respective places. The note describes the risk that may occur and
preventive measures to avoid that risk.

2.1 Basics
The ELAU components are built according to the state of
technology and generally accepted safety rules. Nevertheless, their
use may cause a risk to life and limb or material damage if:
„ you do not use the components as directed

„ work on the components is not done by experts or instructed

staff
„ you inexpertly alter or modify a component

„ you fail to test the protective measures in place after installation,

commissioning or servicing
„ you do not observe the safety notes and regulations.

Only operate the components in perfect technical condition, as

directed, with regard to safety and risks and observe this manual.
The flawless and safe operation of the components requires
appropriate transport, storage, mounting and installation as well as
careful maintenance.
In case of any circumstances that impair the safety and cause
changes in the operating behavior, immediately put the
component(s) to a stop and inform the service staff in charge.
In addition to this manual, observe
„ the prohibiting, warning and mandatory signs on the component,
the connected components and in the switching cabinet
„ the relevant laws and regulations

„ the operating manuals of the other components

„ the universally valid local and national rules for safety and the
prevention of accidents.
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2 General Safety Notes

2.2 Depiction of Safety Notes

Risk categories
The safety notes in this manual are grouped into different risk

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categories. The table below shows which risk and possible
consequences the symbol (pictograph) and the signal words
indicate.

Pictograph Signal word Definition

Indicates an immediately dangerous

situation that will result in death or very
DANGER!
serious injuries if the safety rules are
not observed.

Indicates a possibly dangerous

situation that can result in serious
WARNING!
injuries or major material damage if the
safety rules are not observed.

Indicates a possibly dangerous

situation that might result in material
CAUTION!
damage if the safety rules are not
observed.

Table 2-1: Risk categories

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page 12 PacDrive ELAU AG

 2.3 Use as Directed

2.3 Use as Directed

The ELAU components are designed for installation in a machine/
plant or for combination with other components to form a machine/
plant. The components may only be used under the installation and
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operating conditions described in this documentation. You must use

the accessories and ancillary parts (components, cables, etc.)
mentioned in the documentation. You must not use any foreign
objects or components that are not explicitly approved by ELAU.
"Use as directed" also means that you
„ observe the Operating Manuals and other documentations (see
appendix),
„ observe the instructions for inspection and maintenance.

Use other The operating conditions at the place where the device is used
than directed must be checked on the basis of the given technical data
(performance information and ambient conditions) and observed.
The device must not be put into operation until it is guaranteed that
the useable machine or the plant in which the motor is installed
meets in its entirety EC directive 98/37/EC (machine directive).
In addition, observe the following norms, directives and regulations:
„ DIN EN 60204 Safety of machines:
Electrical equipment of machines.
„ DIN EN 292 part 1 and part 2 Safety of machines:
Basics, general design guidelines.
„ DIN EN 50178 Equipment of high-voltage plants with electronic
operating means.
„ EMC directive 89/336/EEC
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2 General Safety Notes

2.4 Selection and Qualification of Staff

This manual is aimed exclusively at technically qualified staff with
detailed knowledge in the field of automation technology.
Only qualified staff can recognize the significance of safety notes

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and implement them accordingly.
This manual is aimed in particular at design and application
engineers in the fields of mechanical and electrical engineering, at
programmers, service and commissioning engineers.

Working on Work on electrical equipment must only be done by qualified

electrical electricians or by instructed staff supervised by an electrician
equipment according to the electrotechnical rules.
An electrician is a person who, due to his vocational training, know-
how and experience as well as knowledge of the valid regulations,
is able to:
„ evaluate the work he is supposed to do

„ identify potential risks

„ implement suitable safety measures.

2.5 Residual Risks

We minimized the health risk for people by means of appropriate
construction and safety technology. Nevertheless, there is a
residual risk, since the components work with electrical current and
voltage.

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 2.5 Residual Risks

2.5.1 Installation and Handling

WARNING!
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Risk of injury while handling the unit!

Risk of injury due to squeezing, cutting or hitting!
„ Observe the universally valid construction and safety rules for
handling and installation.
„ Use suitable installation and transport facilities and use them
professionally. If necessary, use special tools.
„ Take precautions against squeezing.

„ If necessary, use suitable protective clothing (e.g. safety

glasses, safety shoes, protective gloves).
„ Do not stay under pending loads.

„ Remove any leaking liquids from the floor immediately to avoid

skidding.
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2 General Safety Notes

2.5.2 Protection against Touching Electrical Parts

Touching parts carrying a voltage of 50 Volts or higher can be
dangerous. When electric appliances are operated, certain parts of
these appliances inevitably carry a dangerous voltage.

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DANGER!
High voltage!
Life hazard!
„ Observe the universally valid construction and safety rules for
working on high-voltage units.
„ After installation, check the fixed connection of the earth
conductor on all electric appliances according to the connection
plan.
„ Operation, even for short-term measuring and test purposes, is
only permitted with an earth conductor firmly connected to all
electric components.
„ Before accessing electrical parts with voltages exceeding 50
Volts, disconnect the unit from mains or power supply and lock it
out. After switching off, wait for at lest 5 minutes before touching
any components.
„ Do not touch electrical connections of the components while the
unit is on.
„ Before switching on the unit, cover all voltage carrying parts to
prevent accidental contact.
„ Provide for protection against indirect touching (EN 50178 /
1998 section 5.3.2).

DANGER!
High leak current!
Life hazard!
„ The leak current is greater than 3.5 mA. Therefore the units
must have a firm connection to the power grid (according to DIN
EN 50178 / 1998 - equipment of high-voltage systems).
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 2.5 Residual Risks

2.5.3 "Safely Separated Low Voltages"

PELV Signal voltage and control voltage of the PacDrive units are <33 V.
Protective-Extra- In this range the specification as PELV system according to IEC
Low-Voltage 364-4-41 includes a protective measure against directly and
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directly touching dangerous voltages by means of a "safe

separation" from the primary to the secondary side in the plant/
machine. ELAU urgently recommends to execute the plant/
machine with safe separation.

DANGER!
High voltage due to wrong connection!
Life hazard or risk of serious injury!
„ Only units, electric components or cables with a sufficient safe
separation of the connected power supplies according to EN
50178 / 1998 (equipment of high-voltage systems with electronic
operating means) may be connected to the signal voltage
connections of these components.
„ Make sure that the existing safe separation is retained
throughout the entire current circuit.

FELV When using ELAU components in systems that do not include a

Functional- safe separation as a means of protection against directly or
Extra-Low- indirectly touching dangerous voltages, all connections and
Voltage
contacts (e.g. MAx-4, Sub-D connector, serial inerface) that do not
comply with protection class IP2X must be permanently covered.
The cover or device connection must be such that it can only be
removed with the help of a tool. The protective measure must be
observed on all connected devices.
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2 General Safety Notes

2.5.4 Potentially Dangerous Movements

There can be different causes for potentially dangerous
movements:
„ mistakes in wiring or cable connection

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„ software errors

„ faulty components

„ errors in measuring value and signal encoders

„ operating mistakes

The protection of people must be insured by superior means or

monitoring on the plant side. You must not rely on the internal
monitoring in the drive components alone. Monitoring or measures
are to be provided according to a risk and error analysis by the
plant builder according to the specific conditions of the plant. The
valid safety rules for the plant are to be included in this process.

DANGER!
Potentially dangerous movements!
Life hazard, serious injury or material damage!
„ No persons are allowed within the motion range of the machine.
This is to be ensured by means of devices like protective fences,
grids, covers or photoelectric barriers.
„ The fences and covers must be sufficiently strong to withstand
the maximum possible motion energy.
„ The emergency stop switch must be located very close to the
operator. Check the operation of the emergency stop before
starting up the plant.
„ Secure against unintentional start by enabling the mains
contactor of the drives via an emergency off circuit or by means
of the function 'safe stop'.
„ Before accessing the danger zone, bring the drives to a safe
stop.
„ To work on the plant, power must be turned off and locked out.

„ Avoid operating high-frequency, remote-control and radio

devices in the vicinity of the plant's electronics and connecting
wires. If the use of those devices is inevitable, check system and
plant for possible malfunctions before first operation. In some
cases a special EMT check may be necessary.
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 3.1 Drive Concepts of Packaging Machines

3 System Overview

3.1 Drive Concepts of Packaging Machines

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Modern machine concepts in the packaging industry are

characterized by the need for high dynamism, flexibility, modularity
and efficiency. Packaging machines were traditionally equipped
with a mechanical vertical shaft, which drove the secondary
motions in the machine usually with mechanical components with
complicated motion functions. Designing such a machine flexibly
for different products is a highly complex task. Even minor changes
in the packaging process, particularly in case of a product change,
require major modifications and standstill time.
Packaging machines with electronic vertical shafts, by contrast,
permit full flexibility. Electronic servo drive systems replace cam
and coupling gears, and a virtual electronic vertical shaft ensures
that the motion axes are synchronous. Any pulse and angle
synchronous movements are determined by a central control.
Unplanned machine states, such as stop or emergency off
situations or initialization movements can be realized
synchronously. Dynamic changes of the goods to be packed or the
packaging material in the plant, (like slippage of the products to be
packed or expansion of the packaging material) can be registered
by sensors while the machine is running and eliminated by
modifying the corresponding drive movements. This development
substantially changes and highly simplifies the classical mechanical
machine concept. The structure of the packaging machine can be
broken down into modules that are easy to apply and can be
standardized.
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3 System Overview

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Fig. 3-1: Sketch of a packaging machine

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 3.2 Structure of the PacDrive™ Automation

3.2 Structure of the PacDrive™ Automation System

The PacDrive™ automation system offers a technically and
economically optimal solution for electronic packaging machines.
PacDrive™ consists of an efficient PC-based control, the MAx-4
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PacController and the digital MC-4 MotorControllers, which include

the mains connection unit, the end-stage power and the servo
regulator of the individual axes (Fig. 3-2).
The MAx-4 PacController is the intelligent head of the system, and
is based on an industrial PC. The MAx-4 PacController
synchronizes and coordinates the motion functions of the
packaging machine. Using an IEC 1131-3 soft PLC, it ventures into
applications previously reserved for standard PLCs. The individual
PLC or positioning tasks can be broken down into several parallel
tasks, which are implemented with the EPAS-4 programming
environment according to the IEC 1131-3 standard. Up to 40 servo
axes can be connected to a MAx-4 PacController and supplied with
positioning data.
The circular digital SERCOS real-time bus realizes the safe data
exchange with the MC-4 MotorControllers. Due to the use of optical
fiber technology, the data bus is insensitive to electromagnetic
disturbance and cyclically supplies the decentralized MC-4
MotorControllers with new set values at a data rate of 4MBaud. All
internal states of the axes can be checked via the real-time bus and
processed in the MAx-4 PacController.
In addition to digital and analog inputs and outputs, the MAx-4
PacController has two serial interfaces and one Ethernet interface.
A variety of process visualization and control systems can be
connected to the PacDrive™ M via the integrated OPC interface.
Further peripheral components can be connected via field bus
interface modules. The MAx-4 PacController can act as a field bus
master or slave.
The international field bus standards CANopen, PROFIBUS-DP
and DeviceNet are supported. The built-in interfaces enable remote
diagnosis via telephone modem or Internet. Via TCP/IP, PCs can
communicate with the MAx-4 PacController and diagnose the state
of the control directly.
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 3.3

page 22
TCP/IP Ethernet
3 System Overview

Industrial PC PacController
MAx-4
Concept

I/O Module BT4/DIO-1 IEC 61131-3 PLC

BT4
IEC 61131-3 Motion Control
PacNet

drive bus SERCOS

CANopen
PROFIBUS
DeviceNet

PacDrive
Ethernet/IP Motor Power supply
MC-4 MC-4 MC-4 MC-4 Controller PS-4 PS-4
MC-4

Axis group 1 Axis group 2

PD-8 PD-8

n xSCL055

peripheral I/Os

PLC (superior to the PacController) via a field bus.

SCL055
Power + SERCOS SCL055
SCL055

Fig. 3-2: System overview of the PacDrive™ automation concept

SCL055
SCL055
SM-Servomotor SM-Servomotor
initiator (opt)

SM-Servomotor SM-Servomotor

Alternatively, the PacController can be connected to a conventional

SCL055-Servomotor SCL055-Servomotor SCL055-Servomotor

ELAU AG
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 3.4 Components

3.4 Components

Automation Toolkit EPAS-4

EPAS-4 has extensive and proven functions and tools. A key
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advantage of EPAS-4 is that all components are integrated and

intuitive.
For you as a user, this means:
Quick familiarization, eas handling, all tools integrated.
Libraries ELAU maintains extensive libraries geared to the packaging
industry, helping you obtain cost effective and speedy answers to
any concern. They will also help you to improve the quality of your
user programs.
The highlights of EPAS-4 Automation Toolkit
„ Runs under Windows (as of Win95)

„ Programming language IEC 61131-3

„ SCOPE tool (oscilloscope functions)

„ Diagnosing tool

„ very good debugging features

„ serial or TCP/IP connection to the MAx-4 PacController

MAx-4 PacController
The MAx-4 PacController, a Pentium based controller hardware
with VxWorks real-time operating system, realize the PLC and
motion functions.
A PacController synchronizes, coordinates and generates the
positioning functions for a maximum of 44 drives of a food and
packaging machine.
For HMI tasks, various standard HMIs are used. Whether low-cost
clear text or IPC - no problem for the flexible MAx-4.
The highlights of the MAx-4 PacController
„ Pentium controller hardware

„ VxWorks real-time operating system

„ IEC 61131 PLC and motion control

„ Coordinates up to 47 axis

„ Standard interfaces to low cost operating panels or PC based HMI

„ compact book size case

„ Ethernet interface

„ Standard field busses

„ VarioCam® Motion Control

„ SERCOS drive bus

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ELAU AG PacDrive page 23

3 System Overview

MC-4 MotorController
Leading-edge The digital MC-4 MotorController is characterised by its compact
technology and autonomous structure suitable for wall mounting as well as its
leading-edge technology. The innovative MC-4 has the mains
supply unit, end stage and software regulator for one axis

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integrated in a compact casing. As it communicates with the
PacController or PacPC only via fibre optical cable, it is also
suitable for a decentralized structure. It requires no user program,
comes with single- and multi-turn processing features as standard
and configures itself with the help of the electronic name plate in
the SM motor.
The highlights of the MC-4 MotorController
„ World-wide voltage range

„ Integrated mains supply unit

„ Max. power 34,5 / 69 kVA

„ Automatic motor recognition

„ Minimum size

„ Safety input Inverter Enable

„ 250 % overload

„ Integrated SERCOS interface

„ few types

SM-Motor
Highly Machines with fast cycle rates require highly dynamic AC servo
dynamic servo motors. The SM motor series offers you as a user an optimum
motors motor concept for your food and packaging machines. The dynamic
brushless servo motors are furnished with high-resolution encoders
(single-turn or multi-turn) and electronic name plate. Smooth
surface and compact size meet the requirements of the target
market.
The highlights of the SM motors
„ Low mass moment of inertia

„ 4-fold overload

„ Reliable high-voltage technology

„ Leading-edge magnetic technology

„ High-resolution single- or multi-turn encoder

„ Electronic name plate

„ Plug in junction box

„ IP 65 protection
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page 24 PacDrive ELAU AG

 4.1 Programmable Logic Controls

4 The Basics of IEC-61131

4.1 Programmable Logic Controls

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Around the end of the 1980s, a development started that made pro-
grammable logic controls (PLCs) central components of automation
technology.
The PLC systems have various advantages compared with conven-
tional relay technology: The systems can be adjusted fast in case of
process changes, they are easily extendable etc. The function and
structure of the systems are independent of the size of the PLC. A
PLC consists of hardware and software. The hardware comprises a
processor with storage components and further electronics for the
connection of input and output systems. Modular PLC systems con-
sist of various components such as component carriers with system
bus, power unit, central processing unit and application storage,
digital inputs and outputs and intelligent components for analog
data processing or drive control.
For the input and output level, a standardized voltage of 24 V has
been set. By means of the standardized voltage, a resistance that
complies with the industrial environment was achieved.
The software comprises the operating system and the application
program. The operating system manages the system resources
and the organizational functions. In addition, the operating system
ensures a controlled start after the operating voltage is switched on,
it takes charge of error management and enables the exchange of
information via communication groups. It coordinates the execution
of the application program, which maps the logic course of the con-
trol task.
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4.1 Programmable Logic Controls

Controller
Power On

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Delete the remanent Marker,
Counter, Times and the output
image.

Operating System
- Start / Stop Save inputs in the input image. Inputs
- etc ...

PLC program active

Send output image to the outputs. Outputs

Fig. 4-1: Flow structure of a “classical“ PLC

An PLC starts processing the application program immediately after

it is switched on (in the so-called RUN mode). Directly after the
system is switched on, all non-remanent memories are reset and
the processing cycle starts scanning in the input image.Then, the
complete PLC instruction list is processed. In the next step, the out-
put image that was created through the instruction list is sent to the
outputs. The program cycle starts anew with scanning in the input
image. The cycle time is probably the most important speed crite-
rion for a PLC. In practical operation, it typically ranges from some
ms to several hundred ms.

NOTE
The sequence structure described here applies in particular to sin-
gle-task systems. Since the PacDriveTM system is a multi-task
system, there are deviations.
See also „Special Features of the PacDrive TM “, page 86.
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 4.1 Programmable Logic Controls

The simple flow structure shows its advantages when data and pro-
grams are manipulated in ongoing operation. Almost all
programming environments allow for the change of all variables
during a processing cycle. Due to the set program structure, pro-
gram sequences can be loaded at run time (Online Change), since
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there are always exact starting points at the beginning and the end
of a cycle.
When these new systems were launched, the producers had to
make their customers, who were used to contactors, acquainted
with the programming of the new systems. For that reason,
numerous but mostly short-lived attemps were made to find a pro-
gramming language that facilitates the change from the traditional
detailed wiring diagram to the PLC program. The programming lan-
guages Function Block Diagram, Ladder Diagram and Instruction
List were developed then.
At that time, however, developers failed to define a universally bin-
ding standard for programming PLC systems. In consequence,
each producer had specific characteristics in the programming lan-
guages Function Block Diagram, Ladder Diagram and Instruction
List. Therefore, company standards emerged in various geographic
regions, such as Siemens STEP 5 in Europe, Allen Bradley in the
U.S. and MITSUBISHI in the Far East.
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4.2 IEC-61131

4.2 IEC-61131
In recent years, the complexity of the applications and thus the pro-
gramming costs grew at a superproportional rate. The producer-
specific standards did not ensure that the programs could be re-

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used.
Due to the above reasons, the so-called IEC standard IEC 61131
was worked out at the beginning of the 1990s under the lead of the
International Electrotechnical Commission (IEC). Within the context
of this process, the new languages Structured Text (ST) and
Sequential Function Chart (SFC) were defined in addition to the
existing languages Ladder Diagram (LD), Function Block Diagram
(FBD) and Instruction List (IL). IEC 61131 sums up the require-
ments for a modern PLC system. The standard was not intended as
a rigid specification, but as a guideline for PLC programming.
Accordingly, the standard describes the significant properties of an
PLC while leaving producers enough room to use their own
implementation.
IEC-61131 tried to bring modern software engineering into the PLC
world. This was necessary due to more complex processes and
functions and the cost explosion regarding the development of
application programs.
Tested and standardized software modules which can be re-used
was regarded as a solution. However, this is made more complica-
ted due to:
„ direct addressing

„ untypisized variables,

„ no type check.

In general, the objectives of IEC 61131 are:

„ application of software engineering methods with the aim of
reusable software modules
„ holistic approach to problem solutions

„ abstraction of complex tasks into smaller modules

„ definition of unambiguous interfaces

„ standardization of the language scope in order to increase porta-

bility.
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 4.2 IEC-61131

4.2.1 The Programming Model

In addition to the elements for the programming and organization of
the application program, IEC 61131 also gives guidelines for
modelling and structuring PLC composite systems. To structure the
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system, the concepts of configuration and resource were

introduced.
The model also takes into consideration properties such as multi-
processor systems, modern PLC operating systems featuring multi-
tasking properties, unlimited number of analog and digital inputs
and outputs and the ability to communicate with other PLCs and
computers.
A configuration defines the structure of a system. For example, this
can be a PLC with several, even networked, CPUs on machine cell
level. A configuration is comprised of one or more resources, which
represent sub-controls with own signal processing functions. In a
real configuration, a resource is represented by a PLC CPU, which
in most cases has multi-tasking capabilities.
A resource is structured with the help of one or more programs
which are controlled via tasks. A task is an executable program unit
to which both a priority and an execution type are assigned. There-
fore, execution lines with different properties can be formulated
within one and the same program. Thus, not only cyclic taks with a
system-wide uniform cycle time are possible. Cycle times can also
be combined and event-controlled program units can be made
available in the system. By assigning a certain priority to a task,
CPU time is allocated to a resource.
The run time properties of the complete program, which can run
indepentently in a CPU, are defined by linking programs to a certain
task. Thanks to the flexibility of the system modulation, a program
can be linked to several tasks, thus creating several instances with
different run time properties.
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4.2 IEC-61131

Configuration

Resource

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Task

Program

Function block Function

Function block Function Function

Fig. 4-2: The programming model according to IEC 61131

IEC 61131-3 supports local data that can be declared in programs,

function blocks or functions. Local data can only be accessed in the
corresponding program hierarchy level and represent a mechanism
for data encapsulation. Of course also resource-wide available glo-
bal data available for all program elements are possible. If multi-
tasking systems are used, however, access to global data is a risk
source for inconsistent data. In addition, there are directly accessi-
ble data with fixed addresses within the PLC address range.
Usually, those are the addresses of the inputs (I), outputs (O) and
markers (M, also called flags).
Another aspect of the programming model describes the re-booting
behavior of the control. Both the cold restart and the hot restart
(reset) are described. With a cold restart, the program is loaded
anew. All variables are set to their initial values. Either a default
initial value or a value defined by the programmer is set. All tasks of
the resource are started. In case of a hot restart (reset), by contrast,
the variables are not set to their initial values. Instead, the values
held in the storage prior to the interruption will be taken over.
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 4.2 IEC-61131

4.2.2 The Communication Model

An essential aspect in the description of the structural elements is
the data exchange. With the help of the communication model defi-
ned in the IEC 61131, it is possible to create well structured and in
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particular modularized PLC programs, which is a fundamental basic

characteristic for the development of application-oriented, re-
usable program modules. In priniciple, IEC 61131 provides for the
following communication possibilities:
„ access paths (VAR_ACCESS)

„ global variables (VAR_GLOBAL, VAR_EXTERNAL)

„ call parameters

„ communication modules (IEC 61131-5)

All elements of a configuration communicate with one another and

also with other computer systems exclusively via defined access
paths. In addition, global variables are used for the simple commu-
nication of programs within a configuration. Global variables can be
placed and used on configuration, resource and program level.
The data exchange within programs is effected via call parameters,
input and output variables or function values. Although high-level
language programmers are well acquainted with this structural tool,
it brought fundamentally new aspects into conventional PLC pro-
gramming. Call parameters and transfer variables allow for the
definition of unambiguous interfaces and thus make an important
contribution to the encapsulation of functionality.
In addition to the elements of the communication model described
so far, also special „communication modules“ can be used. They
are of monolithic nature and are linked into a program. Thanks to
those modules, data exchange between sender and receiver is
self-sufficient. Communication services are defined in part 5 of IEC
1131, which is still being edited, however.
Looking at the communication model of IEC 1131, the good support
of standardized software modules is particularly striking. Thanks to
the encapsulation of functionality and data, a clearly defined inter-
face and a side-effect free behavior, the acceptance of the modules
among users has increased significantly.
An important standardization of programming languages according
to IEC 61131-3 is the definition of data types. The norm includes
various elementary data types from which derived and user-defined
data types can be composed.
The user can use standard data types and self-defined data types
for programming. Assigned to each identifier is a data type that
defines how much memory space is reserved and which values
correspond to the memory content.
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4.2 IEC-61131

Elementary Data Types

IEC 1131-3 defines five groups of elementary data types. Their
related general data type is given in brackets.
„ Bit string (ANY_BIT)

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„ Integer with and without algebraic sign (ANY_INT)

„ Floating point (ANY_REAL)

„ Date, time (ANY_DATE)

„ String, duration, derived (ANY)

No. of
Data type Description Range Initial
bits
BOOL boolean 1 [0, 1] 0

BYTE bit string 8 8 [0, ..., 255] 0

WORD bit string 15 16 [0, ..., 65535] 0

DWORD bit string 32 32 [0, ..., 4,295 E09] 0

LWORD bit string 64 64 [0, ..., 1,845 E19] 0

Table 4-1: Bit string

No. of
Data type Description Range Initial
bits
SINT short integer 8 [-128, ..., +127] 0

INT integer 16 [-32768, ..., 0

+32767]

DINT double integer 32 [-231, ..., +231-1] 0

63,
LINT long integer 64 [-2 ..., +263-1] 0

USINT short integer 8 [0, ..., +255] 0

UINT integer 16 [0, ..., +65535] 0

UDINT double integer 32 [0, ..., +232-1] 0

64-1]
ULINT long integer 64 [0, ..., +2 0

Table 4-2: Integer with and without sign

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 4.2 IEC-61131

No. of
Data type Description Range Initial
bits
REAL floating-point 32 see IEC 559 0.0
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number

LREAL long floating-point 64 see IEC 559 0.0

number

Table 4-3: Floating point

No. of
Data type Description Range Initial
bits
DATE date like 0001-01-01
DWORD

TOD time like 00:00:00

DWORD

DT date and time like 0001-01-01-

DWORD 00:00:00

Table 4-4: Date, time

No. of
Data type Description Range Initial
bits
TIME duration like 0s
DWORD

STRING string Default=80 "empty" string

Table 4-5: Date, time

Example of a string declaration:

str:STRING(35):='This is a string'

NOTE
The PacDrive™ M system does not support the LWORD, LINT and
ULINT data types.

Data types - notation

The data types listed above can be represented in various forms:
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BOOL, BYTE, WORD, DWORD, LWORD

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4.2 IEC-61131

These data types can be represented as follows:

„ TRUE or 1

„ FALSE or 0

„ decimal, hexadecimal (16#), octal (8#) or binary (2#) representa-

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tion
Example for WORD: 234, 16#ff, 2#1001_1100_0011_1111
SINT, INT, DINT, LINT, USINT, UINT, UDINT, ULINT
Decimal, hexadecimal (16#), octal (8#) or binary (2#) representa-
tion. The underscore (_) separates units.
Examples:
Decimal representation for INT: -123, +234, 0, 1_000
Hexadecimal representation for INT: 16#F1, 16#0A_1B
Binary representation for INT: 2#0001_0011_0111_1111
REAL, LREAL
Normal decimal representation with decimal point or exponential
representation.
Example: 1000.23 and 1.23e3 and 1.23E3 and 1.23E03 are inter-
preted identically.
TIME (Time duration)
TIME#, t# or T# stand at the beginning of a time/date designation.
Overflow is allowed (e.g. 25 hours).
d stands for days, h for hours, m for minutes, s for seconds and ms
for milliseconds. The underscore (_) separates units.
Example: T#2d_26h_4m_12s_123ms
DATE, TIME_OF_DAY or TOD, DATE_AND_TIME or DT
DATE# or D# stands for a date
TIME_OF_DAY# or TOD# stands for a time of day
DATE_AND_TIME# or DT# stands for time of day and date
Date: D#1998-12-07 stands for July 7, 1998
Time of day notation: TOD#12:00:00.123
Date and time: 1998-12-07-12:00:00.123
STRING
Inverted commas ‘ ‘ contain a string.
The dollar sign $ leads control characters (line feed, tabs).
Examples:
String, Control charcter: ‘This is a line feed character $L‘
Empty String:

Derived data types

According to IEC 1131-3, data types can be derived from the ele-
mentary data types. Data types that can be derived are:
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„ Arrays (ARRAY)

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 4.2 IEC-61131

„ Pointers (POINTER)
„ Enumeration types
„ Structures (STRUCT)
„ References
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With the help of derived data types, complex structures can be

managed with simple constructs: With just one assignment, com-
plex data can be transmitted to functions and function blocks. The
derived data types can be composed from the basic data types and
derived data types.
Arrays (ARRAY)
An array is composed of several individual variables of the same
type.
One-, two- and three-dimensional arrays are supported by elemen-
tary data types. Arrays can be defined in the declaration part of a
block and in the global variable lists.
Syntax:
<array_name>: ARRAY [<ug1>..<og1>,<ug2>..<og2>] OF <elem.
type>.
ug1, ug2 represent the lower limit of the array range and og1, og2
the upper limit. The limiting values have to be integer.
Example:
Card game: ARRAY [1..13, 1..4] OF INT;
Initialization of arrays:
Either all elements of an array are initialized or none of them.
Examples for initializations of arrays:
arr1 : ARRAY [1..5] OF INT := 1,2,3,4,5;
arr2 : ARRAY [1..2,3..4] OF INT := 1,3(7);
(* short for 1,7,7,7 *)
arr3 : ARRAY [1..2,2..3,3..4] OF INT := 2(0),4(4),2,3;
(* short for 0,0,4,4,4,4,2,3 *)
In a two-dimensional array, array components are accessed with
the following syntax:
<array_name>[Index1,Index2]
Example:
CardGame[9,2]
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4.2 IEC-61131

Pointer (POINTER)

NOTE
You should avoid using pointers, since they cannot be checked by

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the compiler and at run time.
In most cases, the parameter transfer with VAR_IN_OUT is the bet-
ter solution.

Pointers feature a data type and an address. The data type is the
data type of the data elements to which the pointer is pointing. The
address is the address (the position) where the data element is
stored in the memory unit.
In pointers, the address of variables or function blocks is stored
during the run time of a program.
Pointer declarations have the following syntax:
<identifier>: POINTER TO <data type/function block>;
A pointer can point to any data type and function block, including
self-defined ones.
With the address operator ADR, the address of a variable or
function block is assigned to the pointer.
The dereferentiation of a pointer is effected via the content operator
"^" after the pointer identifier.
Example:
pt:POINTER TO INT;
var_int1:INT := 5;
var_int2:INT;
pt := ADR(var_int1);
var_int2:= pt^; (* var_int2 is now 5 *)
Enumeration type
An enumeration type is a self-defined data type which is made up of
a number of self-defined string constants. Those constants are cal-
led enumeration values.
The enumeration values are known throughout the entire project,
even if they were declared locally in a block. They start with the
keyword TYPE and end with END_TYPE.
Syntax:
TYPE <identifier>:(<Enum_0> ,<Enum_1>, ...,<Enum_n>);
END_TYPE
The <identifier> can take on one of the enumeration values and will
be initialized with the first one. The values are compatible to full
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 4.2 IEC-61131

A number x can be assigned to the <identifier>. If the enumeration

values are not initialized, the enumeration begins with 0. In the
initialization process, make sure that initial values are ascending.
The validity of the number will be checked at run time.
Example:
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TrafficLights: (red, yellow, green:=10); (*red has the

initial value 0, yellow 1, green 10 *)
TrafficLights:=0; (* Traffic lights have the value
red*)
FOR i:= red TO green DO
i := i + 1;
END_FOR;
The same enumeration value must not be used twice.
Example:
TrafficLights: (red, yellow, green);
Color: (blue, white, red);
Error: red must not be used for both TRAFFIC LIGHTS and
COLOR.
Structures (STRUCT)
A structure is composed of several individual data elements that
belong together from the user’s point of view. The individual ele-
ments can belong to different data types.
Structures start with the keyword TYPE and end with END_TYPE.
Structure declarations have the following syntax:
TYPE <structure name>:
STRUCT
<variable declaration 1>
.
.
<variable declaration n>
END_STRUCT
END_TYPE
Nested structures are allowed. The only limitation is that variables
cannot be put on addresses. (AT declaration is not allowed!)
Example for a structure definition named Polygonzug:
TYPE Polygonzug:
STRUCT
Start:ARRAY [1..2] OF INT;
Point1:ARRAY [1..2] OF INT;
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4.2 IEC-61131

Point2:ARRAY [1..2] OF INT;

Point3:ARRAY [1..2] OF INT;
Point4:ARRAY [1..2] OF INT;
End:ARRAY [1..2] OF INT;
END_STRUCT

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END_TYPE
Components of structures are accessed with the following syntax:
<structure_name>.<component name>
If there is e.g. a structure named „week“, which includes a compo-
nent named „Monday“, it is accessed in the following way:
Week.Monday
References
The self-defined data type reference is used to create an alternative
name for a variable, constant or function block.
References start with the keyword TYPE and end with END_TYPE.
Syntax:
TYPE <identifier>: <assignment expression>;
END_TYPE
Example:
TYPE message:STRING[50];
END_TYPE;

Declaration of variables and constants

Variables are identifiers defined by the user. They are used as wild
cards for the data of the PLC program. A main characteritsic of
variables is that their content can be changed. Under IEC 61131-3,
variables are used for storing and processing information. Variables
are identifiers defined by the user.
IEC 61131-3 includes five different categories of variables:
„ Global variables

„ Local variables

„ Input variables

„ Output variables

„ Input and output variables.

Input, output and input/output variables are related to a program, a

function or a function block. They can be used in the specific way
only. Within the assigned program organization unit (POU), they
can be changed in both reading and writing manners, outside the
assigned POU, only in the defined manner.
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 4.2 IEC-61131

According to IEC 61131-3, a marker is a sequence of characters,

numbers and underscores (_). The sequence has to start either
with a letter or an underscore. Markers must not contain blank spa-
ces, special characters and ä, ö, ü. 32 significant characters are
distinguished. Case sensitivity is not recognized.
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The variables defined by the user have to be declared (explained).

All variables used in a POU have to be explained in the declaration
part of the POU.
The declaration part must contain one of the following keywords in
text form:
„ VAR

„ VAR_INPUT

„ VAR_OUTPUT

Declarations are separated by a semicolon and end with the key-

word VAR_END.

Keyword Use of the variable

VAR within the POU

VAR_INPUT coming from outside; cannot be changed within the POU

VAR_OUTPUT supplied from the POU to the outside

VAR_IN_OUT coming from outside; can be changed within the POU

VAR_EXTERNAL supplied by the configuration; can be changed within the

POU

VAR_GLOBAL declaration of global variables

Table 4-6: Keywords for variable declaration

Variable attributes

Keyword Use of the variable

RETAIN variable is buffered (zero-voltage proof)

CONSTANT constant “variable“; cannot be changed

AT allocation of memory place

Table 4-7: Keywords for variable declaration / attributes

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4.2 IEC-61131

Priority Allocation Start behavior

1 (highest) zero-voltage proof by hot restart:
RETAIN (battery-buffered) restoration if voltage returns

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or after stop

2 start value set by declaration cold restart:

start values for defined new
start

3 (lowest) start value for data type cold restart:

(predefined) start values for defined new
start

Table 4-8: Allocation of start value types by priority

NOTE
New initial values can be assigned to derived data types.

Variables have various scopes of validity

They can be declared outside a POU and used program-wide,
included into the POU as call parameters or be of local importance
for the POU.
If a variable is declared in a function block, it is valid for this very
function block only. If it is declared in a program, it is valid for all
function blocks declared in this program.
Variables
<name>:<TYP>;
Example: Test: BOOL;
Constant expressions
VAR CONSTANT <name>:<TYP>:=<value>
Example: VAR CONSTANT Test: BOOL:=TRUE;

Localized - firmly addressed - variables

Such variables resemble conventional PLC technology. They are of
certain importance in IEC 61131-3 systems since they can be used
to link two properties:
„ All process signals are linked via localized variables.

„ Overlappings of localized variables are allowed and can be used

as a programming tool.
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 4.2 IEC-61131

„ The definition of a certain memory space for variables starts with

the AT identifier and defines three parameters:
„ the start address (after the AT identifier as offset of zero)
„ the memory range (input, output, marker)
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„ the length of the variables in the memory (by means of a varia-

ble type abbreviation)
In this case,
„ the first letter of the length definition is a „%“

„ the second letter is

– I for input , Q for output, M for marker

– the length of a variable in the memory (by means of variable
type abbreviation)
„ the third letter defines the length:

– X for bits (the bit address is always complemented in

„Byte.N“, e.g. 1.0),
– B for byte,
– W for word,
– D for double and
– L for long word.
Examples:
%IB24, %QX1.1, %MW12

Overlapping location of variables

Overlapping locations of variables are allowed, e.g. %MB12 is the
first byte of %MW12 and the first byte of %MD12. Also on bit level,
this kind of overlapping is desired and to be used in a meaningful
way: %MX12.0 is the first (least significant) bit of %MB12.

Initialization of variables
In principle, each variable is initialized after a cold restart. Usually,
the default value is 0 or FALSE. A user-specific setting to another
value is of course possible. In the declaration, it is assigned with
the = sign.
The initialization can also be effected within derived data types
(arrays, structures). The necessary syntax is shown in the example.
Example:
VAR
a : INT := 13;
b : STRING := ‘this is a string‘;
c : REAL := 1.1;
END_VAR
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4.2 IEC-61131

VAR
a : myStruct :=
(
state := TRUE,
inputValue := 2.5

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);
END_VAR

VAR
a : ARRAY[1..10] OF INT :=
1, 2, 2(4), 5, 6, 7, 8, 9,10;
END_VAR

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 4.2 IEC-61131

4.2.3 Program Organization Units POU

IEC 61131-3 limited the diversity of module types used in existing
producer-specific PLC programming models. With so-called pro-
gram organization units (POUs), the program organization is made
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easier and more homogenous.

In earlier systems, the implicit, non-transparent and producer-
dependent meaning of individual modules or module areas had
made it difficult if not impossible even for experienced program
developers to change to a PLC of another producer.
By structuring a POU into program, function and function block, a
comprehensible depth was chosen, making it possible to manage
the complete application-specific implementation.

Program
This POU type represents the “main program“. All variables of the
complete program to which physical addresses are assigned (such
as inputs and outputs of the PLC) have to be declared in this POU
or on a higher level (resource, configuration). Access to global
variables and access paths.

Function
A function describes a complex linking logic that has no „memory“,
i.e. no static variables. A special feature of a function is that it will
always return the same result if the input values are the same.
Example:

Fig. 4-3: The AND connection is a boolean standard funciton

Function block
If an intelligent module with a memory is needed, the function block
(FB) with local static variables offers the necessary basis. An FB
(e.g. time or counter) can return different results even if the input
data are the same (e.g. regarding a time or counter). According to
the new norm, each instance of an FB has its own „encapsulated“
data range where the calculations are done: the instance (see
below).
In order to standardize typical PLC functionalities, the new standard
introduced standard functions and function blocks. This library is an
important basis for uniform, producer-independent programming of
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4.2 IEC-61131

Example:
The switch-on delay TON (Timer ON) is a function block (standard
FB). If the Boolean variable „1“ is created at INPUT (IN), the link
time PT (time value) is started. If the time ran out, output Q takes on
the Boolean variable „1“. At output ET (elapsed time) the present

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actual value of the time can be read.

Fig. 4-4: Switch-on delay TON (Timer ON)

In summary, a POU can be regarded as a unit that can be transla-

ted by the compiler of a PLC programming environment
independently of other program parts. The properties of a POU
allow for a wide-reaching modularization of the application program
and the re-use of implemented and tested software modules. In
order to enable program modules to access POUs, at least the
declaration of the call interface is required (prototype). Translated
program parts can later be linked into a joint program (linker). In
contrast to some high-level languages, IEC 61131 knows no validity
range for POUs. In a project, the name of a POU is global and
cannot be assigned more than once. After its declaration, a POU is
globally available to all other POUs.

Structure of program organization units

POUs consist of a declaration part and an instruction part.
In the declaration part, the variables are declared.
Following the declaration part, the instruction part describes the
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Keyword POU Comment

PROGRAM program This is a main program, which ena-
bles access to the PLC periphery.
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Global variables and access paths

are defined here.

FUNCTION_BLO function block Has input and output variables; is

CK used very often for program crea-
tion.

FUNCTION function Simple PLC component which

expands the stock of operations in
programing.

END_FUNCTION End mark of the POU.

Table 4-9: Program organization units with keywords

Functions
Functions can be coded in all IEC 61131-3 languages except SFC.
The return value is declared with the name of the function.
Example:
FUNCTION TEST: REAL
(* -> Data type of the return value is REAL *)
(* Declaration part*)
VAR_INPUT
Switch1: BOOL;
Switch2: BOOL;
END_VAR
VAR
Intermediate result: BOOL;
END_VAR
(* Instruction part*)
TEST:= Switch1 AND Switch2;
(* -> Assign return value to function *)
END_FUNCTION

NOTE
IEC 61131-3 defines standard functions, which are supported by
most implementations. These standard functions are explained in
detail in the Programming Manual -Reference-.
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4.2 IEC-61131

Function Blocks
Function blocks are used to set input, output and internal variables.
States of an FB call are buffered from cycle to cycle. In that pro-
cess, the program code of the FB creates changes of the input,
output and internal variables.

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Only the input and output variables can be reached from the calling
program. Calls from other FBs are allowed, from all languages into
all languages.
Example:
FUNCTION_BLOCK Counter
(* Declaration part*)
VAR_INPUT
iMode : INT; (* 0 = Reset, 1 = Count *)
END_VAR
VAR_OUTPUT
iCounter : INT; (*actual counter value*)
END_VAR
(* Instruction part*)
IF iMode = 0 THEN
iCounter:= 0; (*Reset*)
ELSEIF Mode = 1 THEN
iCounter:= iCounter + 1;
ENDIF;
END_FUNCTION_BLOCK

NOTE
IEC 61131-3 defines standard function blocks which are supported
by most implementations. These standard function blocks are
explained in detail in the Programming Manual -Reference-.

IEC 61131-3 provides for the instancing of function blocks: An

instance is a structure in which all internal variables, inputs and out-
puts of a call of an FB are stored. In consequence, a program which
calls FB1 five times has five instances of FB1, one for each call.
The advantage of this rather uncommon object-oriented procedure
is that the program diagnosis can be made exactly to the call and
without side effects. With an automatic declaration, modern tools
help carry out this instancing: For a call of an FB, an instance name
which manages the data of this call is set.
An important characteristic is that all instances use the same pro-
gram code of the FB. For that reason, changes in the program code
have the same consequences in all calls. Thus, an instance is no
copy of the FB for a call.
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Example:

Function block A
(instance 1)
local data
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Program A Functions block A

Global (code)
local data Data local data

Function block A
(instance 2)
local data

Fig. 4-5: Instancing

For each instance, a copy of the data areas is created.

Function block A is instantiated in two calls: For each call there is a
structure (with the name of the instance) which contains the call-
specific variable values without side effects.
Instance 1 and instance 2 in the above example are local data
(structures) in the calling program. These local instance data can
be input variables for other function blocks or programs.
This instancing, which is rather unusual for the traditional PLC pro-
grammer, enables a side effect-free processing of variables and
their diagnosis with the programming tool, which has been standard
in modern PC-based programming environments. The convenient
benefit of the absolute lack of side effects for the diagnosis of the
program flow by far justifies the additional complication of the
instancing: In older PLC environments, the code of an FB was
copied several times and program changes were then done in each
code copy.
Programs
Programs are superior program organization units: A program calls
up functions and function blocks, in some implementations also
other programs. They can be written in all languages.
In contrast to function blocks, programs are not instanced. They do
not feature a memory function for local data if they are called up
more than once.
Program example:
PROGRAM Main
(* Declaration part*)
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VAR
counter_1 : Counter; (* instance of FB counter *)
iActCount : INT;
END_VAR
(* Instruction part*)

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IF bfirstCycle THEN
counter_1(Mode := 0);
(* -> Call of FB counter with reset mode *)
ELSE
counter_1(Mode := 1);
(* -> Call of FB counter with counter mode*)
END_IF
actCount := counter_1.Out;
(* -> access to output variable of counter_1*)
END_PROGRAM

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 4.2 IEC-61131

4.2.4 The Programming Languages

Sequential Function Chart (SFC), Instruction List (IL), Ladder Dia-
gram (LD), Function Block Diagram (FBD) and Structured Text (ST)
are supported as programming languages. Each language is suited
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for special applications and for the solution of particular problems.

The syntax of the programming languages is exactly specified in
the norm, so that the user can be sure that at least the identical
syntax is used in all IEC 61131 compatible development packages.

Instruction List (IL)

Instruction List (IL) is the assembler among the programming lan-
guages for PLCs. Regarded as the mother of PLC programming, IL
is mainly used in Europe. IL is excellent for processing simple
sequential programmes. If loop constructions are necessary, howe-
ver, IL has a tendency to get rather unclear.
IL is a low-level language derived from earlier assemblers, working
accumulator-oriented. Per line of program code, just one action
(such as load in accumulator, save in register) can be performed.
Flow control, such as branches, are executed with coordinated and
uncoordinated jumps and jump marks. Comments are added after
the control statements in the line.
Each instruction begins in a new line and comprises an operator
and, depending on the kind of operation, one or several operands,
separated by commas.
In front of each instruction, an identification mark can be used, follo-
wed by a colon (:) .
A comment has to be the last element in a line. Empty lines can be
inserted between instructions.
Example:

Jump
Operator Operand Comment
mark
LD 17

ST lint (* comment *)

GE 5

JMPC next

LD idword

EQ instruct.sdword

STN test

next:
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Modifiers and Operators in IL

In IL, the following modifiers and operators can be used.
Modifiers:
„ C for JMP, CAL, RET: The instruction is only executed if the

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result of the preceding expression is TRUE.
„ N for JMPC, CALC, RETC: The instruction is only executed if the
result of the preceding expression is FALSE.
„ N for others: Negation of the operand (not of the accumulator)

In the following table all operators in IL are listed with their possible
modifiers and their corresponding meaning.

Modi-
Operator Meaning
fiers
LD N set actual result equal to operand

ST N save actual result in place of operand

S set Bool operand to TRUE exactly if actual result is

TRUE

R set Bool operand to FALSE exactly if actual result

is TRUE

AND N,( bitwise AND

OR N,( bitwise OR

XOR N,( bitwise exclusive OR

ADD ( addition

SUB ( subtraction

MUL ( multiplication

DIV ( division

GT ( >

GE ( >=

EQ ( =

NE ( <>

LE ( <=

LT ( <

JMP CN jump to mark

CAL CN call up function block

RET CN return from calling function block

) evaluate reset operation

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Table 4-10: Operators in IL

See also „Operators“, page 71.

Example for an IL program using some modifiers:
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Jump
Operator Operand Comment
mark
LD TRUE (* load TRUE into accu-
mulator *)

ANDN BOOL1 (* execute AND with

negated value of variable
BOOL1 *)

JMPC mark (* if result was TRUE,

jump to mark „mark“ *)

LDN BOOL2 (* save negated value of

*)

ST ERG (* BOOL2 in ERG *)

marke: LD BOOL2 (* save value of *)

ST ERG (* BOOL2 in ERG *)

In IL, brackets can also be used after an operation. The value in the
brackets is then taken as operand.
For example:
LD 2
MUL 2
ADD 3
ST Erg
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Here the value of Erg is 7. However, if brackets are used:

LD 2
MUL( 2
ADD 3
) ST Erg

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Here the value for Erg is 10, as the operation MUL will not be eva-
luated until „)“ is reached; consequently, 5 is calculcated as
operand for MUL.

Structured Text (ST)

The programming language ST (Structured Text) is a high-level lan-
guage that resembles C and Pascal. The language syntax
resembles that of Pascal. Under ST, efficient loop programming is
possible without branch instructions. In addition, mathematical
functions can be mapped in an excellent way: Iterations (For,
While, Repeat) and conditional instructions (If ... Then ... Else,
Case) are part of this language. Practical experience has shown
that ST constructions are well readable and comprehensible - simi-
lar to Pascal. PLC programmers in Europe often choose ST as the
mainly used language if they can use the language variety of IEC
1131.
Structured Text consists of a number of instructions, which can be
executed either conditional, as in high-level languages,
(„IF..THEN..ELSE“) or in loops (WHILE..DO).
Instructions always end with ";".
Example:
IF value < 7 THEN
WHILE value < 8 DO
value := value + 1;
END_WHILE;
END_IF;
Expressions
An expression is a construct which delivers a value after being
evaluated.
Expressions are comprised of operators and operands. An operand
can be a constant expression, a variable, a function call or another
expression.
Evaluation of expressions
An expression is evaluated by processing the operators according
to certain binding rules. The operator featuring the strongest bin-
ding is processed first, the operator with the second strongest
binding next etc. until all operators are processed.
Operators of equal binding strength are processed from left to right.
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In the following table the ST operators are shown according to their

binding strength.

Binding
Operation Symbol
strength
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bracketing (<expression>) strongest

function call <function name> ( <parameter list>)

exponentiation **

negation -

complement formation NOT

multiplication *

division /

modulo MOD

addition +

subtraction -

comparison <,>,<=, >=

equality =

inequality <>

Bool AND AND

Bool XOR XOR

Bool OR OR weakest

Table 4-11: Binding strength of operations

The table below shows the instructions available in ST, along with
examples.

Instruction type Example

assignment A:=B; CV := CV + 1; C:=SIN(X);

call of an FB and use of CMD_TMR(IN := %IX5, PT := 300);

the FB output A:=CMD_TMR.Q

RETURN RETURN;

IF D:=B*B;
IF D<0.0 THEN
C:=A;
ELSIF D=0.0 THEN
C:=B;
ELSE
C:=D;
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4.2 IEC-61131

Instruction type Example

CASE CASE INT1 OF
1:BOOL1 := TRUE;
2:BOOL2 := TRUE;
ELSE

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BOOL1 := FALSE;
BOOL2 := FALSE;
END_CASE;

FOR J:=101;
FOR I:=1 TO 100 BY 2 DO
IF ARR[I] = 70 THEN
J:=I;
EXIT;
END_IF;
END_FOR;

WHILE J:=1;
WHILE J<= 100 AND ARR[J] <> 70 DO
J:=J+2;
END_WHILE;

REPEAT J:=-1;
REPEAT
J:=J+2;
UNTIL J= 101 OR ARR[J] = 70
END_REPEAT;

EXIT EXIT;

empty command ;

Table 4-12: Commands in ST

Instructions in Structured Text

As the name suggests, Structured Text was developed for structu-
red programming. It offers set structures for programming certain
constructs that are used rather often, such as loops.
The advantages are a lower error probability and a more structured
program.
Here is a comparison of equal program sequences in IL and ST:
A loop for calculating powers of two in IL:
Loop:
LD Counter
EQ 0
JMPC end

LD Var1
MUL 2
ST Var1
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LD Counter
SUB 1
ST Counter
JMP Loop
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end:
LD Var1
ST Erg
The same loop programmed in ST would be:
WHILE Counter<>0 DO
Var1:=Var1*2;
Counter:=Counter-1;
END_WHILE

Erg:=Var1;
As can be seen, in ST, the loop can not only be programmed shor-
ter, it is also much easier to read, in particular when imagining loops
that are nested into one another in larger constructions.
The various structures are described below.
Assignment operator
On the left side of an assignment is an operand (variable, address),
to which the value of the expression on the right side is assigned
with the assignment operator :=
Example:
Var1 := Var2 * 10;
After this line is executed, Var1 has the tenfold value of Var2.
Call of function blocks in ST
A function block in ST is called by writing the name of the instance
of the function block and assigning the desired parameter values in
brackets. In the following example, a timer is called with assign-
ments for the parameters IN and PT. In a next step, the derived
variable Q is assigned to variable A.
As in IL, the calculated variable is addressed with the name of the
function block, followed by a dot and the name of the variable:
CMD_TMR(IN := %IX5, PT := 300);
A:=CMD_TMR.Q
RETURN instruction
The RETURN instruction can be used to end a function, e.g.
dependent on a condition.
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Example:
IF COUNTER > 10 THEN
RETURN;
END_IF;
IF instruction/alternative branching

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With the IF instruction, a condition can be checked and dependent
on this condition, instructions can be executed.
Syntax:
IF <Boolean_expression1> THEN
<IF_instructions>
{ELSIF <Boolean_expression2> THEN
<ELSIF_instructions1>
.
.
ELSIF <Boolean_expression n> THEN
<ELSIF_instructions n-1>
ELSE
<ELSE_instructions>}
END_IF;
The part in curly brackets {} is optional.
If <Boolean_expression1> is TRUE, then only the <IF_instructions>
will be executed. None of the other instructions will be executed.
Otherwise, the Boolean expressions will be evaluated in line begin-
ning with <Boolean_expression2> until one of the expressions is
TRUE. Then, only the instructions after this Bool expression and
before the next ELSE or ELSIF will be evaluated.
If none of the Boolean expressions is TRUE, then only the
<ELSE_instructions> will be evaluated.
Example:
IF temp<17 THEN
heating_on := TRUE;
ELSE
heating_on := FALSE;
END_IF;
In this case, the heating will be switched on if the temperature falls
below 17 degrees centigrade, otherwise, it will remain off.
CASE instruction/multiple choice
With the CASE instruction, several conditional instructions with the
same conditional variable can be combined in one construct.
Syntax:
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CASE <Var1> OF
<value 1>:<instruction 1>
<value 2>:<instruction 2>
...
<Wert n>:<instruction n>
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ELSE<ELSE-instruction>
END_CASE;
A CASE instruction is processed according to the following
scheme:
„ If the variable in <VAR1> has the value <value i>, the instruction
<instruction i> will be executed.
„ If <Var 1> has none of the given values, the <ELSE instruction>
will be executed.
„ If the same instruction has to be executed for several values of
the variable, these values can be written one after another,
separated by a comma. Thereby, the joint instruction can be
effected.
Example:
CASE INT1 OF
1, 5:BOOL1 := TRUE;
BOOL3 := FALSE;
2: BOOL2 := FALSE;
BOOL3 := TRUE;
ELSE
BOOL1 := NOT BOOL1;
BOOL2 := BOOL1 OR BOOL2;
END_CASE;
FOR loop/counting loop
With the FOR loop, repeated procedures can be programmed.
Syntax:
INT_Var :INT;
FOR <INT_Var> := <INIT_VALUE> TO <END_VALUE> {BY <step
size>} DO
<instructions>
END_FOR;
The part in curly brackets {} is optional.
The <instructions> will be carried out as long as the counter
<INT_Var> is not bigger than <END_VALUE>. This is checked
before the <instructions> are carried out, so that the <instructions>
are never carried out if <INIT_VALUE> is greater than
<END_VALUE>.
Always when <instructions> was executed, <INT_Var> is increased
by <stepsize>. The step size can have any integer value. If it is mis-
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sing, it is set to 1. Since <INT_Var> can only get bigger, the loop
must terminate.
Example:
FOR counter:=1 TO 5 BY 1 DO

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Var1:=Var1*2;
END_FOR;
Erg:=Var1;
Assuming that variable Var1 was pre-assigned with the value 1,
then it will have the value 32 after the FOR loop.
WHILE loop/rejecting loop
The WHILE loop can be used like the FOR loop, with the exception
that the truncation condition can be any Boolean expression. That
means you set a condition which, if it is true, will result in the execu-
tion of the loop.
Syntax:
WHILE <Boolean expression> DO
<instructions>
END_WHILE;
The <instructions> are repeated as long as <Boolean expression>
is TRUE. If <Boolean expression> is FALSE in the first evaluation,
then the <instructions> will never be carried out. If <Boolean
expression> is never FALSE, then the <instructions> will be repea-
ted endlessly, which will cause a run time error.

NOTE
The programmer has to make sure that there is no endless loop by
changing the condition in the instruction part of the loop, e.g. by
counting upward or downward a counter. If there is an endless loop,
the the diagnosis Cycle time transgression will be triggered in the
PacController.

Example:
WHILE counter<>0 DO
Var1 := Var1*2;
counter := counter-1;
END_WHILE
In a way, the WHILE loop and the REPEAT loop are both more
powerful than the FOR loop, since the number of loop runs does
not have to be known before the loop is executed. In some cases,
these two loop types will be sufficient. However, if the number of
loop runs is clear, a FOR loop should be chosen, since it will not
allow an endless loop.
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REPEAT loop/non-rejecting loop

In the REPEAT loop, the truncation condition will be checked only
after the loop is executed. In consequence, the loop is run at least
once irrespective of the truncation condition.
Syntax:
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REPEAT
<instructions>
UNTIL <Boolean expression>
END_REPEAT;
The <instructions> are carried out as long as <Boolean expres-
sion> is TRUE.
If <Boolean expression> is TRUE in the first evaluation, then the
<instructions> will be carried out just once. If <Boolean expression>
is never TRUE, then the <instructions> will be repeated endlessly,
which will cause a run time error.

NOTE
The programmer has to make sure that there is no endless loop by
changing the condition in the instruction part of the loop, e.g. by
counting upward or downward a counter. If there is an endless loop,
the diagnosis Cycle time transgression will be triggered in the Pac-
Controller.

Example:
REPEAT
Var1 := Var1*2;
counter := counter-1;
UNTIL
counter=0
END_REPEAT
EXIT instruction
If FOR, WHILE or REPEAT loops contain the EXIT instruction, the
innermost loop will be completed, independent of the truncation
condition.

Sequential Function Chart (SFC)

The programming language Sequential Function Chart (SFC) is a
graphic language to represent a state machine, which in one cycle
carries out a single transition to a (next) action state. The graphic
representation of transitions and actions resembles a flow diagram,
is easy to read and well suited for programming superior state
sequences. Programmers often fall victim to the misunderstanding
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4.2 IEC-61131

cycle. This is not the case. For that reason, fast complex calculati-
ons cannot be executed well in SFC but only in the reserved action
modules, which in turn can be filled in any language.
Under TRUE, the transitions between action states become active
as Boolean equations. SFC allows both alternative and parallel

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branches:
„ Actions in alternative branches are executed if the respective
entry transition is fulfilled. The check sequence (priority) is set
from left to right.
„ Actions in simultaneous branches are all started together. A
transition at the end of the simultaneous branch defines the exit
event.

Fig. 4-6: Example for a network in SFC

Step
A block that is written in Instruction List is made up of a sequence
of steps, which are linked with one another via directed connections
(transitions).
Two kinds of steps can be distinguished.
„ The simplified form consists of an action and a marker, which
indicates whether the step is active. If an action is implemented
to a step, a small triangle appears in the upper right corner of the
step.
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„ An IEC step consists of a marker and one or more assigned

actions. The associated actions appear to the right of the step.
More details will be given later.
Action
An action can contain a sequence of instructions in IL or ST, a
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quantity of networks in FBD or LD or again a sequential structure.

In simplified steps, an action is always linked to a step. In order to
edit an action, doubleclick on the step to which the action belongs
or highlight the step and choose the menu item EXTRAS | ZOOM
ACTION / TRANSITION.
Actions of IEC steps are arranged in the Object Organizer directly
under their SFC module. They are loaded into their editor by dou-
bleclicking or pressing <ENTER>. New actions can be created with
PROJECT | ADD ACTION.
Input and Output Actions
An input and an output action can be added to a step. An input
action is executed just once, immediately after the step is activated.
An output action is executed just once before the step is
deactivated.
A step with an input action is marked with an ’I’ in the lower left cor-
ner while the output action is marked with an ’X’ in the lower right
corner.
The input and output actions can be implemented in any language.
In order to edit input and output actions, doubleclick on the respec-
tive corner in the step.
Input and output actions can only be defined as a simplified step,
not to an IEC step.
Example of a step with input and output actions:

Transition / Transition Conditions

Inbetween steps, there are so-called transitions.
A transition condition can be a Boolean variable, an address, a con-
stant expression or a sequence of instruction with a Boolean result
in any language.
Active step
After the SFC module is called, the action belonging to the initial
step (double edged) will be executed. A step the action of which is
being executed is called active. If the step is active, the respective
action is executed once per cycle. In online mode, active steps are
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To each step belongs a flag which stores the state of the step. The
step marker (active or inactive state of the step) is represented by
the logic value of a Boolean structural element <StepName>.x. This
Boolean variable is TRUE if the step is active and FALSE if the step
is inactive. This variable is declared implicitly and can be used in

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each action and transition of the SFC block.
In a control cycle, all actions which belong to active steps are exe-
cuted. Next, the respective following steps of active steps will
become active if the transition conditions of the subsequent steps
are TRUE. The now active steps will only be executed in the next
cycle.
IEC step
In addition to simplified steps, norm-conformous IEC steps are
available in SFC.
Any number of actions can be assigned to an IEC step. The actions
of IEC steps are available separately from the steps and can be
used more than once within their block. For that purpose, they have
to be associated with the individual steps with the command
EXTRAS | ASSOCIATE ACTION.
Alongside actions, also Boolean variables can be assigned to
steps. The actions and Boolean variables can be activated and
deactivated with so-called qualifiers, partly with time delays. Since
an action can still be active even if the next step is already being
processed, e.g. by qualifier S (Set), ancillarities can be achieved.
The associated actions to an IEC step are indicated to the right of
the step in a split box. The left field contains the qualifier and
maybe also a time constant while the right field contains the name
of the action.
Example for an IEC step with two actions:

In order to make it easier to follow the procedures, all actions in

online mode are blue, like the active steps. After each cycle it is
checked which actions are active.
Whether a newly inserted step is an IEC step depends on whether
the menu command EXTRAS USE IEC STEPS is chosen.
In the Object Organizer, the actions are arranged directly under
their IL block. New actions can be created with PROJECT | ADD
ACTION.
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NOTE
In order to be able to use IEC steps, the project has to be embed-
ded in the special SFC library lecsfc.lib.
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Fig. 4-7: SFC block with actions in object organizer

Qualifiers
The following qualifiers are available to associate actions to IEC
steps:

Qualifier Meaning Remark

N Non-stored action is active as long as the step

R overriding Reset action is deactivated

S Set (Stored) action is activated and remains active

until reset

L time Limited action is activated for a certain time

D time Delayed action becomes active after a certain

time, if the step is still active

P Pulse action is executed exactly once if the

step is active

SD Stored and time action is activated after a certain time

Delayed and remains active until reset

DS Delayed and Stored action is activated after a certain time, if

the step is still active, and remains
active until reset

SL Stored and time action is activated for a certain time

Limited

Table 4-13: Qualifier in SFC

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Alternative branch
Two or more branches in SFC can be defined as alternative bran-
ches. Each alternative branch has to begin and end with a
transition. Alternative branches can contain simultaneous branches
and further alternative branches. An alternative branch begins at a

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horizontal line (alternative start) and ends at a horizontal line (alter-
native end) or with a branch.
If the step preceding the alternative start line is active, the first tran-
sition of each alternative branch will be evaluated from left to right.
The first transition from the left that carries a TRUE transition condi-
tion will be opened and the following steps will become active (see
active step).
Parallel branch
Two or more branches in SFC can be defined as parallel branches.
Each parallel branch has to start and to end with a step. Parallel
branches can contain alternative branches or further parallel bran-
ches. A parallel branch begins at a double line (simultaneous
beginning) and ends at a double line (parallel start) or at a branch.
If the step preceding the parallel start line is active and the transi-
tion condition after this step is TRUE, the first steps of all parallel
branches become active (see active step). The branches are then
processed simultaneously to one another. The step after the paral-
lel end line becomes active if all earlier steps are active and the
transition condition preceding the step is TRUE.
Jump
A jump is a connection to the step the name of which is indicated
under the jump symbol. Jumps are needed since it is not allowed to
create ascending or crossing connections.

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 4.2 IEC-61131

The diagram shows a simple procedure of actions in stored, normal

and reset operating mode:
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Fig. 4-8: The transitions a, b and c control the development of steps 1 and 2.

The action qualifiers control the execution of the code independent

of the active step: Stored actions will not become inactive before
the following steps.

Fig. 4-9: Action 1 is terminated only by Reset in step 2, not by end of step 1.

The action qualifiers L and D in their operating mode: limited pro-

cessing by L and delayed start of the processing until the end of the
step by D.
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4.2 IEC-61131

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Fig. 4-10: Action qualifyers L and D for time control of actions.

Function Block Diagram (FBD), Function Block Language

(FBL)
The graphic programming language Function Block Diagram can
be used to realize even complicated control tasks. Based on defi-
ned function blocks, any program sequences can be realized with
the help of connecting elements. Data flow through the program
can be presented in a pattern, thus helping make the program
sequences transparent. A loop construct or branches can be diffi-
cult. Often, also hardware components are offered with the
respective function blocks, so that corresponding modules are
available on both hardware and software levels.
Outputs of function blocks are linked with inputs of the following
blocks. Data flow can be presented in full graphic. Jump and return
jump facilitate programming.
Function Block Diagram is a programming language with a graphic
orientation. It uses a list of networks, with each network containing
a structure representing a logic/arithmetic expression, the call of a
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 4.2 IEC-61131

Example for a network in Function Block Diagram, as it could typi-

cally look like in EPAS-4:
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Fig. 4-11: Network in function block diagram

Ladder Diagram (LD)

A program in Ladder Diagram (LD) is regarded as the easiest way
to give controls well-defined functionality. LD is particularly advan-
tageous if the control is to be implemented as a replacement for a
wired logic or if basic functions, such as start-up locks, are to be
programmed. LD is particularly well suited for complex AND / OR
logics. Since it is so easy, it is the prefered language e.g. in the US.
As the norm provides for the start of complex blocks (written in
other languages) with the help of an enable input, powerful con-
structions can be controlled with Ladder logic.
The graphic representation is the simulation of a current flow
through a „left contact rail“ through input switch (represented by
variables) via current paths to output actuators (coils), which are
also represented through variables. Branches and returns to the
beginning are allowed.
The Ladder Diagram is also a graphic-oriented language. In prin-
ciple, the Ladder Diagram is similar to the principle of an electric
circuit/.
On the one hand, the Ladder Diagram is good for constructing
sequential logic systems. On the other hand, it can also be applied
to create networks like in FBD. Thus, Ladder Diagram is also excel-
lent to control the call of other modules. More details are given in a
later chapter.
The Ladder Diagram consists of a sequence of networks. A net-
work is restricted on the left and right sides by a left and a right
vertical power line. Inbetween the power lines, there is a wiring dia-
gram of contacts, coils and connecting lines.
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4.2 IEC-61131

On the left side, each network consists of a sequence of contacts

which transmit the states ON or OFF from left to right. These states
correspond to the Boolean values TRUE and FALSE. To each con-
tact belongs a Boolean variable. If the variable is TRUE, the state
will be transmitted via the connecting line from left to right. Other-

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wise, the right connection has the value OFF.
Example for a network in the Ladder Diagram, as it could typically
look in EPAS-4:

Fig. 4-12: Network in Ladder Diagram

Contact
On the left side, each network in the Ladder Diagram consists of a
network of contacts (represented by two parallel lines: | |), which
transmit the state ON or OFF from left to right.
These states correspond to the Boolean values TRUE and FALSE.
To each contact belongs a Boolean variable. If the variable is
TRUE, the state will be transmitted via the connecting line from left
to right. Otherwise, the right connection has the value OFF“.
Contacts can be switched parallel. In this case, one of the parallel
branches has to transmit the value ON for the parallel branch to
transmit the value ON. If the contacts are switched in line, all con-
tacts have to transmit the state „On“ for the last contact to transmit
the state ON. The contact connections correspond to an electric
parallel connection and serial connection, respectively.
A contact can also be negated. This is indicated by a slash in the
contact symbol: |/|. In this case, the value of the line is transmitted if
the variable is FALSE.
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Coil
On the left side of a network in the Ladder Diagram any number of
so-called coils can be found. Coils are represented by brackets: ().
Coils can only be switched parallel. A coil transmits the value of the
connection from left to right and copies it into a corresponding Boo-
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lean variable. The values On and Off can be set on the input line.
On corresponds to the Boolean variable TRUE and Off to the Boo-
lean variable FALSE.
Contacts and coils can also be negated. (In the example, contact
SWITCH1 and coil %QX3.0 are negated.) If a coil is negated (indi-
cated by a slash in the coil symbol: (/)), it copies the negated value
to the corresponding Boolean variable. If a contact is negated, it
interconnects only if the Boolean variable is FALSE.
Function blocks in Ladder Diagram
In addition to contacts and coils, also function blocks and programs
can be entered. In the network, they have to have an input and an
output with Boolean values. They can be used at the same sites as
contacts, i.e., on the left side of the Ladder Diagram network.
Set/reset coils
Coils can also be defined as Set or Reset coils. A set coil (repre-
sented by an ’S’ in the coil symbol (S)) never overwrites the value
TRUE in the respective Boolean variable. That is, if a variable was
once set on TRUE it will also remain so.
A Reset coil (’R’ in the coil symbol (R)) never overwrites the value
FALSE in the respective Boolean variable. If the variable was once
set to FALSE, it will remain so.
LD as FBD
When working with Ladder Diagram, you might want to use the
result of the contact connection to control other blocks. Then you
can file the result with the help of the coils in a global variable that is
used further elsewhere. You can also fit the possible call directly
into your Ladder Diagram network. In order to do so, insert a
module with and EN input.
Such blocks are conventional operands, functions, programs or
function blocks that feature an additional input marked with EN.
The EN input is always of the Boolean type. It has the following
meaning: The block featuring the EN input will be evaluated if EN is
TRUE.
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An EN block is switched parallel to the coils, while the EN input is

connected with the connecting line between the contacts and coils.
If the information ON is transmitted via this line, the block will be
evaluated in the usual way.
Taking such an EN block as the basis, networks can be created like

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in FBD.

Fig. 4-13: Part of an LD network with an EN block

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 4.2 IEC-61131

4.2.5 Operators
In contrast to standard functions, IEC operators are implicitly known
in the complete project. In the block implementation, operators are
used like functions.
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The list blow shows all operators that are supported:

Overview
In expressions, operands are linked by operators.

Operator /
Short description Explanation
Symbol
[] start and end for :
1. field index (access to field ele-
ment)
2. string length (for declaration)

( ... ) bracketing A:= (5*2) + (4/2)

-> A = 12

function name function evaluation ADD (A, B, C)

(argument list)

EXPT exponentiation A:= 2**3

** (** currently not supported) -> A = 8

- negation A:= -5
-> A = -5

NOT complement

MUL multiplication A:= 5*2

* -> A = 10

DIV division A:= 4/2

/ -> A = 2

MOD modulo A:= 12 MOD

(not supported for REAL and 10
LREAL.) -> A = 2

ADD addition A:= 3+4

+ -> A = 7

SUB subtraction A:= 4-2

- -> A = 2

> comparison operator greater than

< comparison operator less than

>= comparison operator equal to or

greater than

<= comparison operator equal to or less

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than

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4.2 IEC-61131

Operator /
Short description Explanation
Symbol
= comparison operator equal to

<> comparison operator not equal to

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AND boolean AND
&

XOR boolean exclusive OR

OR boolean OR

MOVE allocation
:= 1. operator for start value allocation
2. input connection operator (alloca-
tion of actual parameters to formal
parameters at POU call)
3. instruction operator

Table 4-14: Operators

Operators of equal rank are evaluated from left to right..

Rank Operation Operator

highest []

bracketing ( ... )

function evaluation function name

(argument list)

exponentiation **

negation -

complement NOT

multiplication *

division /

modulo MOD

addition +

subtraction -

comparison >, <, >=, <=

equality =

inequality <>

AND AND, &

exclusive OR XOR
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OR OR

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 4.2 IEC-61131

Rank Operation Operator

lowest allocation :=

Table 4-15: Operators - priority and associativity

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Further operators:

Name Function Description

*_TO_**

TRUNC conversion of a REAL into an INT

value

BCD_TO_** conversion of a BCD value e.g. into

an INT

*_TO_BCD conversion e.g. of an INT value into

a BCD value

Table 4-16: Operators for type conversion

* Data type of the input, e.g. REAL

** Data type of the output, e.g. INT
Further operators:

Name Function Description

ABS absolute value F:= | IN |

SQRT square root F:= √IN

LN natural logarithm F:= loge (IN)

LOG logarithm to the base of 10 F:= log10 (IN)

EXP exponent to the base e F:= eIN

SIN sinus, IN in radial measure F:= SIN (IN)

COS cosine, IN in radial measure F:= COS (IN)

TAN tangent, IN in radial measure F:= TAN (IN)

ASIN Arcsin, main value F:= ARCSIN (IN)

ACOS Arccos, main value F:= ARCCOS (IN)

ATAN Arctan, main value F:= ARCTAN (IN)

EXPT exponentiation of one variable with F:= IN1IN2

another

Table 4-17: Numeric operators

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Arithmetic Operators
ADD
Addition of variables of the BYTE, WORD, DWORD, SINT, USINT,
INT, UINT, DINT, UDINT, REAL and LREAL types.

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Also two TIME variables can be added. Their sum is again a time
(e.g. t#45s + t#50s = t#1m35s)
Example in IL:
LD 7
ADD 2,4,7
ST var1
Example in ST:
var1 := 7+2+4+7;
MUL
Multiplication of variables of the BYTE, WORD, DWORD, SINT,
USINT, INT, UINT, DINT, UDINT, REAL and LREAL types.
Example in IL:
LD 7
MUL 2,4,7
ST var1
Example in ST:
var1 := 7*2*4*7;
SUB
Subtraction of a variable of the BYTE, WORD, DWORD, SINT,
USINT, INT, DINT, UDINT, REAL and LREAL types from another
variable of one of the above types.
A TIME variable can also be subtracted from another TIME varia-
ble, the result is again a TIME type. Note that negative TIME values
are not defined.
Example in IL:
LD 7
SUB 8
ST var1
Example in ST:
var1 := 7-2;
DIV
Division of a variable of the BYTE, WORD, DWORD, SINT, USINT,
INT, UINT, DINT, UDINT, REAL und LREAL types by another varia-
ble of one of the same types.
Example in IL:
LD 8
DIV2
STvar1
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Example in ST:

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var1 := 8/2;
MOD
Modulo Division of a variable of the BYTE, WORD, DWORD, SINT,
USINT, INT, UINT, DINT, UDINT, REAL and LREAL types by
another variable of one of the same types. The function delivers as
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result the integer remainder of the division.

Example in IL:
LD 9
MOD 2
ST var1 (* result is 1 *)
Example in ST:
var1 := 9 MOD 2;
INDEXOF
This function delivers as result the internal index of a block.
Example in ST:
var1 := INDEXOF(baustein2);
SIZEOF
This function delivers as result the number of bytes required by the
data type.
Example in IL:
arr1:ARRAY[0..4] OF INT;
var1:=INT;
LD arr1
SIZEOF
ST var1 (* result is 10 *)
Example in ST: :
var1 : INT;
pt := ADR(pt^) + SIZEOF(INT);

Bitstring operators
AND
Bitwise AND of bit operands. The operands should be of the BOOL,
BYTE, WORD or DWORD types.
Example in IL:
var1 :BYTE;
LD 2#1001_0011
AND 2#1000_1010
ST var1 (* result is 2#1000_0010 *)
Example in ST:
var1 := 2#1001_0011 AND 2#1000_1010
OR
Bitwise OR of bit operands. The operands should be of the BOOL,
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BYTE, WORD or DWORD types.

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4.2 IEC-61131

Example in IL:
var1 :BYTE;
LD 2#1001_0011
OR 2#1000_1010
ST var1 (* result is 2#1001_1011 *)

Korrekturausdruck
Example in ST:
Var1 := 2#1001_0011 OR 2#1000_1010
XOR
Bitwise XOR of bit operands. The operands should be of the BOOL,
BYTE, WORD or DWORD type.
Example in IL:
Var1 :BYTE;
LD 2#1001_0011
XOR 2#1000_1010
ST Var1 (* result is 2#0001_1001 *)
Example in ST:
Var1 := 2#1001_0011 XOR 2#1000_1010
NOT
Bitwise NOT of a bit operand. The operand should be of BOOL,
BYTE, WORD or DWORD type.
Example in IL:
Var1 :BYTE;
LD2#1001_0011
NOT
STVar1 (* result is 2#0110_1100 *)
Example in ST:
Var1 := NOT 2#1001_0011

Bit-shift operators
The following operators are represented with a map as FBD
operators.
SHL

Bitwise left shift of an operand: A:= SHL (IN, N)

A, IN and N should be of the BYTE, WORD, DWORD type. IN is
shifted to the left by N bits and filled up with zeros from the right.
Example:
LD 1
SHL 1
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ST Var1 (* result is 2 *)

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SHR
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Bitwise right shift of an operand: A:= SHR (IN, N)

A, IN and N should by of the BYTE, WORD or DWORD type. IN is
shifted to the right by N bits and filled up with zeros from the left.
Example:
LD 32
SHL 2
ST Var1(* result is 8 *)
ROL

Bitwise left rotation of an operand: A:= ROL (IN, N)

A, IN and N should be of the BYTE, WORD or DWORD type. IN is
shifted to the left N times one bit position and the most left bit is re-
inserted from the right.
Example:
Var1 :BYTE;
LD2#1001_0011
ROL3
STVar1 (* result is 2#1001_1100 *)
ROR

Bitwise right rotation of an operand: A:= ROR (IN, N)

A, IN and N should be of the BYTE, WORD or DWORD type. IN is
shifted to the right N times one bit position while the most right bit is
re-inserted again from the left.
Example:
Var1 :BYTE;
LD 2#1001_0011
ROR 3
ST Var1 (* result is 2#0111_0010 *)
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4.2 IEC-61131

Selection Operators
All selection operators can also be executed on variables. For illu-
strative reasons, the following example is restricted to constant
expressions as operators.
SEL

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Binary selection
OUT := SEL(G, IN0, IN1) means:
OUT := IN0 if G=FALSE;
OUT := IN1 if G=TRUE.
IN0, IN1 and OUT can be of any type, G has to be of the BOOL
type. The result of the selection is IN0 if G is FALSE and IN1 if G is
TRUE.
Example in IL:
LD TRUE
SEL 3,4
ST Var1 (* result is 4 *)
LD FALSE
SEL 3,4
ST Var1 (* result is 3 *)
MAX
Maximum function. Delivers the greater one of two values.
OUT := MAX(IN0, IN1)
IN0, IN1 and OUT can be of any type.
Example in IL:
LD 90
MAX 30
MAX 40
MAX 77
ST Var1 (* result is 90 *)
MIN
Minimum function. Delivers the lesser one of two values.
OUT := MIN(IN0, IN1)
IN0, IN1 and OUT can be of any type.
Example in IL:
LD 90
MIN 30
MIN 40
MIN 77
ST Var1 (* result is 30 *)
LIMIT
Limitation
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OUT := LIMIT(Min, IN, Max) means:

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OUT := MIN (MAX (IN, Min), Max)

Max is the upper, Min the lower limit for the result. If the IN value is
greater than the upper limit, LIMIT will deliver Max. If IN is less than
Min, the result will be Min.
IN and OUT can be of any type.
Korrekturausdruck

Example in IL:
LD 90
LIMIT 30,80
ST Var1 (* result is 80 *)
MUX
Multiplexer
OUT := MUX(K, IN0,...,INn) means:
OUT := INK.
IN0, ...,INn and OUT can be of any type. K has to be of the BYTE,
WORD, DWORD, SINT, USINT, INT, UINT, DINT or UDINT type.
MUX choses the Kth from a quantity of values.
Example in IL:
LD 0
MUX 30,40,50,60,70,80
ST Var1 (* result is 30 *)

Comparative operators
GT
Greater than
A Boolean operator with the result TRUE, if the first operand is
greater than the second operand. The operands can be of the
BOOL, BYTE, WORD, DWORD, SINT, USINT, INT, UINT, DINT,
UDINT, REAL, LREAL, TIME, DATE, TIME_OF_DAY,
DATE_AND_TIME and STRING type.
Example in IL:
LD 20
GT 30
ST Var1 (* result is FALSE *)
Example in ST:
VAR1 := 20 > 30 > 40 > 50 > 60 > 70;
LT
Less than
A Boolean operator with the result TRUE, if the first operand is less
than the second operand. The operands can be of the BOOL,
BYTE, WORD, DWORD, SINT, USINT, INT, UINT, DINT, UDINT,
REAL, LREAL, TIME, DATE, TIME_OF_DAY, DATE_AND_TIME
and STRING type.
PD_UserMan_IEC_us.fm

Example in IL:

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4.2 IEC-61131

LD 20
LT 30
ST Var1 (* result is TRUE *)
Example in ST: :
VAR1 := 20 < 30;

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LE
Less than or equal to
A Boolean operator with the result TRUE, if the first operand is less
than or equal to the second operand. The operands can be of the
BOOL, BYTE, WORD, DWORD, SINT, USINT, INT, UINT, DINT,
UDINT, REAL, LREAL, TIME, DATE, TIME_OF_DAY,
DATE_AND_TIME and STRING types.
Example in IL:
LD 20
LE 30
ST Var1 (* result is TRUE *)
Example in ST:
VAR1 := 20 <= 30;
GE
Greater than or equal to
A Boolean operator with the result TRUE, if the first operand is
greater than or equal to the second one. The operands can be of
the BOOL, BYTE, WORD, DWORD, SINT, USINT, INT, UINT, DINT,
UDINT, REAL, LREAL, TIME, DATE, TIME_OF_DAY,
DATE_AND_TIME and STRING types.
Example in IL: :
LD 60
GE 40
ST Var1 (* result is TRUE *)
Example in ST:
VAR1 := 60 >= 40;
EQ
Equal to
A Boolean operator with the result TRUE, if the operands are equal.
The operands can be of the BOOL, BYTE, WORD, DWORD, SINT,
USINT, INT, UINT, DINT, UDINT, REAL, LREAL, TIME, DATE,
TIME_OF_DAY, DATE_AND_TIME and STRING types.
Example in IL:
LD 40
EQ 40
ST Var1 (* result is TRUE *)
Example in ST:
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VAR1 := 40 = 40;

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 4.2 IEC-61131

NE
Not equal to
A Boolean operator with the result TRUE, if the operands are not
equal. The operands can be of the BOOL, BYTE, WORD, DWORD,
SINT, USINT, INT, U-INT, DINT, UDINT, REAL, LREAL, TIME,
Korrekturausdruck

DATE, TIME_OF_DAY, DATE_AND_TIME and STRING types.

Example in IL:
LD 40
NE 40
ST Var1 (* result is FALSE *)
Example in ST:
VAR1 := 40 <> 40;

Address operators
ADR
Address function
ADR delivers the address of its argument in a DWORD. This
address can be sent to producer functions, where it can be treated
like a pointer. Within the project, it can also be assigned to a
pointer.
Example in IL:
LD var1
ADR
ST var2
man_fun1
Content operator
The dereferentiation of a pointer is effected via a content operator
"^" after the pointer identifier.
Example in ST:
pt:POINTER TO INT;
var_int1:INT;
var_int2:INT;
pt := ADR(var_int1);
var_int2:=pt^;

Call operator
CAL
Call of a function block
In IL, CAL is used to call the instance of a function block. After the
name of the instance follows in brackets the assignment of the
input variable of the function block.
Example:
Call of the instance of a function block with assignment of the input
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4.2 IEC-61131

CAL INST(PAR1 := 0, PAR2 := TRUE)

Type conversion operators

It is not allowed to convert implicity from a “bigger“ type to a “smal-
ler“ one (e.g. from INT to BYTE or from DINT to WORD). If you

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want to do that, you have to use special type conversion functions.
In principle, you can convert from any elementary type to any other
elementary type.
Syntax:
<elem.Typ1>_TO_<elem.Typ2>
BOOL_TO Conversion
Conversion from the BOOL type into another type:
In number types, the result is 1 if the operand is TRUE. The result
is 0 if the operand is FALSE.
In the STRING type, the result is TRUE or FALSE.
Examples in ST:
i:=BOOL_TO_INT(TRUE);
(* -> result is 1 *)
str:=BOOL_TO_STRING(TRUE);
(* -> result is 'TRUE' *)
t:=BOOL_TO_TIME(TRUE);
(* -> result is T#1ms *)
tof:=BOOL_TO_TOD(TRUE);
(* -> result is TOD#00:00:00.001 *)
dat:=BOOL_TO_DATE(FALSE);
(* -> result is D#1970-01-01 *)
dandt:=BOOL_TO_DT(TRUE);
(* -> result isDT#1970-01-01-00:00:01 *)
TO_BOOL conversions
Conversion from one type into the BOOL type:
The result is TRUE if the operand is not 0. The result is FALSE if
the operand is 0.
In the STRING type, the result is TRUE if the operand is TRUE.
Otherwise, the result is FALSE.
Examples in ST:
b := BYTE_TO_BOOL(2#11010101);
(* -> result is TRUE *)
b := INT_TO_BOOL(0);
(* -> result is FALSE *)
b := TIME_TO_BOOL(T#5ms);
(* -> result is TRUE *)
b := STRING_TO_BOOL('TRUE');
(* -> result is TRUE *)
Conversions between integer number types
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Conversion from an integer number type into another number type:

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 4.2 IEC-61131

In the type conversion from greater to lower types, information can

be lost. If the to be converted exceeds the range, the first bytes of
the number will not be taken into consideration.
Example in ST:
si := INT_TO_SINT(4223); (* result is 127 *)
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If the integer number 4223 (16#107f in hexadecimal representation)

is stored in a SINT variable, the latter will contain the number 127
(16#7f in hexadecimal representation).
Example in IL:
LD 2
INT_TO_REAL
MUL 3.5
REAL_TO/ LREAL_TO conversions
Conversion from the REAL/LREAL types into another type:
The value is rounded up or down to an integer value and converted
into the corresponding type. STRING, BOOL, REAL and LREAL
types are exceptions.
In the type conversion from higher to lower types, information can
be lost.
Example in ST:
i := REAL_TO_INT(1.5); (* result is 2 *)
j := REAL_TO_INT(1.4); (* result is 1 *)
Example in IL:
LD 2.7
REAL_TO_INT
GE %MW8
TIME_TO / TIME_OF_DAY conversions
Conversion of the TIME and TIME_OF_DAY type into another type:
On an internal basis, time is stored in a DWORD in milliseconds (in
the case of TIME_OF_DAY since 00:00). This value is converted.
In the type conversion from higher to lower types, information can
be lost.
In the STRING type, the result is the time constant.
Examples in ST:
str :=TIME_TO_STRING(T#12ms);
(* -> result is 'T#12ms' *)
dw:=TIME_TO_DWORD(T#5m);
(* -> result is 300000 *)
si:=TOD_TO_SINT(TOD#00:00:00.012);
(* -> result is 12 *)
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4.2 IEC-61131

DATE_TO / DT_TO conversions

Conversions from the DATE and DATE_AND_TIME type into
another type:
On an internal basis, the date has been stored in a DWORD in
seconds since January 1st, 1970. This value is converted.

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In the type conversion from a higher to a lower type, information
can be lost.
In the STRING type, the result is a date constant. .
Examples in ST:
b :=DATE_TO_BOOL(D#1970-01-01);
(* -> result is FALSE *)
i :=DATE_TO_INT(D#1970-01-15);
(* -> result is 29952 *)
byt :=DT_TO_BYTE(DT#1970-01-15-05:05:05);
(* -> result is 129 *)
str:=DT_TO_STRING(DT#1998-02-13-14:20);
(* -> result is 'DT#1998-02-13-14:20' *)
STRING_TO conversion
Conversion from the STRING type into another type:
The operand ot the STRING type must have a valid value of the tar-
get type. Otherwise, the result is 0.
Examples in ST:
b :=STRING_TO_BOOL('TRUE');
(* -> result is TRUE *)
w :=STRING_TO_WORD('abc34');
(* -> result is 0 *)
t :=STRING_TO_TIME('T#127ms');
(* -> result is T#127ms *)
TRUNC
Conversion from the REAL type into the INT type. Only the integer
fraction of the number is taken.
In the type conversion from higher to lower types, information can
be lost.
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 4.2 IEC-61131

Examples in ST:
i:=TRUNC(1.9); (* result is 1 *).
i:=TRUNC(-1.4); (* result is -1 *).
Example in IL:
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LD 2.7
TRUNC
GE %MW8

Numeric operators
ABS
Gives the absolute value of a number. ABS(-2) gives 2.
SQRT
Gives the square root of a number.
LN
Gives the natural logarithm of a number.l
LOG
Gives the logarithm to base 10 of a number. Liefert den Logarith-
mus zur Basis 10 einer Zahl.
EXP
Gives the exponential funtion.
SIN
Gives the sine of a number.
COS
Gives the cosine of a number.
TAN
Gives the tangent of a number.
ASIN
Gives the antisine (inverse function of sinus) of a number.
ACOS
Gives the arc cosine (inverse function of cosine) of a number.
ATAN
Gives the arc tangent (inverse function of tangent) of a number.
EXPT
Exponentiation of a variable by another variable:
OUT = IN1IN2.
OUT, IN1 and IN2 can be of the BYTE, WORD, DWORD, INT,
DINT, REAL types.
Example in IL:
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4.2 IEC-61131

LD 7
EXPT 2
ST var1 (* result is 49 *)
Example in ST:
var1 := EXPT (7,2);

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 4.2 IEC-61131

4.2.6 Operands
In the PacDrive™, constant expressions, variables, addresses and
also function calls can occur as operands.
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Constants
Boolean constants
Boolean constants are the truth values TRUE and FALSE
TIME constants
In EPAS-4, TIME constants can be declared. They are used in par-
ticular in order to operate timers from the standard library. A TIME
constant always consists of a leading t or T (i.e., time or TIME in the
detailled version) and a double cross „#“.
The actual time declaration follows after the TIME constant. It can
consist of days (d), hours (h), minutes (m), seconds (s) and millise-
conds (ms). Note that the time data have to be put in order of their
size (d before h before m before s before ms). However, not all
times have to be included.
Examples for correct TIME constants in an ST assignment:
TIME1 := T#14ms;
TIME1 := T#100S12ms;
(*>Overflow in the highest component is allowed*)
TIME1 := t#12h34m15s;
The following example is not correct:
TIME1 := t#5m68s;
(* -> Overflow in a lower place*)
TIME1 := 15ms;
(* -> Es fehlt T#*)
TIME1 := t#4ms13d;
(* -> wrong order of time data*)
DATE constants
With the help of DATE constants, date indications can be made. A
DATE constant is declared by a leading d, D, date or DATE follo-
wed by #. Thereafter, any date can be entered in the form year-
month-day.
Examples:
DATE#1996-05-06
d#1972-03-29
TIME_OF_DAY constants
With the help of TIME_OF_DAY constants, times of day can be
stored. A TIME_OF_DAY declaration starts with tod#, TOD#,
TIME_OF_DAY# or time_of_day#. After that, a time of day can be
entered in the following form: hour:minute:second. Seconds can be
entered either as real numbers or fractions.
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4.2 IEC-61131

Examples:
TIME_OF_DAY#15:36:30.123
tod#00:00:00
DATE_AND_TIME constants

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Date constants and times can also be combined in so-called
DATE_AND_TIME constants. DATE_AND_TIME constants start
with dt#, DT#, DATE_AND_TIME# or date_and_time#. The date is
followed by a hyphen and the time of day.
Examples:
DATE_AND_TIME#1996-05-06-15:36:30
dt#1972-03-29-00:00:00
Number constants
Numbers can occur as dual numbers, octal numbers, decimal num-
bers and hexadecimal numbers. If an integer value is not a decimal
number, then the base, followed by a double cross (#), has to be
written in front of the integer constant. For hexadecimal numbers,
the numeric values for numbers 10 to 15 are represented by the let-
ters A to F.
Underscores within a number value are allowed.
Examples:
14 (decimal number)
2#1001_0011 (dual number)
8#67 (octal number)
16#A (hexadecimal number)
The digit values can be of the BYTE, WORD, DWORD, SINT,
USINT, INT, UINT, DINT, UDINT, REAL and LREAL types.
Implicit conversions from „greater“ to „lower“ types are not allowed.
That is, a DINT variable cannot simply be converted into an INT
variable. For such operations, the type conversion function of stan-
dard.lib has to be used (see chapter Type Conversion in the
appendix).
REAL/LREAL constants
REAL and LREAL constants can be represented as decimal frac-
tion or exponential notation. In this case, the American way of
writing with a point is used.
Example:
7.4 instead of 7,4
1.64e+009 instead of t 1,64e+009
STRING constants
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 4.2 IEC-61131

A string is any character sequence. String constants are delimited

with inverted commas. Also blank spaces and umlaut characters
can be used. They are treated just like all other characters.
In strings, the combination of a dollar sign ($) followed by two
hexadecimal numbers is interpreted as hexidecimal representation
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of the eight bit character code. In addition, if they occur in a string,

combinations of two characters starting with the dollar sign are
interpreted as follows:
$$ dollar sign
$ 'inverted comma
$L or $lline feed
$N or $nnew line
$P or $ppage feed
$R or $rline break
$T or $ttab
Examples:
'w1Wüß?'
'Susi and Claus'
':-)'

Variables
Variables are either declared locally in the declaration part of a
block or in the global variable lists.
Note that identifiers of variables must neither contain blank spa-
cesn nor umlaut characters. Furthermore, they must not be
declared double and they must not be identical with keywords.
Case sensitivity is not recognized, i.e., VAR1, Var1 and var1 are not
different variables. Underscores are significant in identifiers, e.g.
A_BCD and AB_CD are interpreted as different identifiers. More
than one underscore at the beginning of an identifier or within an
identifier are not allowed. The first 32 characters are significant.
Variables can be used everywhere, where allowed by the declared
type. You can call the available variables via the input help.
System flags
System flags are implicitly declared variables that depend on their
special controls. In order to find out which system flags your system
is using, choose the command INSERT OPERAND. In the input
help dialogue, go to the category System Variable.
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4.2 IEC-61131

Access to variables from arrays, structures and blocks

Components of two-dimensional arrays can be accessed with the
following syntax:
<Array name>[Index1, Index2}]

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Variables of structures can be accessed with the following syntax:
<structure name>.<variable name>
Variables of function blocks and programs can be accessed with
the following syntax:
<Function block name>.<Variable name>

Addresses
Address
The direct representation of single memory cells are special cha-
racter strings. These special character strings are created from the
concatenation of the percentage character (%), a prefix for the
value and one or more natural numbers which are separated from
each other by blank spaces.
The following area prefixes are supported:
I input
Q output
M marker
The following prefixes for the size are supported:
X single bit
None single bit
B byte (8 bits)
W word (16 bits)
D double word (32 bits)
Examples:
%QX75 and %Q75 Output bit 75
%IW215 input word215
%QB7 output byte 7
%MD48 double word at memorylocation
%IW2.5.7.1dependent on the control configuration
Whether an address is valid depends on the actual control configu-
ration of the program.
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 4.2 IEC-61131

Marker
All supported values can be used to access the marker.
The address %MD48 would e.g. address the bytes 192, 193, 194
and 195 in the marker area (48 * 4 = 192). The first byte is byte no.
0.
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Words, bytes and even bits can be accessed in the same way: With
%MX5.0 for example, the first bit in the fifth word is accessed.
(Usually, bit are saved in words.)

Functions
In ST, also a function call can appear as operand.
Example:
Result := Fct(7) + 3;
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4.2 IEC-61131

4.2.7 References
IEC 61131 is a standard for industrial automation systems. It com-
prises 5 chapters and 2 technical reports. By far the most important
part of this standard is part 3: Programming Languages.

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This part describes a set of high-level programming languages,
which can be used for various applications.
Various books deal with IEC 61131-3 standard in detail. To mention
some:
„ SPS-Standard IEC 1131
Karl-Heinz John, Michael Tiegelkamp
ISBN 3-540-58635-0
„ SPS-Programmierung mit IEC 1131-3
Neumann / Grötsch / Lubkoll / Simon
ISBN 3-486-23348-3
„ SPS-Programmierung nach IEC 1131-3
(zur Einarbeitung in das Thema empfohlen)
Wellers
ISBN 3-464-48062-3
„ Moderne Programmiertechnik für Automatisierungssysteme
Peter Wratil
ISBN 3-8023-1575-8
„ Grundkurs IEC 1131
(Programmierbeispiele für die Prozeßautomatisierung)
Karl Pusch
ISBN 3-8023-1807-2

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 4.3 Special Features of the PacDrive

4.3 Special Features of the PacDrive

4.3.1 General Function

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The PacDrive - System is a multi-tasking system. In order to avoid

access problems to inputs and outputs that are globally available in
the system, input and output maps are not created for each task.
The problem is avoided as inputs and outputs are read and written
as soon as an instruction, accessing inputs and outputs, is proces-
sed.
This kind of processing method also gives a speed advantage.

Controller
Power On

Delete the remanent Marker,

Counter, Times and the output
image.

Operating System
- Start / Stop
- etc ...

Inputs

PLC program active

Outputs

Fig. 4-14: General function of the “multitasking“ PacDrive - system

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4.3 Special Features of the PacDrive

4.3.2 Data Types of the Control Configuration

In the configuration of a PacDriveTM project, data types are decla-
red automatically (see also Programming Manual / Reference /
Control Configuration / Table: Objects of the PacDrive - System).

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Example:
Transfer of a reference to a block.
An MC-4 was configurated with the object name Axis_10.
Procedure(r_MC_4:=Axis_10);
In this modular procedure, the logical address can be addressed in
the following way:
ControllerEnableSet(r_MC_4.logAdr);(* enable for MC-4
*)

4.3.3 Size of Programs and Variable Ranges

See also „System Data“, page 231.

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 5.1 The Concept of Mapping

5 Programming Guidelines

5.1 The Concept of Mapping

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5.1.1 The Structure of Packaging Machines

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Fig. 5-1: Example of a structure of a packaging machine

ELAU AG Programming Manual page 95

 5.1.2

page 96
TCP/IP Ethernet

Industrial PC PacController
MAx-4
I/O Module BT4/DIO-1 IEC 61131-3 PLC
BT4
IEC 61131-3 Motion Control
PacNet
5.1 The Concept of Mapping

drive bus SERCOS

CANopen
PROFIBUS
DeviceNet
The Automation System

Ethernet/IP Motor Power supply

MC-4 MC-4 MC-4 MC-4 Controller PS-4 PS-4
MC-4

Programming Manual
Axis group 1 Axis group 2
PD-8 PD-8

n xSCL055

peripheral I/Os

SCL055
Power + SERCOS SCL055

Fig. 5-2: System overview of the PacDrive™ automation system

SCL055
SCL055
SCL055
SM-Servomotor SM-Servomotor
initiator (opt)

SM-Servomotor SM-Servomotor
SCL055-Servomotor SCL055-Servomotor SCL055-Servomotor

ELAU AG
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 5.1 The Concept of Mapping

5.1.3 From Problem Definition to Solution

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Fig. 5-3: From problem definition to solution with PacDrive

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5.1 The Concept of Mapping

5.1.4 Method for Solving a Defined Problem

Mechanics of the machine

Schemes

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Schedules, Sequence Description
State Diagrams
Problem PacController + Optional Modules
Definition MotorController
SM-Motors

New Project (Communication box)

Expansion Objects
Hardware insert
parametering
Libraries

POU's insert
POU's editing
Function Check insert FB's in POU's
Error Search
Configuration
parametering FB's (like data structure)
declare data types
declare global variables
Create Task Configuration
Create Visualization
User Program Create Watch- and Receipt Manager

Send User Program

Start and StartUp the user program
Monitor Window of the Editors (Forcen, Set)
configure Trace
Observe &
start Trace
Operate
judging Traces
Message Logger
Visualization
Watch- and Receipt Manager

Fig. 5-4: Method for solving a defined problem

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 5.2 The Structure of a Project

5.2 The Structure of a Project

5.2.1 Program Organization with Tasks

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In General
As a rule, a PacDrive™ M program (runtime program) consists of
several tasks. A task is a program characterized by its priority and
cycle time.
Tasks can be used e.g. to determine that a temperature check is
only made if there are no more important jobs waiting. Or that the
temperature check is made “only“ every 30 seconds.

Fig. 5-5: Software model

Characteristics of a task:
„ It consists of one or several blocks (POUs; program organization
units)
„ It has a priority of between 0 and 31 (0 is the highest priority)

„ Tasks of higher priority supersede tasks of lower priority

„ Tasks of equal priority are processed consecutively in time slices

of 250 µs
„ A maximum of 127 tasks are supported
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5.2 The Structure of a Project

The figure below shows how the individual tasks are processed in
the system.

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Fig. 5-6: Task model

Tasks of higher priority interrupt tasks of lower priority. After the

tasks of higher priority have been processed, the processing of the
interrupted tasks of lower priority is resumed.
If there are several tasks of equal priority and they are not interrup-
ted by tasks of higher priority, the tasks of equal priority will be
processed in the so-called time slice method. This means that each
task is processed for 250 µs before the next task is processed for
another 250 µs.

Overleaf you will find a practical example for a task processing.

1) Task change due to higher priority
2) Task change at the end of a time slice in case of tasks of equal
priority
3) Task change due to higher priority
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 5.2 The Structure of a Project

PDM_Taskmodel_Beispiel_us0003.fh8
t/ms
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Task calculates
Task would like to calculate
3)

Task would not like to calculate

CycleTime

2)
CycleLoad

Cycle finished
0,25
1)
Prio: 250 / 30

Prio: 251 / 31

Prio: 251 / 31

Prio: 251 / 31

Prio: 251 / 31
IEC-Task_5

IEC-Task_4

IEC-Task_3

IEC-Task_2

IEC-Task_1
Task_Rtp
Priority 1

Idle

Fig. 5-7: Practical example for a task model

The following figure shows the connection between the set interval
for a task, the actual interval time and the load time of the task. For
this figure, the following values apply:
„ set interval: 10ms
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„ cycle is the actual interval time

„ load is the processing time or load time of the task

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5.2 The Structure of a Project

priority
IEC Task 2 1)

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Cycle Cycle Cycle Cycle
Load Load
IEC Task 1

5 10 15 20 25 30 35 40 45 50 55 t/ms
1): This delay can be caused e.g. by a task with higher priority or by the system.

Note: This is a greatly simplified representation of the real behaviour.

PDM_CycleLoad_us9912.fh8

Fig. 5-8: Example for the behavior of cycle and load

The system tries to adhere to the set interval. It may happen, howe-
ver, that an interval is longer than the given time. This is the case if
the new start of a cycle is delayed by the system or a task of higher
priority. The system then tries to shorten the next cycle in order to
return to the time grid.
The processing of the programs allocated to a task is marked by
“load“. The processing of the programs must be completed within
the set interval; otherwise there will be a diagnosis message (cycle
time transgression or serious cycle time transgression).

NOTE
There are several system tasks which are processed according to
the same principles. You will find those system tasks and the classi-
fication of their IEC priority later in this manual under the heading
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 5.2 The Structure of a Project

Developing a project-specific task model

At the beginning of a project, you need to develop a task model.
The following points need to be defined:
„ number of tasks
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„ priority of the tasks

„ cycle time

NOTE
Parameters that can be read and/or written via SERCOS may delay
program execution significantly (e.g. for TRACE, Error Quit, ...).
See also EPAS-4 Online help / Control Configuration / Types of
Object Parameters

How many tasks do I need?

In many cases it is sufficient to use one single task for the posi-
tioning function or the entire project. In addition, further tasks may
be required for monitoring functions, PLC functionality, operating
units, etc. The aim is to use as few tasks as possible.
General rules:
„ If possible there should be only one task.

„ Functions that take a longer time to process (e.g. file services,

access to SERCOS parameters) should be moved to a task of
lower priority.
„ It may be necessary to introduce a task of higher priority e.g. for
safety reasons.
„ In practice you rarely need more than three tasks.

„ There should be no tasks of equal priorities. In this case, it is

better to call up the functions from a “jump-in program“. This
results in a fixed time frame for the respective tasks.
Which is the right priority?
The PacDrive™ system has 252 priorities internally. The lowest 32
of these priorities are available for the IEC programs. From the
figure below, you can see the allocation of the IEC priority in the
system priority.
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5.2 The Structure of a Project

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Fig. 5-9: Task model / priority allocation

These rules apply to the user program:

„ If only one task is used, the priority of that task hardly matters.
you should choose a priority between 6 and 31.
„ A task of lower priority may be used for functions which require
e.g. a longer time for processing (e.g. file services, access to
SERCOS parameters) or whose execution may be superseded
(maybe heating regulators).
„ It may be necessary to introduce a task of higher priority for safty
aspects.
„ If the cycle time of a task must be less than 5ms, you should
choose a priority of less than 5 in order to avoid interruptions by
the TCP-IP communication server.
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 5.2 The Structure of a Project

NOTE
Should sporadic cycle errors (505 “simple cycle error“, 506 “multi-
ple cycle error“) occur in your application, the reason may be that
the Ethernet communcation (Ftp, Ping, EPAS-4, ...) slows down the
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processing of your IEC task.

In this case it is advisable to choose the IEC task priority higher
than 5 (priority at 0 ... 4).
If the priority of an IEC task accessing field bus modules is higher
than (0 ... 3) or equal to (4) the priority of the IO map updating, data
consistency is only ensured for an element access (e.g. Byte, Bool,
Word, ...).

Which cycle time should I choose?

For the selection of the cycle time, observe the following points:
„ cycle time of the positioning procedure

„ minimum time in which a CAM function must be processed

„ access to SERCOS parameters (delay! -> see EPAS-4 Online

help / Control Configuration)
„ use of functions with delay

NOTE
A typical value for the cycle time lies in the range of 5 ... 10 ms.
If a cycle time of less than 5ms must be achieved, it may be neces-
sary to change the priority of the task.
-> see also “Which is the right priority“?
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5.2 The Structure of a Project

Monitoring
What types of monitoring are there?
The execution of cyclic tasks is monitored. The following diagnosis
messages can occur:

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Class Diagnosis Language-specific quittable
(default) code diagnosis text (default)
4 313 serious cycle time transgression no

6 317 cycle time transgression yes

What are the causes and how can they be cleared?

313 Serious cycle time transgression

The serious cycle time error of an IEC task is reported if the 10-
fold cycle time is exceeded (see Task Configuration). The task
moves to error state. This state can only be quitted by an IEC
task reset.
Note: The cycle time monitoring of the IEC tasks refers to the
object parameter Load, which is shown in the expansion object
IEC Task.
Cause 1: Call of a parameter or system component which takes
“very long“ to process.
Handling: Check program (e.g. access to SERCOS parameter ->
see Types of Object Parameters or Function WAITT).

Cause 2: Time interval too short.

Handling: Check task configuration.

317 Cycle time transgression

A "minor" cycle time error was detected. It is triggered if the cycle
time is exceeded by more than 250µs. The actual cycle time /
cycle time from the task configuraiton in ms can be found in
DiagExtCode.
Cause: See diagnosis message 313
Handling:
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 5.2 The Structure of a Project

FastTask concept
The “FastTask“ concept permits high-priority, fast, synchronous and
interrupt-controlled IEC tasks.
Further information on the FastTask concept is available in EPAS-4
online help > library “MAx-4“ > IEC_Tasks > General notes on the
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FastTask concept.

NOTE
Before you use the “FastTask“ concept, we recommend that you
familiarize yourself thoroughly with the subject and contact our
application department.

IEC task state machine

Fig. 5-10: IEC task state machine

The state of the task can be read with the help of the configuration
object IEC Task (Parameter State).

Value Designation Meaning

0 no task
initialization state; no task defined

1 READY ready
task defined and ready to start
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2 RUNNING running
task is running

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5.2 The Structure of a Project

Value Designation Meaning

3 CRUNNING cyclic operation
task is running in cyclic operation

4 STOPPED stopped

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task stopped

5 BP standing at breakpoint
task stopped by a breakpoint or single-step

6 ERROR error
a serious error occurred; task suspended

7 FINISHED finished
task has reached its end

Table 5-1: Values of the IEC state machine

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 5.3 ELAU Program Structure

Measuring possibilities
It is possible to measure the capacity utilization of the IEC tasks.
For this purpose you can use the IEC task object, which you can
insert in the control configuration. The individual parameters are
described in the EPAS-4 Online help / Control Configuration.
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Method:
¾ Insert as many IEC task objects in the control configuration as
you have tasks entered in the task configuration.

NOTE
The first IEC task object in the control configuration is linked with
the first task in the task configuration. The first n IEC task objects
are linked with the first n tasks in the task configuration. In principle,
there can be more or less IEC task objects in the system than there
are tasks.

¾ Transmit the project to the PacDrive Controller.

¾ To start measuring, set EnableLoad to on / TRUE.

5.3 ELAU Program Structure

To create a program structure, it is important for you to know in
which areas the blocks (POUs = program organization units) differ.
See also „The Basics of IEC-61131“, page 25.
Create the first level of your program in the programming language
SFC (sequential function chart).
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5.3 ELAU Program Structure

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Fig. 5-11: Example for the first level in SFC

The inferior program parts should be created in FBD.

Fig. 5-12: Example for an inferior program in FBD

More complex functions and function blocks should be program-

med in ST, as this programming language offers comfortable
commands for structuring (e.g. WHILE, FOR, CASE, ...).
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 5.3 ELAU Program Structure
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Fig. 5-13: Example for a function block in ST

Use of state machines

In practice, it has turned out to be sensible, and in most cases
necessary, to build the programming in the programs, functions and
function blocks on state machines.
When programming in structured text (ST), state machines are
created with the CASE command.
CASE lState OF
1: (* initialization *)
< commands >
lState:=lState+1;(* switch to next state *)

2: (* state 2 *)
< commands >
lState:=lState+1;(* switch to next state *)
:
n: (* state n *)
< commands >
lState:=x; (* switch to next state*)
END_CASE;
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5.3 ELAU Program Structure

5.3.1 ELAU Functions and Function Blocks

ELAU offers a number of libraries with functions and function blocks
focusing on certain subjects.
„ Standard.lib

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Standard IEC library with elementary functions (e.g. counter,
string functions, timer, etc.).
„ MAx-4.lib
Interface library for basic functions of MAx-4 PacController.
„ Check.lib
Interface library for checking ARRAYs (debugging functions).
„ Basic.lib
IEC library with positioning functions. Based on MAx-4.lib.
„ IECsfc.lib
Use of IEC steps with V00.06.00 or higher.
„ CSpline.lib
Interface library on VarioCam® CSpline functions for online con-
version of supporting point data into cam data.
„ TorqueCam.lib
Interface library on torque cams.
„ CANL2.lib
Interface library on CAN Layer 2.
„ CANopen_M.lib
Interface library on CANopen Master
„ CANopen_S.lib
Interface library on CANopen Slave.
„ PBDP_M.lib
Interface library on PROFIBUS-DP Master.
„ PBDP_S.lib
Interface library on PROFIBUS-DP Slave.
„ DNet_S.lib
Interface library on Device Net Slave
„ HMI_pcs.lib
Interface library for connection with Lauer PCS
„ HMI_Simatic.lib
Interface library for connection with Simatic.
„ ModBus.lib
Interface library for connection with ModBus.
„ TSC.lib
Interface library for connection with ModBus (see also Operating
Manual HMI Libraries).
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 5.3 ELAU Program Structure

„ VarioCam.lib
Library for complex positioning tasks.
„ PLC Library
Bit functions, communication, PID regulator, conversion
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functions, etc.

Further libraries (separate products)

„ robotic library
„ library for robot applications

Runtime properties
The processing times of the functions and function blocks differ
greatly. Here are some examples:
„ MultiCam3(): typically 12 µs

„ AppendToWriteFile(): several 100 ms

To be able to use blocks with longer processing time, it is often

necessary to increase the cycle time monitoring of a task tempora-
rily. For this purpose, you can use the function
CycleCheckTimeSet().

5.3.2 Parameter Transmission

For parameter transmission, please note:

VAR_IN / VAR_OUT
Transmission of the value, i.e. the value is copied. This means that
the transmission of the value requires memory space and time to
copy the value to the new place.
Therefore avoid transmitting large variables (ARRAY and
STRUCT).

NOTE
Data types of the control configuration (MC_4, D_IN, ...) are auto-
matically transmitted as a reference.
In case of a transmission for reference, the variables in the program
seem to be transmitted “normally“. Internally, however, no copy of
the variable, but only a pointer is transmitted.

VAR_IN_OUT
Transmission to the address of the variable.
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The advantage is that no copy procedure is initiated, which saves

resources and time.

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5.4 Designator Names

5.4 Designator Names

The purpose of the following project conventions is to standardize
the names for objects, variables and instances of objects and
variables. The code and particularly the interfaces of function

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blocks and functions thus are easy to read and understand. Code
maintenance is facilitated.
This should be regarded as a guideline for PacDriveTM users and
programmers, as IEC 61131-3 does not prescribe those
programming conventions.
The designators should all be named with the same prefixes, so
that the object type can easily be identified.

Prefix Type Example

TASK_ Task TASK_Main

FB_ Function block FB_Pos

ST_ Structure ST_BufferEntry

E_ Enumeration type (ENUM) E_PosStates

T_ Reference (TYPE) T_Nibble

P_ Program P_Main

F_ Function F_Convert

Table 5-2: Defining object names

Prefix Type Example

fb Instance name of a function block fbPos

st Instance name of a structure stBufferEntry

e Instance name of an enumeration ePosStates

type (ENUM)

none Instance of a reference type Nibble

Table 5-3: Generate the instances of the object names

Give your variables “talking“ names.

We recommend two prefixes:
„ scope prefix

„ type prefix
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Scope prefix Type Example

no prefix local variable bName

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 5.4 Designator Names

Scope prefix Type Example

I_ input I_bSleighThere

O_ output O_bValveOpen
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g_ global variable g_bName

s_ static variable (constant) s_bName

r_ reference (e.g. to object MC_4) r_MC_4

Table 5-4: Scope prefixes

Type prefix Type Keywords Example

b BOOL boolean (1) bName

c BYTE bit string 8 (8) cName

w WORD bit string 16 (16) wName

lw DWORD bit string 32 (32) lwName

si SINT short integer (8) siName

i INT integer (16) iName

l DINT double integer (32) lName

usi USINT short integer (8) usiName

ui UINT integer (16) uiName

ul UDINT double integer (32) ulName

r REAL floating-point number rName

(32)

lr LREAL long floating-point lrName

number (64)

d DATE date (32) dName

to TOD time (32) toName

dt DT date and time (32) dtName

t TIME duration (32) tName

s STRING string sName

p Pointer pointer pbName

a Array field abName

t Struct structure tbName

Table 5-5: Type prefixes

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5.5 Upper and Lower Case

5.5 Upper and Lower Case

The prefix in object names is always in upper case. The separator
between prefix and object name is an underscore “_“. The prefix for
variable and instance names is always in lower case. The first

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character of a designator is always in upper case. If a designator
consists of several words, the first character of a word is always in
upper case. No separator (e.g. _) should be used between words.

NOTE
EPAS-4 is not case-sensitive.

5.6 Valid Characters

The designators should only contain the following letters, numbers
and special characters:
0 ... 9, A ... Z, a ... z

NOTE
All designators should be in English.

5.7 Create a PacDriveTM project

5.7.1 Problem Definition

We want to create a simple project. The only requirement is that the
output of the MAx-4 flashes at a frequency of 1 Hz.
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 5.7 Create a PacDriveTM project

Define input and output variables, sensor and actuators

Opera-
Input/output
ting Comment
designation
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means
H1 O_bEquipmentOn- An indicator lamp is connected to the
IndicatorH1 output. It will flash at a frequency of
1 Hz as soon as the equipment is
switched on.

Table 5-6: I/O definition

NOTE
Unclear function descriptions result in misinterpretations. Therefore
work with particular diligence at this point. Supplement the descrip-
tion by diagrams where necessary.

Identifier Kind of operating means Examples

A assembly groups

B converter from non-electrical to measuring conver-

electrical sizes and vice-versa ter for tempera-
ture, light, turning
frequency, etc.
approximation
initiators, way and
angle converters

C capacitors

D binary elements, deceleration

facilities, storage facilities

E various

F protection means

G power supplies, generators

H messaging units

K contactors, relays

L inductivities

M motors

N amplifiers, regulators
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P measuring units, test facilities

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5.7 Create a PacDriveTM project

Identifier Kind of operating means Examples

Q high-voltage switch gear

S switches, dials calipers, limit tra-

cers, command

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units, dials

T transformer

U modulator, converter from electrical

sizes to other electrical sizes

V semiconductors, tubes

W transmission ways, lines, aerials

X clamps, connector plugs, sockets

Y electronically actuated mechanical brakes, clutches,

facility valves

Z filters, equalizers, limiters,

terminations

Table 5-7: Identification of electrical operating means

Depict the development over the time

L
1 2 t/s
Fig. 5-14: Development over the time

5.7.2 Hardware
A MAx-4 PacDrive Controller is sufficient to solve this problem.
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 5.7 Create a PacDriveTM project

5.7.3 Configuration

Create a project
¾ To create a new project, click on FILE | NEW.
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You will see a dialog box where the parameters for the online con-
nection are defined.
(-> for further information, see Operating Manual EPAS-4)

Fig. 5-15: Communication parameter box

Fig. 5-16: IP address assistant

Configure a project
The composition of the PacDrive™ system and the “properties“ of
the individual parts are defined in the control configuration.
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5.7 Create a PacDriveTM project

A PacDrive™ system consists of at least one MAx-4 PacDrive Con-

troller, which basically provides the following configuration groups.

Group Explanation
general general parameters of thePacDrive Controller

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diagnosis diagnosis parameters of the PacDrive Controller

versions version parameters of the PacDrive Controller

real-time bus object of the PacDrive Controller

digital output groups object of the PacDrive Controller

digital input groups object of the PacDrive Controller

digital measuring input object of the PacDrive Controller

groups

Table 5-8: Basic configuration groups / objects

¾ Select Resources to call up the configuration editor.

Fig. 5-17: Selection of resources in the Object Organizer

¾ Now select the item Control configuration.

Fig. 5-18: Select control configuration

The minimum configuration for a PacDrive™ system will appear.

For our first example, this is sufficient.
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 5.7 Create a PacDriveTM project
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Fig. 5-19: Control configuration with minimum configuration

Two files for the control configuration, the configuration file and the
parameter file are stored in the PacDrive Controller.
In principle, the objects (MC-4 MotorController, logic encoder, etc.)
are administered in the control configuration.
The “inputs with user initialization“ (see “Types of MAx-4 PacDrive
Controller object parameters“) are stored with their initial values in
the parameter file.

NOTE
If the control configuration file is changed (object added or deleted),
the PacDrive Controller must be reset (or booted)!
For further information, please see Programming Manual -Refe-
rence- , chapter Control Configuration.

In principle, we do not need to change the default configuration for

our project. However, we want to give our output a “sensible“ sym-
bolic name. We already defined this name when defining the
problem.
¾ To enter the name, click on the symbolic name written in brak-
kets after output_0.
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5.7 Create a PacDriveTM project

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Fig. 5-20: Enter symbolic name for output_0

5.7.4 User Program

¾ To be able to enter the program, please switch to Components.

Fig. 5-21: Component selection in the Object Organizer

¾ Click with the right mouse button on “POUs“ and then select
“Add object...“.

Fig. 5-22: Click on POUs with the right mouse button

¾ Now enter a talking name for your program and confirm with OK.
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 5.7 Create a PacDriveTM project
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Fig. 5-23: Add component / dialog box

You are now in program editor for the programming language Struc-
tured Text.

Fig. 5-24: Program editor for Structured Text

¾ Now enter the program and compile it by pressing F11 (or

MENU | PROJECT | COMPILE ALL).
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5.7 Create a PacDriveTM project

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Fig. 5-25: Enter user program

An error message appears!

This error message indicates that no program has been entered in
the task configuration.
¾ Select Resource to change to the task configuration.

Fig. 5-26: Selection of resources in the Object Organizer

¾ Select Task configuration to reach the corresponding editor.

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 5.7 Create a PacDriveTM project
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Fig. 5-27: Select task configuration

First you have to create a task now.

¾ Click with the right mouse button and select "Add task".

Fig. 5-28: Add task

¾ Now give the task a name in the dialog box. For the time being,
leave the priority at 31. As interval, please enter 100 ms.
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5.7 Create a PacDriveTM project

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Fig. 5-29: Define task properties

¾ Confirm your entry with “OK“.

Fig. 5-30: Task configuration with the new task

Now you have to add the newly created program to the task. Pro-
ceed as follows:
¾ Click with right mouse button on Task1 (text in brackets)

¾ Select "Append Program Call"

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Fig. 5-31: Dialog box: Program call

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 5.7 Create a PacDriveTM project

¾ Go Select to open a selection of existing programs.

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Fig. 5-32: Assistant for dialog “Program call“

¾ Select the program “PowerIndicatorH1“ and confirm with OK

¾ Confirm selection in dialog “Program call“ with OK

Fig. 5-33: Task configuration with new task and program call

¾ Now check the program again, using “Compile all" (F11).

No errors have occurred; the project can be transmitted to the
PacDrive Controller.
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5.7 Create a PacDriveTM project

5.7.5 Observe & Operate

Transmit a project
¾ To transmit the program to the PacDrive Controller, select
“Login“ from the menu item ONLINE in EPAS-4.

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You can also establish a connection with the PacDrive Controller
by using the symbol Login.
¾ Answer the following question by selecting “Login".

Fig. 5-34: Login dialog box

Now the program will be transmitted to the PacDrive Controller. As

the configuration has changed, the PacDrive Controller must be
restarted!

Test a program
The following functions can be executed under the menu item
ONLINE:
„ Start
The program is restarted or continued with the next command
after a stop.
„ Stop
The IEC program is interrupted.
„ Reset
The IEC program is terminated.
You can also set breakpoints an then e.g. go through a program
task in single step.
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 5.7 Create a PacDriveTM project

Watch and receipt administrator

You can enter all relevant object parameters and variables in a list
in the watch and receipt administrator and observe them in
ONLINE operation without having to scroll up and down or opening
several windows.
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Trace recording
Trace recording helps to record object parameter values and varia-
ble values chronologically. This function is a kind of oscilloscope.
To be able to create a trace record, you first need to configure the
trace.

Fig. 5-35: Trace configuration

A record of your operating display looks for example like this:

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5.7 Create a PacDriveTM project

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Fig. 5-36: Trace recording of equipment-on indicator H1

NOTE
For further explanations on the trace function, see Operating
Manual EPAS-4.

If you checked your record thoroughly, you certainly noticed that the
frequency at which our equipment-on indicator is flashing is not
exactly 1 Hz.
Why is that?
The IEC program we wrote is only called up every 100 ms. You set
this in the task configuration.
Due to this setting, the “waiting time“ of 500 ms can fluctuate bet-
ween 501 and 600 ms.
For our equipment-on indicator, however, this does not matter since
only a lamp is addressed.

5.7.6 Document and Save a Project

The complete documentation of your project includes the following
parts:
„ performance specification
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„ EPAS-4 project file and maybe further supplementary files

„ software and hardware versions of the components

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 5.8 Expansion of the Example by Positioning

„ test reports
„ acceptance protocol
„ documentation print-out from EPAS-4
Make surey you use "talking" variable names and comment the pro-
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gram components. Otherwise it will be much harder to service the

project.
Program changes should always be documented and also identfia-
ble from the project name. This can be achieved by means of a
vesion number or by including the date in the name of the project
file.
In EPAS-4, there is the menu item PROJECT | DOCUMENTATION
in order to support the user in his documenation.

Fig. 5-37: Dialog “Project documentation“ in EPAS-4

5.8 Expansion of the Example by Positioning

Functions

5.8.1 Problem Definition

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Now we want to expand the “simple“ project by positioning

functions on a motor. Here is the extended problem definition:

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5.8 Expansion of the Example by Positioning Functions

An equipment-on indicator H1 is to flash on the unit as soon as the

unit is active. Packaging material is to be delivered on a belt to the
cutting facility as soon as a start switch has been activated. If the
start switch is switched off again, the plant is to stop.

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Describe the motion profile
The motion profile of the conveyer belt consists of a start cam,
which is driven once when the start switch is activated, a straight
line, which runs permanently during operation, and a stop cam,
which is driven when the plant is switched off (start switch OFF).

Fig. 5-38: Motion profile

Define input and ouput values, sensors and actuators

Opera-
Input/output
ting Comment
designation
means
H1 O_bEquipmentOnIndicat An indicator lamp is connected to the
orH1 output. It will flash with a frequency
of 1 Hz as soon as the unit is swit-
ched on.

S1 I_bStartS1 On -> start unit or unit is active

Off -> stop unit or unit is stopped

Table 5-9: I/O definition

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 5.8 Expansion of the Example by Positioning

Depict the development over the time

H
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H1

L
1 2 t/s

S1

L
t
VEL

Axis 1

t
PDM_Projekt_ZA_2_us0001.fh8

Fig. 5-39: Development over the time

5.8.2 Hardware
To be able to solve the problem, a PacDrive MC-4 is now needed in
addition to the MAx-4 PacDrive Controller.
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5.8 Expansion of the Example by Positioning Functions

5.8.3 Configuration

Configure the project

To be able to realize the project, an additional MC-4 MotorControl-
ler with SM motor is needed to drive the conveyer belt.

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The MC-4 MotorController is entered in the control configuration as
follows:
¾ Click with the right mouse button on Real-time bus

Fig. 5-40: Insert MC-4 MotorController in control configuration

¾ Select “Add MC-4“

¾ Assign the "symbolc" name "conveyer_belt" to the MC-4.

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Fig. 5-41: Assign a symbolic name to MC-4 MotorController

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 5.8 Expansion of the Example by Positioning

NOTE
As we want to “simulate“ the MC-4 MotorController with the motor
for the time being, no further settings in the control configuration
are required at this stage.
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Next we want to give the input S1 a symbolic name. We already

defined this name in the problem definition.
¾ Enter the name in the control configuration.

Fig. 5-42: Create a symbolic name for Input_0

As the motion profile consists of cams, a master encoder is

needed.

NOTE
ELAU calls the principle of cam treatment and processing Vario-
Cam™. An axis (following axis) follows a master position (master
axis). The cam sets the following position in dependence of the
master position.
To forward master positions in the IEC program to cam functions, a
logic encoder is needed.
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5.8 Expansion of the Example by Positioning Functions

The logic encoder is entered as follows:

¾ Click with the right mouse button on MAx-4

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Fig. 5-43: Add a logic encoder to the configuration

¾ Select logic encoder

¾ Assign the symbolic name "MasterEncoder" to the logic enco-
der.

Fig. 5-44: Assign symbolic name for logic encoder

5.8.4 User Program

Now create a new program (as described above) to program the
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motion function for the conveyer belt.

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 5.8 Expansion of the Example by Positioning

¾ First you have to load the cam profiles and adapt them to the
problem:
(* load profiles*)
StartKurveId:=ProfilLoad('modisin');
ProfilSetLambda(StartCamId, 1.0);
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(* -> dwell -> velocity *)

CyclicCamId:=ProfilLoad('straight');
(* -> velocity -> velocity *)

StopCamId:=ProfilLoad('modisin');
ProfilSetLambda(StopCamId, 0.0);
(* -> velocity -> dwell *)

NOTE
The ELAU libraries are described in detail in the EPAS-4 Online
help.

¾ Now the individual cams have to be scaled:

(* scale axes---------- *)
lrYFactor1:=ScalFollPos(1.0, g_lrPartLength,
g_K_MS);(* start cam *)
lrYFactor2:=ScalFollPos(1.0, g_lrPartLength,
g_K_ST);(* cyclic cam *)
lrYFactor3:=ScalFollPos(1.0, g_lrPartLength,
g_K_MS);(* stop cam *)

NOTE
The function “ScalFollPos“ takes over the calculation for lrYFactor.
It merely makes the following calculation:
ScalFollPos:=(m * sMasterPos) / K;

¾ Now the actual positioning procedure is programmed:

(* start cam ---------------------------------- *)
4:(* prepare start cam*)
bCamReset:=TRUE;
g_lState_1:=g_lState_1+1;
5:(* start start cam*)
CAM(lAxisId:= _ConveyerBelt, lEncId:=
_MasterEncoder,
lProfilId:= StartCamId, lrXOffset:= 0.0,
lrYOffset:= 0.0, lrXFactor:= g_lrPartLength,
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lrYFactor:= lrYFactor1,lrXLimMin:= 0.0,

lrXLimMax:= g_lrPartLength,bXLimMinOn:= TRUE,
bXLimMaxOn:= TRUE, iXSetposMode:= ABSOLUTE,

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5.8 Expansion of the Example by Positioning Functions

lrXSetposPos:= 0.0, iYSetposMode:= ABSOLUTE,

lrYSetposPos:= 0.0, bReset:= bCamReset);
bCamReset:=FALSE;
IF (CAM.lResult = 0) THEN
Schlz_DC:=0;

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bCamReset:=TRUE;
g_lState_1:=g_lState_1+1;
END_IF;
(* cyclic cam ----------------------------- *)
(* 1st cycle must have different position manupula-
tion! *)
6:(* start cyclic cam *)

:
¾ Now you have to program the positioning coordinates.

NOTE
The complete example project can be found on the EPAS-4 CD.

¾ Create a new task in the task configuration and enter the pro-
gram “conveyer_belt“. Please note that the priority of the pro-
gram “conveyer_belt“ must be higher than that of the equipment-
on indicator. Set priority = 30. As interval time, select 10 ms, so
that the cams can be linked fast enough and there will be no
"jumps" in the positioning movement.

Fig. 5-45: Task configuration with the two tasks of different priorities

5.8.5 Observe & Operate

Transmit the project

Now log into the PacDrive Controller (as described above).

Program test / debugging

In addition to the possibilities presented in the first version of our
project, there are further possibilities, which are desribed below.
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Single step
The program can be run in single-step mode. Proceed as follows:

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 5.8 Expansion of the Example by Positioning

¾ First you have to define the debug task. Go to the task configura-
tion and click with the right mouse button on the task you want to
debug.
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Fig. 5-46: Define debug task in the task configuration

¾ Select “Set Debug Task“. [DEBUG] appears as a marker behind

the task.

Fig. 5-47: Display of the debug task in the task configuration

¾ Now you have to set a breakpoint. A breakpoint is a point in the

program at which processing is halted. To set a breakpoint, go to
a POU and click with the left mouse button on the line number at
which the program is to be halted. The following safety check
appears:

Fig. 5-48: Safety check when setting a breakpoint

¾ Confirm with “Yes“ to set the breakpoint. The line at which you
set the breakpoint is marked in color.
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5.8 Expansion of the Example by Positioning Functions

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Fig. 5-49: ST program editor in online operation with breakpoint

¾ Now start the program. As soon as the breakpoint is reached,

the color mark will change.

Fig. 5-50: Breakpoint reached

¾ Now you can continue running the program (or the POU) in sin-
gle-step. You can carry out single steps using the symbol or the
menu item ONLINE or the function keys.
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 5.8 Expansion of the Example by Positioning
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Fig. 5-51: Symbol for single-step and menu items Single-step

Call hierarchy
This function can be used to display the call stack in case of an
actual diagnosis message.
Example:
¾ We will cause an error on purpose by extending the program as
follows:

Fig. 5-52: ST program with error

¾ Start the program and wait until the diagnosis message is trigge-
red (err-LED on MAx-4 flashing).
PD_UserMan_Richtlinien_us.fm

¾ Open the message logger and click with the right mouse button
on the error message Division error.

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5.8 Expansion of the Example by Positioning Functions

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Fig. 5-53: Select call hierarchy in the message logger

¾ Select Call hierarchy...

Fig. 5-54: Dialog: Call hierarchy

The last component is always the component at which the proces-

sing is standing at the moment.
After selecting the component and clicking on the button Go to, the
selected component is loaded into a window and the line or network
where the processing is at the moment is shown.

5.8.6 Document and Save the Project

NOTE
Again you should not forget to document and save four project!
See also „Document and Save a Project“, page 130.
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 6.1 Method

6 Error Search Strategies

In this chapter we will try to make it easier for you to look delibera-
tely for errors in your system.
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6.1 Method

The LEDs permit first conclusions as to the cause of

LEDs on the units see “LEDs“
the error.

control With the help of object parameters, the error can be see “Control
configuration narrowed down further in the control configuration. Configuration“

The message logger permits a detailed error

analyis.
Thanks to the error history, even following errors see
message logger
can be recognized easily. “Message Logger“
The message logger is the most important tool for
error analysis in the PacDrive™ M system.

Table 6-1: Method for commissioning

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ELAU AG Programming Manual page 143

6.2 LEDs

6.2 LEDs
From the LEDs, first conclusions as to the cause of an error are
possible.
The LEDs are contained in the chapter “Configuration /

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Programming / Diagnosis“ of the corresponding device-specific
operating manual.
Further documentation:
„ MAx-4 Controller operating manual

„ MC-4 Servo Drive operating manual

„ ...

AU
R
MAx-4

reset
wd pow
C ® US
reset LISTED
(INDUSTRIAL CONTROL
EQUIPMENT)
wd pow 72KL

err bus
err
24V/wd

err bus
com1 rs232

X1

err
analog in

X5

X2
com2 rs485

X6
digital in

X7
X3

X8
physical enc
touchprobe in/digital out

X9
ethernet

X4
X10
Made in Germany

Fig. 6-1: Diagnosis LEDs of the MAx-4 PacDrive Controller

PD_UserMan_Fehlersuche_us.fm

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 6.3 PLC configuration

6.3 PLC configuration

For a more detailed diagnosis, you can use the diagnosis parame-
ters in the control configuration.
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Fig. 6-2: PLC configuration

The MAx-4 PacDrive Controller has the object parameters Diag-

Code, DiagExtCode and DiagMsg. The parameters contain the
currently most important diagnosis information. They are only over-
written if a diagnosis message of a diagnosis class of higher priority
occurs. Diagnosis messages of equal or lower priority will not
change the parameter. Such diagnosis messages are only reset by
quitting.

Example:
DiagCode 3117
DiagExtCode "1.1 3117"
DiagMsg "MC-4/axis1: motor temperature too high"
In case of axis-specific errors (sender: MC_4), the MC-4 MotorCon-
troller object parameters DiagCode and DiagMsg are triggered. The
contents of the parameters arise in analogy with the MAx-4
PacDrive Controller diagnosis parameters. The same rules apply
for updating.

Example:
DiagCode 3117
DiagMsg "motor temperature too high"

NOTE
For further information, please see EPAS-4 Online help, chapters
PD_UserMan_Fehlersuche_us.fm

“Control Configuration“ and “Diagnosis“.

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6.4 Message Logger

6.4 Message Logger

6.4.1 Function

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The message logger records system, diagnosis and usage messa-
ges in a message log buffer in the RAM range of the MAx-4
PacDrive Controller.
The errors are recorded in chronological order in a ring buffer
(approx. 325 entries). A time stamp (ms since system start), the
time, object, instance, diagnosis code, external diagnosis and mes-
sage text are recorded.
As the message buffer in the RAM can only be buffered for a maxi-
mum of 7 days in case of power failure, it is possible to save the
message log buffer in a messge log file on the disk in the MAx-4
PacDrive Controller. The MAx-4 PacDrive Controller can save
several message log files on its disk.
The message log files can be transmitted from the MAx-4 PacDrive
Controller to the PC with the help of EPAS-4. Several message log
files can be saved there as well.

EPAS-4 window
EPAS4.mel
n-files
Text.mel PC

new messages from:

- system
- diagnosis
- IEC program

MAx-4
ring buffer (RAM)
(storage n-files
max. 7 days) EPAS4.mel Text.mel

message log buffer message log files

PDM_Meldungslogger_us.vsd

Fig. 6-3: Resources / Message logger

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 6.4 Message Logger

6.4.2 The Functions of a Message Logger in Detail

Save and load a log file
Load the current message logger from MAx-4 PacDrive Controller
in EPAS-4.
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Save log file

message log buffer (RAM)
-> message log file (MAx-4 file)
Reset log entries
clear message log buffer (RAM)
Save and reset log file
message log file (RAM)
-> message log file (MAx-4 file)
-> clear message log buffer (RAM)
Load log file ...
message log file (MAx-4 foile)
-> PC file
-> display
Delete log file ...
delete MAx-4 file
Load from file ...
PC file
-> display
Save as file ...
display
-> PC file

EPAS-4 / Message log-

Functions IEC program
ger (menu item Tools)
show current message save and load log file
logger in EPAS-4

save log file save log file MsgLogSave()

reset log entries reset log entries MsgLogReset()

save and reset log file save and reset log file

load log file load log file

delete log file delete log file MsgLogDelete()

PD_UserMan_Fehlersuche_us.fm

load from file ... load from file ...

ELAU AG Programming Manual page 147

6.4 Message Logger

EPAS-4 / Message log-

Functions IEC program
ger (menu item Tools)
save as file ... save as file ...

entry in message logger MsgLogInsert()

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(RAM)

Table 6-2: Functions of the messge logger and access types

NOTE
It is also possible to filter the message recording (see EPAS-4
Online help / Control Configuration / MAx-4 / MsgFilter) or to filter
only the display of the messages (see next chapter).

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 6.4 Message Logger

6.4.3 Filtering Messages

The system messages in the message logger can be filtered in two
ways:
„ Filter when recording them from the system via the object para-
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meter MsgFilter in the control configuration.

„ Filter when displaying in EPAS-4 using the menu item TOOLS |
SET FILTER...
The message logger differentiates between 16 different message
classes. These classes can be switched on and off individualy.

Fig. 6-4: Resources / Message logger / Dialog: Messge filter

NOTE
The individual classes are described in the EPAS-4 Online help
under PLC Configuration.
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6.4 Message Logger

6.4.4 Establish a Connection with the PacDrive Controller

MAx-4 in Case of an Error
If you establish the connection with the MAx-4 PacDrive Controller
in case of an error, the following selection box will appear:

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Fig. 6-5: Resources / Message logger / Establish a connection in case of an error

In case of an error, the menu item Load message file is selected.

¾ If you select LOGIN, the message file will be loaded from the
MAx-4 PacDrive Controller in EPAS-4 and displayed.

Fig. 6-6: Resources / Message logger / Message file

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 6.4 Message Logger

Meaning of the entries in the message logger

No.
Consecutive number of the logger entries. The highest number is
the latest logger entry.
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Time stamp
Time since switching on the MAx-4 PacDrive Controller in the
format:
DDD HH:MM:SS.sss
with
„ DDD - days

„ HH - hours (0 ... 23)

„ MM - minutes (0 ... 59)

„ SS - seconds (0 ... 59)

„ sss - milliseconds (0 ... 999)

In versions < 00.07.00 the time is shown in ms.

Type
Shows the filter type of the message.
See also EPAS-4 Online help, Control Configuration
MAx-4.General.MsgFilter.
Object
Shows the type of the object that caused the logger entry.
See also EPAS-4 Online help / Control Configuration.
Instance
Shows the instance of the object that caused the logger entry.
See also EPAS-4 Online help / Control Configuration.
Diag. Code
Shows the diagnosis code.
See also EPAS-4 Online help / Diagnosis.
Ext. diagnosis
Provides optional additional information on the diagnosis code. The
information is also shown as optional additional information in the
control configuration in MAx-4.diagnosis.DiagExtCode.
Message text
Shows the corresponding message text for the diagnosis code.
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6.5 Further Possibilities for Diagnosis

6.5 Further Possibilities for Diagnosis

NOTE

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For further information, please see Operating Manuals, chapter
“Diagnosis and Maintenance" and EPAS-4 Online help, chapter
"Diagnosis".

6.5.1 Trace
The purpose of the trace recording is to record the time relations
and the dynamic behavior of the system.

NOTE
For further information, see Operating Manual EPAS-4.

6.5.2 Debugging
The PacDrive™ system provides comfortable program debugging
facilities for the user.
See also „Program test / debugging“, page 138.

6.5.3 Check Library

If the “Check“ library is integrated in the project, the function block
Check, which checks the limits of array elements, is automatically
called up every time an array element is accessed. Moreover,
division errors (division by 0) are recognized.

NOTE
For the reason described above, the integration of the “Check“
library increases the runtime. The “Check“ library should therefore
be removed from the project once the test phase is completed.
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 6.5 Further Possibilities for Diagnosis

6.5.4 Call Hierarchy (CallStack)

You can start the call stack command (“Online > Call hierarchy“)
when the project stops at a breakpoint. A list of components
actually in the call stack is shown.
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Example for a call hierarchy:

The first component is always PLC_PRG, as this is where the
processing starts.
The last component is always the one that is up for processing at
that particular moment.
After you selected one of the components and clicked on the button
"go to", the selected component will be loaded into a window, and
the line or network in which the processing is will be shown.
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6.5 Further Possibilities for Diagnosis

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 7.1 Overview

7 Teleservice

7.1 Overview
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In recent years, the significance of teleservice in the capital goods

industry has increased dramatically. This trend results not only from
the Information and Communication technologies (IaC) available
for teleservice (or remote service), but also from the possibility to
create new unique selling points on the global markets.
Teleservice means not only remote support for fault clearance.
Rather, the use of teleservice technologies opens up new and
above all innovative approaches for customer service over the
entire life cylce of the packaging machine (“after-sales service“).
This is why also terms like “tele-engineering“ or “teleconsulting“ are
used.

Fig. 7-1: Teleservice concept

Definition
Teleservice is defined as the support of customer service and appli-
cation departments by IaC components and services, which make it
possible to execute diagnosis and solve problems on machines
from a remote place. Teleservice is used for the installation of new
machines and plants, for fault clearance and for the transmission of
new software versions. In the future, new applications for teleser-
vice will include process support and customer consulting.
PD_UserMan_Teleservice_us.fm

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7.1 Overview

Connection of the PacDrive Controller

The MAx-4 PacDrive Controller (server) has a RS232 and an
Ethernet interface. The RS232 interface is the basis for serial com-
munication (connection of a zero modem cable or a modem). The
Ethernet interface permits a direct connection of the control to a

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LAN (local area network) with TCP/IP support. The standard client
(PC) also has a COM interface and an Ethernet card with appro-
priate connection. Thus, both sides have the physical interfaces to
the outside world.
There are different options for connecting to the PacDrive™
System via a client:
„ local Ethernet,

„ direct telecommunication connection (via modem) and

„ internet connection.

Local Ethernet
The first way to do a telediagnosis on the controller is a simple
Ethernet connection. As the figure below shows, server and client
must be connected via a TCP/IP network. The network can e.g. be
installed within a company and connect several computers in a
network.

Server Client

Ethernet über TCP/IP

Fig. 7-2: Local Ethernet network

This method requires the TCP/IP protocol. Both computers must

have an IP address, which must be unambiguous in the network.
Ethernet by default supports the connection via a local Ethernet.
Therefore it will not be described here.
Direct telecommuncation connection
A direct modem connection to a control can be established with the
help of the EPAS-4 Automation Toolkit.
Advantage:
Full access to all functions of the system.
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 7.2 Direct Telecommunication Connection

Disadvantage:
You can only establish a direct connection between two computers.
EPAS-4 must be installed on the client computer. This means that
the system is no longer independent of platforms.
Internet connection
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Teleservice is to ensure worldwide access to the MAx-4 PacDrive

Controller. The World Wide Web is particularly suitable for this pur-
pose. No matter where you are on the globe, you can dial up to the
Internet with a PC, modem and telephone connection.
Advantage:
Remote diagnosis can be used independent of location and plat-
form. EPAS-4 needs not be installed.
Disadvantage:
Very restricted system access.

7.2 Direct Telecommunication Connection

By all means observe the following information:

NOTE
As the modem is connected to the serial interface COM1 of the
MAx-4 PacDrive Controller, a serial EPAS-4 connection is not pos-
sible at the same time. Therefore you should always have a
functioning TCP/IP connection for EPAS-4 if you use telservice via
modem connection.

7.2.1 Principle
In principle, teleservice via a direct telecommunication connection
with a modem and EPAS-4 enables the user to use all the functions
that are available in case of a “direct“ connection.

WARNING!
Restricted view of the machine!
Risk of injuries and material damage!
¾ Only do teleservice if a qualified person is available on site, i.e.
at the machine.
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7.2 Direct Telecommunication Connection

¾ Always keep in touch with this person (e.g. via telephone or

video conference).

The prerequisite for this is a modem connection (on client and

server side).

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Fig. 7-3: Direct telecommunication connection

You can use an analog or ISDN modem. If you use an ISDN

modem, make sure that not the normal ISDN driver, but an analog
modem emulator is active on the client computer. The connection
to the server requires an analog modem, as ISDN is not yet
supported.
Again, the TCP/IP protocol must be installed on both sides. Client
and controller must have an IP address, which the user can assign
himself. Only those two computers are connected, so that you need
not check if those IP addresses are already being used by other
computers.
The modem is connected to the serial port COM1 of the MAx-4
PacDrive Controller. To start the PPP server, which controls the
connection in the PacDrive Controller, a project containing a
modem object must be loaded and the parameter Com1User of the
MAx-4 PacDrive Controller must have the value “Modem / 1“ or
“Auto / 2“.
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 7.2 Direct Telecommunication Connection
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Bild 7-4: Configuration of the modem

The modem is then recognized automatically when the PacDrive

controller is booted, as long as it is switched on when booting and
connected to the COM port.
If no modem which is on is detected, the COM port is released for
serial EPAS-4 communication.
See also „Settings in the Project for the PacDrive Controller“,
page 162.
The MAx-4 PacDrive Controller monitors the serial port until the
modem answers an incoming call and then establishes a
connection.
The call is initialized by the telecommunication network of the
remote PC. When dialling up, the user has to enter the user name
and the password entered in the control configuration for the
Modem object in order to be able to establish a connection. If user
name and password are correct, the connection is established. On
the remote PC, it can be treated like a normal TCP/IP connection to
the MAx-4 PacDrive Controller.
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7.2 Direct Telecommunication Connection

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Fig. 7-5: Overview of the assignment of TCP/IP addresses

On the client side, a communication network must be installed to

access the server. You can set up the network with the help of an
assistant. For detailed instructions, please consult the Windows
online help. We will only explain the most important settings. You
need to enter the telephone number of the connected modem on
the server and its IP address.
When the client dials up the server via the modem, a username and
password is requested for security reasons. Those parameters can
be configured in EPAS-4.

7.2.2 Selection of a Suitable Modem

The modem used for the connection to the MAx-4 PacDrive Con-
troller must be Hayes-compatible and support the AT command set.
Nevertheless, you have to check if the following settings are
entered in the standard configuration:
„ auto-answer function (AT S0=2 - modem answers call after 2nd
ring)
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 7.2 Direct Telecommunication Connection

„ DCD signal processing (AT &C1 - DCD signal follows carrier

state)
„ hardware handshake on (AT &R0 - modem reacts to CTS signal)
„ echo function off (AT E0)
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„ modem state messages on (AT Q0)

„ verbose modem state messages (AT V1)
The serial interface for the modem communication has the follo-
wing settings:
„ baud rate: 38400

„ data bits: 8

„ stop bits: 1

„ parity: none

When starting, the MAx-4 PacDrive Controller tries to initialize the

modem accordingly. This is done via the InitString parameter of the
modem. The appropriate AT commands for the basic settings must
be entered here. For most modems, the standard init string should
already contain the necessary commands. However, you should
check in the modem manual if these commands are the same as
those of the modem. If necessary, the parameter has to be adju-
sted. The modem should automatically detect the settings of the
serial interface. If automatic detection is not possible, you will have
to make the necessary settings manually. For further information,
consult the modem manual. Usually settings can be changed by
means of DIP switch or with the help of a terminal program such as
Hyperterminal (part of Windows).

ELAU recommends:
„ INSYS modem 56k (INSYS order number: 110.756.WD03)
„ INSYS Modem 144 (INSYS order number: 110.6144.WD03)
„ Westermo TD-33 v. 90 telemodem (Westermo order number:
31790010)
„ Westermo TD-32 telemodem (Westermo order number: 3178-
0040)
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7.2 Direct Telecommunication Connection

7.2.3 Settings in the Project for the PacDrive Controller

¾ Enter the object “Modem“ in the control configuration.

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Fig. 7-6: Object “Modem“ in the control configuration

The seven parameters of the modem object have the following

meanding:

RemoteIpAddress
IP address for the computer that connects via modem to the MAx-4
PacDrive Controller. The MAx-4 PacDrive Controller automatically
assigns this IP address to the computer when establishing the con-
nection. By default, this address is set to 190.200.100.101.

LocalIpAddress
IP address assigned to the MAx-4 when establishing a modem con-
nection. This IP address is valid for the PPP adapter of the MAx-4
only. By default, this address is set to 190.200.100.100. It cannot
be changed.

UserName
User name that must be entered when logging in to establish a
connection.

Password
Password that must be entered when logging in to establish a
connection.
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 7.2 Direct Telecommunication Connection

InitString
The init string contains a sequence of AT commands that are sent
to the modem during the initialization phase. In oder to ensure cor-
rect modem operation on the MAx-4 PacDrive Controller, some
basic settings are required on the modem. The default init string
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makes these settings and should be valid for most standard

modems. However, you should check the AT commands of the
modem in the modem manual and, if necessary, change the init
string in order to switch on the required functions. The following set-
tings are required:
Default InitString: AT&F E0 Q0 V1 &S0 &C1 &R0 S0=2

Default Meaning
AT initiate an AT command

&F set the modem to the default configuration

E0 switch off the echo function of the modem

Q0 switch on the modem state messages

V1 verbose modem state messages

&S0 DSR signal always 1 if modem ready

&C1 switch on DCD signal (DCD follows the state of the

carrier)

&R0 switch on hardware handshake (modem treats the

CTS signal)

S0=2 switch on auto-answer function (modem answers after

second ring)

Table 7-1: Meaning of the default InitString

ExpInitString
As InitString is limited to 40 characters, another 40 charcters can
be entered in ExpInitString in order to avoid possible modem pro-
blems. The latter will be transmitted to the modem in a second
round. The string must start with AT, even if no further commands
follow. ExpInitString is only transmitted to the modem if InitString
was processed correctly.
Default-ExpInitString: AT +MS=,0

Value Meaning

AT initiate an AT command
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7.2 Direct Telecommunication Connection

Value Meaning

+MS=,0 switch off automatic baud rate detection

This command is only necessary if hand-
shake problems occur in the dial-up proce-

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dure and may not be available in your
modem if it has no Rockwell chip set.
The modem recommended by ELAU sup-
ports this command.

Table 7-2: Meaning of the default ExpInitString

State
Shows the state of the modem.

Value Meaning
Init / 0 checking modem

No Modem / 1 no modem connected to COM1 / modem off

Offline / 2 modem in offline mode

Online / 3 modem in online mode (incoming call)

InitString OK / 4 InitString accepted by modem

InitString ERROR / 5 The modem could not be initialized with the init string
(maybe the InitString of the modem is faulty or the
modem could not be set accordingly). To restart the init
procedure, you either have to switch off and on the
modem or first change the Com1User parameter of the
MAx-4 object via a TCP/IP connection and then write it
again.

InitString TIMEOUT / no reply from modem to IniString (see InitString

6 ERROR / 5)

ExpInitString OK / 7 ExpInitString accepted by modem

ExpInitString ERROR InitString causes error on modem (see InitString

/8 ERROR / 5)

ExpInitString TIME- no reply from modem to ExpInitString (see InitString

OUT / 9 ERROR / 5)

Table 7-3: Possible values for State

MAx-4.Com1User
Furthermore, there is the parameter Com1User of the object “MAx-
4“ under “General“ in Meaning. Here, the COM1 port of the MAx-4
PacDrive Controller is set. It has to be set to “Modem / 1“ or “Auto /
2“.
PD_UserMan_Teleservice_us.fm

The setting “Modem / 1“ always allocates COM1 to the modem; the

COM1 port is checked until a modem is found. The check is done

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 7.2 Direct Telecommunication Connection

every 10 seconds.
The setting “Auto / 2“ checks the COM1 port. If a ready modem is
detected, that modem is initialized. Otherwise the port is always
released for EPAS-4.
In principle, the parameter only has an effect if its value was
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actually changed in the MAx-4 PacDrive Controller. To re-initialize

e.g. a modem, the parameter must first be set from Modem or Auto
to None and then reset to the desired value. In the state “Modem /
1“ or “Auto / 2“, the MAx-4 PacDrive Controller also reacts to the
removal or connection of devices.

NOTE
The parameter Com1User directly influences the serial interface
COM1. Therefore this parameter must not be changed by a serial
EPAS-4 connection or a modem connection. This would mean that
you cut off the connection of the COM port for your own connection,
which would result in a serious communication error. In case of
remote servicing via modem connection, there must always be a
functioning local TCP/IP connection, so that the serial interface can
be switched accordingly.

MAx-4.Com1UserState
The parameter Max4.Com1UserState returns the state of the
COM1 port.

Value Meaning

Init / 0 checking for connected devices

EPAS-4 / 1 Com1User is EPAS-4.
Modem -> EPAS- Com1User is Modem; no modem found or
4/2 modem could not be initialized
Auto -> Search / 3 Com1User is Auto; looking for modem
Modem -> Search Com1User is Modem; looking for modem
/4
Modem -> Test / 5 Com1User is Modem; initializing detected
modem
Modem -> Offline Com1User is Modem; a modem was found
/6 and initialized successfully
Modem -> Online Com1User is Modem; modem receiving
/7 incoming call
PD_UserMan_Teleservice_us.fm

None / 8 Com1User is None

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7.2 Direct Telecommunication Connection

Value Meaning

Auto -> Test / 9 Com1User is Auto; initializing detected

modem
Auto -> EPAS-4 / Com1User is Auto; no modem found or

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10 modem could not be initialized
Auto -> Modem Com1User is Auto; a modem was found and
Offline / 11 initialized successfully
Auto -> Modem Com1User is Auto; modem receiving inco-
Online / 12 ming call

Table 7-4: Possible values for MAx-4.Com1UserState

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 7.2 Direct Telecommunication Connection

7.2.4 Settings on the Remote PC

To be able to connect a PC to the MAx-4 PacDrive Controller via
modem, several prerequisites must be fulfilled:
„ EPAS-4 installed
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„ telecommunication network (Windows 95/98) or RAS service

(Windows NT) with TCP/IP installed
„ modem installed

The installation of EPAS-4 is described in the User Manual EPAS-4.

Below, the installation of a telecommunication connection and a
modem for Windows 95/98 and Windows NT are described
separately.

Windows 95/98
Installation of the telecommunication network
¾ To check if the telecommunication network is already installed,
select the menu item Software from the Control Panel.

Fig. 7-7: Control panel Win 95/98

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7.2 Direct Telecommunication Connection

¾ In the register sheet “Windows Setup“, select the component

“Connections“ and click on the button “Details...“ .

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Fig. 7-8: Properties of Software / Windows Setup

¾ Mark the item Telecommunication network, if it is not marked

already.

Fig. 7-9: Connections

¾ Confirm your selection by clicking on the button “OK“.

This starts the installation of the telecommunication network, which
requires your Windows installation CD. The telecommunication net-
PD_UserMan_Teleservice_us.fm

work will be available after restarting your PC. As the TCP/IP

protocol will be installed in the next step, you do not need to restart

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 7.2 Direct Telecommunication Connection

your PC at this stage, because another restart will be necessary

after the TCP/IP installation.
Installation of the TCP/IP protocol
¾ If the TCP/IP protocol is not yet installed on your PC, you will
have to do it now. The installation is described in the Operating
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Manual EPAS-4.
Configuration of telecommunication connection and modem
¾ Start the telecommunication connection (Start -> Programs
-> Accessories -> Telecommunication Network for Win95; Start
-> Programs -> Accessories -> Comminication -> Telecommuni-
cation Network for Win98). When you start for the first time or
select Create new connection, an assistant will appear and take
you through the configuration of your connection. If no modem
has been installed, this will be done now.

Fig. 7-10: Dialog: Install new modem

You have the choice to have the modem detected automatically or

to select it from a list.
¾ Clicking on “Continue“ will take you through the modem installa-
tion procedure.

NOTE
In case of installation problems, please consult the manual of your
modem.
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7.2 Direct Telecommunication Connection

¾ Enter the location settings for the modem.

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Fig. 7-11: Location settings

The modem is now installed and you can establish a connection

from the PC to the MAx-4 PacDrive Controller using “Create new
connection“.
Establishing a connection between the PC and the MAx-4 PacDrive
Controller
¾ In the telecommunication network, select “Create new connec-
tion“.

Fig. 7-12: Telecommunication network / Create new connection

¾ Give the connection a name and select the desired modem.

Then click on the button “Configure...“ to make the modem set-
tings.
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 7.2 Direct Telecommunication Connection

.
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Fig. 7-13: Create new connection

¾ Select the register sheet “Settings“. Please check the connec-

tion settings for the following values:
– data bits: 8
– parity: none
– stop bits:1
¾ Under “Extended modem settings“, error control and data com-
pression should be marked and “Hardware handshake (RTS/
CTS)“ should be set as Data flow control.

Fig. 7-14: Extended modem settings

¾ After clicking on OK twice, you can terminate the first step of the
assistant with “Continue“.
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7.2 Direct Telecommunication Connection

¾ In the second step, enter the telephone number at which the

MAx-4 PacDrive Controller can be reached and confirm with
“Continue“.

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Fig. 7-15: Create a new connection

¾ Then the connection is created by clicking on the button Finish.

¾ Call up the properties dialog of the connection by clicking with
the right mouse button and selecting “Properties“ from the con-
text menu.

Fig. 7-16: Connection with MAx-4 PacDrive Controller / General

¾ Select the register “Server Types“ and make the following set-
tings:
– Type of telecommunication server: PPP: Internet, Windows
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 7.2 Direct Telecommunication Connection

NT Server, Windows 95 or Windows 98

– Deactivate all other options
– Activate only TCP/IP as admissible network protocols
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Fig. 7-17: Connection with MAx-4 PacDrive Controller / Server types

¾ Now make the TCP/IP settings by clicking on the corresponding

buttons.
– mark the IP address assigned by the server
– activate the name server adress assigned by the server
– activate IP header compression
– activate standard gateway in the remote network

Fig. 7-18: PPP TCP / IP settings

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7.2 Direct Telecommunication Connection

¾ Click on OK
¾ The connection is now available.

Use standard gateway for remote network

Indicates if the standard gateway is used in the remote network for

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the duration of the connection. When you create a
telecommunication or VPN connection, a new standard route using
the connection to the RAS server is added to the IP routing table.
This standard route receives the lowest metrics. If a standard route
already exists, it remains in the routing table, but receives higher
metrics. If a new standard route with lower metrics is added,
locations that could previously be reached via the original standard
route may no longer be reachable.
A computer with this operating system in a firmware network has
e.g. a LAN connection in that network and is configured with a
standard gateway of the local IP router. If the option Use standard
gateway for remote network is selected, the standard gateway
and not the local company router becomes the Internet service
provider when the user calls up an Internet service provider. This is
why all locations in the corporate network, except those in the local
network, cannot be reached for the duration of the connection to
the Internet service provider. If the option Use standard gateway
for remote network is not selected, the original standard route
remains unchanged, no new standard route is added and the
locations on the Internet are not available.

Windows NT 4.0
Set up TCP / IP protocol
¾ If the TCP/IP protocol has not yet been installed on your PC, you
have to do it now. The installation is described in the Operating
Manual EPAS-4.
Set up the RAS service (Remote Access Service)
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 7.2 Direct Telecommunication Connection

¾ From the Control panel, select “Network“.

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Fig. 7-19: Control panel Win NT

¾ Check in the dialog box “Network“ in the register “Services“ if the

RAS service exists. If not, you have to install it using the button
“Add...“.

Fig. 7-20: Control panel Win NT / Network / Services

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7.2 Direct Telecommunication Connection

¾ Select RAS service and click on “OK“.

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Fig. 7-21: Control panel Win NT / Network / RAS serivce

¾ If no modem has been installed, the RAS setup will ask if you
want to call up the modem installation program. Confirm with
“Yes“.

Fig. 7-22: RAS setup

You have the choice to have the moden detected automatically or

selet it from a list.
¾ Clicking on the button “Continue“ will take you through the instal-
lation procedure.

NOTE
In case of installation problems, please consult the manual of your
modem.
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 7.2 Direct Telecommunication Connection

¾ Now the RAS service should detect the modem installed and
and select it (confirm with OK).
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Fig. 7-23: Add RAS device

¾ Now select a connection in the RAS setup and click on the but-
ton “Network...“.

Fig. 7-24: RAS setup

¾ Mark only TCP/IP as client protocols and confirm your selection

with “OK“.

Fig. 7-25: Newtork configuration

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7.2 Direct Telecommunication Connection

¾ Now you need to check under “Configure...“ if the setting is „out-

going calls only“. (If the PC is to take calls for other purposes,
you can also mark incoming and outgoing calls).

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Fig. 7-26: Configure connection purpose

¾ Confirm your selection with “OK“

¾ Select “Continue“ to complete the configuration.
Now the RAS service is available.
Establishing a connection between PC and MAx-4 PacController
¾ Start the telecommunication network under Start, Programs,
Accessories, Telecommunication network. You will be asked to
create a new directory entry (confirm with OK).

Fig. 7-27: Assistant for new directory entries

¾ Give the connection a name, mark the checkbox “No further

information required“ and confirm by clicking on “Finish“. This
will take you to the configuration dialog box for the new directory
entry.
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 7.2 Direct Telecommunication Connection

¾ In the register “Entries“ you can enter the telephone number at

which the MAx-4 PacDrive Controller can be reached.
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Fig. 7-28: New directory entry

¾ Click on the button “Configure...“ to open the configuration dialog

for hte modem and activate all hardware properties.

Fig. 7-29: Modem configuration

¾ Confirm your selection with “OK“.

¾ In the register sheet Server, make the following settings:
– type of telecommunication server: PPP: Windows NT, Win-
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7.2 Direct Telecommunication Connection

dows 95 or 98, Internet

– activate only TCP/IP as network protocols
– deactivate Activate Software compression
– activate Activate LCP extensions for PPP

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Fig. 7-30: New directory entry / Server

¾ The TCP/IP settings are made by clicking on the corresponding

buttons.
– mark the setting IP address allocated by server
– activate Name server addresses allocated by server
– activate IP header compression
– activate Use standard gateway in remote network

Fig. 7-31: TCP/IP settings

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¾ Confirm with “OK“.

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 7.2 Direct Telecommunication Connection

¾ In the register sheet “Safety“, you have to mark the setting

“Accept any authentification (even non-encoded).
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Fig. 7-32: New directory entry / Safety

¾ Confirm your selection with “OK“

The connection is now available for selection.

Windows 2000
Installation of the TCP/IP protocol
¾ If the TCP/IP protocol is not installed on your PC, you have to
install it now. The installation is described in the EPAS-4 opera-
ting manual.
Installation of the modem on the PC
¾ Open the control panel (Start / Settings / Control panel).

¾ Select Telephone and modem options.

Bild 7-33: Control panel Windows 2000 / XP

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7.2 Direct Telecommunication Connection

¾ Select Telephone and modem options.

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Bild 7-34: Dialog location information

¾ Choose in the register Modem „add to...“

Bild 7-35: Hardware Assistant / Win 2000 / XP

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¾ Follow the instructions of the hardware assistant

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 7.2 Direct Telecommunication Connection

NOTE
In case of installation problems, please consult the operating
manual of your modem.
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Creating a connection with the MAx-4 PacDrive controller

¾ Start the telecommunication network (Start -> Programs ->
Accessories -> Communication -> Network and telecommunica-
tion connections).
¾ In the telecommunication network, select “Create new connec-
tion“.
n

Bild 7-36: Network telecommunication / create new connection

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Bild 7-37: Network connection assistant / 1

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7.2 Direct Telecommunication Connection

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Bild 7-38: Network connection assistant / 2
a

Bild 7-39: Network connection assistant / 3

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 7.2 Direct Telecommunication Connection
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Bild 7-40: Network connection assistant / 4

Bild 7-41: Network connection assistant / 5

Once you created the new connection, it is available in the folder

Network and telecommunication connections and can be started
from there.
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7.2 Direct Telecommunication Connection

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Bild 7-42: Dialog to the connection setup

¾ To check the settings, select “Properties“.

¾ In the “General“ tab, select the button “Configure...“ Modem con-
figuration

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 7.2 Direct Telecommunication Connection
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Bild 7-43: Modem configuration

¾ Select the hardware options Activate hardware flow control, Acti-

vate modem error controller and Activate modem compression.
¾ Confirm your selection with “OK“.
¾ Select the tab “Network“.
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7.2 Direct Telecommunication Connection

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Bild 7-44: Properties of the connection / network

4 Check the “Type of dial-up server to be called“. PPP:Windows

95/98/NT4/2000, Internet must be selected.
4 Check that Internet protocol (TCP/IP) is marked as the only
protocol.
4 Select Internet protocol (TCP/IP).
4 Click on the button “Properties“ and select
– Automatically get IP address
– Automatically get DNS server address
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 7.2 Direct Telecommunication Connection
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Bild 7-45: Properties of the internet protocol (TCP/IP)

¾ Click twice on the „OK“ button.

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7.2 Direct Telecommunication Connection

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Fig. 7-46: Dialog to the connection setup

¾ Enter username (see parameter UserName) and password (see

parameter Password) for the connection.
¾ Establish the connection with the button “Dial“.
¾ The connection is now available.

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 7.2 Direct Telecommunication Connection

7.2.5 Establishing a Connection with Remote PC /

PacController
The Operating Manual EPAS-4 includes a detailed description of
how to establish a connection with the MAx-4 PacController. The
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following points are treated there:

„ Checking the TCP/IP connection

„ Setting up the gateway server

„ Setting up the communication channel in EPAS-4

Bild 7-47: Communication parameter at modem connection

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7.2 Direct Telecommunication Connection

7.2.6 Trouble Shooting

NOTE

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In principle, we recommend to make a test and carefully study the
manual before commissioning.

Modem is dialling, but the modem on the MAx-4 PacDrive Control-

ler does not take the call
The modem on the PacDrive Controller is not or not correctly initialized. If CON-
TROL CONFIGURATION | MODEM | in the parameter State shows “offline“, the
modem has been initialized. Check if the InitString configures the modem for
taking calls

Cause 1: The parameter Com1User in EPAS-4 | CONTROL CONFI-

GURATION | GENERAL is not correct.
Handling: Check the parameter Com1User . The parameter must be
set to “Modem“ or “Auto“.

Cause 2: The initialization string is not correct. In this case, the

parameter State will show "[Exp]InitString ERROR" after
the initialization.
Handling: Check the initialization string in the parameter
[Exp]InitString in the control configuration.

Cause 3: The modem is not connected correctly or initialized incor-

rectly. In this case the parameter State will show
"[Exp]InitString TIMEOUT".
Handling: Check the power supply and the serial cable as well as the
parameter [Exp]InitString.

Cause 4: The parameter ExpInitString is not correct.

Handling: Check the parameter ExpInitString.

Cause 5: The chip set in your modem is no Rockwell chip set. In this
case, the command for baud rate detection may not be
recognized correctly.
Handling: Use the valid commands for your modem, which are des-
cribed in your modem manual.
If there are no handshake problems between your
modems, you can replace the content of the parameter
ExpInitString by the command “AT“.

Cause 6: The serial cable or the telephone cable does not match
the modem on the PacDrive Controller.
Handling: Use the cable provided by your manufacturer.
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 7.2 Direct Telecommunication Connection

The modem ends the call before a connection has been esta-
blished
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Cause 1: The time for which the modem waits until a connection has
been established was set too short.
Handling: WIN9x : Telecommunication connection -> Properties ->
Configure -> Settings : deactivate “Interrupt dialling“.
WIN NT : Control panel -> Modem -> Properties -> Set-
tings: deactivate “interrupt dialling".

The modem takes the call, but there is no handshake or the

handshake is broken off

Cause 1: The modems are using different speed settings, i.e. one
modem is set to “Connect with 19200 bps“, while the other
modem only supports 14400 bps
Handling: Set the modems to automatic speed selection.
WIN9x : Telecommunication connection -> Properties ->
Connect via -> Button “Configure“, register “General“:
deactivate "Connect only with this speed"
WIN NT : Control panel -> Modem -> Properties: deacti-
vate "Connect only with this speed"
If any, set the DIP switch on your modem correctly

Cause 2: The modems do not recognize each other’s protocols

Handling: Switch off the automatic modulation adjustment. To do
this, add “+MS=,0“ to the parameter ExpInitString in the
control configuration. Should your modem not support this
command, please consult your manual.

Cause 3: Poor telephone connection:

Handling: It may help to switch the telephone provider or change the
connection. Dial up the MAx-4 modem by telephone. Wait
for the handshake signal of the modem (starts with a
beep). If the signal is very low or there is a lot of back-
ground noise or crackling in the line, the quality of the line
is probably too poor for a connection.
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7.2 Direct Telecommunication Connection

The connection has been established, but the telecommunication

network shows “Verifying user name and password...“. After that
the connection is cut off.

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Cause 1: Password or user name are not identical with those saved
in the MAx-4 PacDrive Controller (parameters UserName
and Password)
Handling: Enter the correct password and user name in EPAS-4.

Cause 2: Only WinNT : The telecommunication network sent an

encrypted password, which the MAx-4 does not recognize.
Activate Telecommunication network -> button “More“ ->
Handling: “Entry and modem settings...“ -> Security -> “Any authenti-
fication“.

Cause 3: Telecommunication connection properties set incorrectly

Handling: Win9x : under Telecommunication network -> button “Pro-
perties“ -> register “Server types“, deactivate everything
except TCP/IP; Type of telecommunication server =
"Internet, WIN NT Server, WIN9x"
WIN NT : Telecommunication network -> button “More“ ->
“Edit entry and modem settings“ -> register “Server“ ->
Type of telecommunication server = "PPP, Internet, WIN
NT Server, WIN9x" , activate TCP/IP and LCP extensions,
deactivate all others

Cause 4: TCP/IP protocol could not be started because IP addres-

ses are invalid (e.g. reserved IP addresses were used).
Handling: Use a valid IP addresses.

Cause 5: The parameter RemoteIpAddress in Control configuration

/ Modem is not identical with the value in the telecommuni-
cation network.
Handling: Check settings at
WIN9x : Telecommunication network -> button “Proper-
ties“ -> register “Server types“ -> button “TCP/IP settings“.
WIN NT : Telecommunication network -> Button “More“ ->
“Edit entry and modem settings“ -> register “Server“ ->
button “TCP/IP settings“.

Cause 6: The modem settings are not identical

Handling: Set “8 data bits, no parity, 1 stop bit“.
WIN9x: Telecommunication network -> Properties -> regi-
ster “General“ -> button “Configure“ -> register “Settings“:
“8 data bits, no parity, 1 stop bit“.
WIN NT : Control panel -> Modems -> Properties -> regi-
ster “Settings“: set “8 data bits, no parity, 1 stop bit“.
Same register (Fig. 7-14) -> button “Extended“: Data flow
control: “Hardware ( RTS / CTS )“ and “Error control“:
Activate data compression.
Should your modem have DIP switches, you may have to
set them.
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 7.2 Direct Telecommunication Connection

When trying to log in, EPAS-4 reports: "Communication error: Log-

ging out"
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Cause 1: The communication parameter in the EPAS-4 menu

ONLINE | COMMUNICATION PARAMETERS are not
identical with LocalIpAddress. By default, LocalIpAddress
is set to 190.200.100.100.
Handling: Check the communication parameters

Cause 2: The modem connection is too slow, e.g. less than 9600
BPS. EPAS-4 recognizes no connection because no com-
plete data package is transmitted within the timeout limit.
Handling: Raise the value of EPAS_StandardTimeout in the WIN-
DOWS directory in EPAS-4.INI. After that, EPAS-4 must
be restarted.

Cause 3: There is already a device in the local network with the IP

address chosen for the MAx-4 PacDrive Controller.
Handling: Change the IP address of the PacDrive Controller.
Disconnect the remote PC from the network. For questi-
ons about your IP addresses, please contact your system
administrator.

Cause 4: Network problem with unknown cause.

Handling: Disconnect remote PC from the network and re-install
telecommunication network from scratch.
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7.2 Direct Telecommunication Connection

EPAS-4 breaks off existing connection: "Communcation error:

Logging out"

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Cause 1: Modem connection remains active.
The timeout limit for modem transmission has been
exceeded. This happens in case of too low data through-
put with slow modem connections and thus too long trans-
mission times for data packages.
Handling: Increase the value of EPAS_StandardTimeout in EPAS-
4.INI in the WINDOWS directory to 10 or more. It might
even be necessary to increase the value of
EPAS_ExtendedTimeout.
The worse the quality of the line and the slower the
modem, the higher should you set this value.

Cause 2: Modem disconnects:

The connection was interrupted e.g. due to poor line qua-
lity.
Handling: Establish connection via a “better“ line.

Cause 3: MAx-4 was rebooted.

Handling: Wait for some seconds until the boot procedure is comple-
ted and dial up again.

Cause 4: Windows interrupted the connection because no data

were sent via the telecommunication adapter for some
time
Handling: WIN9x : Telecommunication network -> Properties -> Con-
figure -> Settings: deactivate “Disconnect after idle time "
WIN NT: Control panel -> Modem -> Properties -> Set-
tings: deactivate “Disconnect after idle time "

Cause 5: Information of a foreign device (e.g. meter pulse, etc.) was

sent to the modem. This caused the modem to interrupt
the connection.
Handling: Switch off any such additional function before establishing
a connection. For information on this subject, consult the
manual of your telephone provider. PD_UserMan_Teleservice_us.fm

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 7.3 Telecommunication network over Remote

7.3 Telecommunication network over Remote PC to

the PacDrive Controller

7.3.1 Principle
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Bild 7-48: Direct telecommunication network over Remote PC to the PacDrive

Controller

Advantages
„ Connection to several PacDrive controllers possible
„ Use of Windows “callback“ functionality possible
„ Use of remote desktop connection or remote control tools such
as VNC

Disadvantages
„ More configuration work compared with a direct connection to
the PacDrive controller
„ Remote PC required on the PacDrive controller
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7.4 Telecommunication Connection via Router to Several

7.4 Telecommunication Connection via Router to

Several PacDrive Controllers

7.4.1 Principle

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r

Bild 7-49: Direct telecommunication network over router to several PacDrive Con-
trollers.

Advantages
„ Connection to several PacDrive controllers possible

Disadvantages
„ More configuration work compared with a direct connection to a
PacDrive controller

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 7.5 Connection via Internet

7.5 Connection via Internet

7.5.1 Direct Connection via IP Address

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To be able to establish a connection via Internet, you need to know

the IP address of the PacDrive controller or remote PC. The TCP/IP
protocol must be installed both on the client and on the server side.
However, the IP address cannot be chosen freely. A worldwide
unambiguous IP address must be assigned.
This address is issued by a central international authority, the NIC
(Network Information Center). Further information is available at
www.denic.de.

Advantages
„ Easy to configure

Disadvantages
„ The possibility to apply for a worldwide unambiguous IP address
for a PacDrive controller is probably irrelevant in practice (costs,
limited number of IP addresses)
If, however, a remote PC dials up the Internet via a provider, that
PC is automatically assigned a dynamic IP address. This makes it
possible to establish a connection to that remote PC if that IP
address is known.

Bild 7-50: Direct connection over IP address and Remote PC

Advantages
„ Connection with several PacDrive controllers possible
„ Easy to configure

Disadvantages
„ IP address changes with every dial-up
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7.5 Connection via Internet

7.5.2 VPN (Virtual Private Network) Connection

With the help of a VPN connection, a network connection can be
established via an Internet connection.
This is suitable e.g. if the PacDrive controller is integrated in an

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in-house network that has Internet access.

Advantage
„ Behavior as if the connection were in a local area network (LAN)

Disadvantage
„ Connection is complicated to configure

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 7.6 Access to the PacDrive Controller with a

7.6 Access to the PacDrive Controller with a

standard browser (not permited)

7.6.1 Prinzip
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Teleservice via Internet with a “standard“ browser permits only very

restricted access to the PacDrive™ M system functions.

WARNING!
Restricted view of the machine!
Risk of injuries and material damage!
¾ Only do teleservice if a qualified person is available on site, i.e.
at the machine.
¾ Always keep in touch with this person (e.g. via telephone or
video conference).

Server with worldwide internet

address (IP address) Client
et

LAN
rn

(Local Area Network) LAN

te

(Local Area Network)

Router Router
In

* operating system: Windows 9x/NT

* Microsoft data network (client)

Fig. 7-51: Internet connection

Connection options
„ Local area network (LAN)
„ Telecommunication network via modem
„ Connection to the Internet
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7.6 Access to the PacDrive Controller with a standard browser

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Bild 7-52: Komponenten der Ferndiagnose

The HTTP server running on the PacController makes it possible to

load HTML pages with integrated diagnosis applets. The applets
are implemented with various simple HTML tags. This guarantees
that remote diagnosis is easy to handle and can be configured indi-
vidually. You can determine design elements, contents and layout
of an HTML page yourself. Then the designed page can be trans-
mitted to the flash disk of the PacController with the help of an FTP
client.

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 8.1 Basic Concept

8 Networks
This chapter will give you an overview of the networking of devices.
You will be familiarized with goals, advantages, applications and
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technologies. You will know the transmission media and communi-

cation protocols, including the basics of TCP/IP. You will be shown
tools for dealing with TCP/IP problems.

8.1 Basic Concept

In the Microsoft network environment, we need to differentiate bet-
ween peer-to-peer environment or workgroup (not server-based)
and domain (server-based).

8.1.1 Peer to Peer

All computer systems are equal and together form a workgroup.
Each computer provides resources and can access resources on
other computers. To be granted access, a user must have a user
account on each computer.
Positive No additional cost for server/operating system.
Negative No central user management; when the network reaches a certain
size, the coordination becomes very complex.
Peer-to-peer is a cost-effective alternative for small networks with
up to ten stations and without high security requirements.

Peer-to-peer operating system

Such operating systems are actually systems for stand-alone PCs
that were extended by network functionality (Win95, Win98,
WinME).
However, those systems lack significant features of “real“ network
operating systems, e.g. log-in authentication. Their use is only sen-
sible in the smallest networks arranged in the form of workgroups of
otherwise independent PCs.
With Microsoft Windows XP a login is required.
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8.2 Topologies

8.1.2 Client-Server
With a client-server concept, usually a centralized user manage-
ment is introduced. The users are broken down into different
groups that have certain rights.

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In a client-server concept the tasks are divided. One or several
computers function as servers providing central resources and ser-
vices. After successful login, all other computers can access those
as clients.
In larger networks, different services are usually distributed on
several specialized servers.
Typical server functions are: file server, print server, mail server,
web server, proxy server.
Positive New users are quickly integrated thanks to the centralized user
management.
The user can log into the network under his own name at any com-
puter in the network and thus access the resources needed.
Negative Higher costs for additional server computers, server operating
systems.

Client-server operating system

Operating systems providing centralized services that can be
accessed by several clients, e.g. Win2000 Server.
Summary As existing peer-to-peer networks can be integrated in client-server
networks, small companies can start out with peer-to-peer and later
upgrade the network with a client-server structure, as needed. Both
concepts do not exclude each other, but can be combined if and
when needed.

8.2 Topologies

8.2.1 The Term “Topologies“

Difference between physical and logic topologies

Networking causes data traffic, and as with many other types of
traffic, you can differentiate between traffic routes and traffic rules in
the IT sector as well.
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 8.2 Topologies

Physical Topology
The physical topology of a network refers to the traffic routes, the
physical structure of the network is described. In simpler terms: The
form in which the cables are laid in a wire-based communication
system.
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The most important basic forms of topology:

„ Bus

„ Star

„ Loop

In practice, you will often find combinations of bus, star and loop.

Logic topology
The logic topology of a network describes the basic traffic rules on
the communication routes, including who is allowed to access the
transmission medium.

Relation
In practical implementation, the two terms are closely related, so
that normally a certain physical topology entails a certain logic topo-
logy. However, physical and logic topology need not be identical.

8.2.2 Bus

All devices are connected to the same cable

The bus topology is characterized by a single central cable known
as “bus“. All devices are connected to that bus and have to share
that medium.
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8.2 Topologies

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Fig. 8-1: Bus topology

Advantages of bus topology

„ Relatively low costs, as it requires the smallest amount of cable.
„ The failure of one station does not cause problems in the rest of
the network.

Disadvantages of bus topology

„ All data are transmitted via a single cable (one conductor).
„ Data transmissions can be tapped quite easily.
„ A distortion of the transmission medium at one place in the bus
(defective cable, loose connector, defective network card) blocks
the entire network.
„ The search for the source of an error is often very tedious.
„ Dense data traffic, as a station sends a message to all other sta-
tions.

8.2.3 Star

Every station has its own cable

In a star topology, every station is connected to a central distributor
via its own cable.
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 8.2 Topologies
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Fig. 8-2: Star topology

Advantages of star topology

„ The failure of a station or defect of a cable has no effect on the
rest of the network.
„ Active distributors act as signal amplifiers.
„ Given the functionality of the star distributor, individual compu-
ters need not share a cable for data transmission. This means
that they can use the full bandwidth, so that this physical topo-
logy permits higher data throughput rates.
„ Further stations and/or distributors can be added fairly easily.

Disadvantages of start topology

„ Large amounts of cable
„ If the distributor fails, network traffic is no longer possible.

8.2.4 Loop

Every station is connected to two neighbors

In a loop topology the cables form a closed loop. The cable has no
beginning or end. All stations are added as elements to the loop,
process and amplify the signals arriving on the cable and forward
them.
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8.2 Topologies

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Fig. 8-3: Loop topology

This network concept is rarely used as physical topology, as the

cabling is very complex.
The main disadvantage is that the failure of one station paralyzes
the entire network.

8.2.5 Mixed Forms

Combinations of bus, star and loop

Of course it is also possible to develop mixed forms of the three
basic forms. One reason for this may be that in growing corporate
networks it becomes more and more likely that all the different typo-
logies exist. Another reason is that a so-called backbone can be
built up by mixing topologies.
Backbone A backbone is a physical connection of several partial networks,
e.g. the connection of several buildings and their respective
networks.

Star-bus network
Combined star-bus networks are common.
Several hubs form the centers of a star each, while the hubs are
connected to each other by a bus cable.
A simple examplefor clarification: In a three-story building each
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floor has a star topology. The three floors, or rather the hubs, are
connected to each other via one single bus cable.

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 8.2 Topologies
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Fig. 8-4: Star-bus topology

If the bus cable fails, the floors can no longer communicate with
each other. If a hub fails, the communication of the floors with each
other and on the floor affected is interrupted.

Star-star network
Several hubs form the center of a star; the individual hubs are con-
nected to a main hub.
Again, a simple example: In a three-story building each floor has a
star topology. The three floors, or rather the hubs, are connected to
the central hub via one cable each.

Fig. 8-5: Star-star topology

If the central hub fails, communication is only possible within the

individual floors. If a cable from the central hub to a floor hub fails,
that floor can no longer communicate with the other floors.
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8.2 Topologies

8.2.6 Transmission Media

Coaxial cable
Coax cables are available in different versions for different
applications.

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Nowadays they are rarely used for new cabling of computer
networks.
The maximum transmission rate is 10Mbps.
Coaxes according to specification RG 58 are common.
RG-58 A/U - impedance 50 Ohm, thinnet 10Base2;
The thinnet cable is also known as “cheapernet“. In a bus network it
is suitable for cable lengths up to 185 m. Networks with such cab-
ling are called 10Base2.
The abbreviations 10Base2 and 10Base5 already include several
characteristics of networking, namely the transmission speed of 10
Mbps in the base band and the extension limit of approx. 200 and
500 meters per segment, respectively.
With coaxial cables, the speed cannot be increased to 100 Mbps .

Twisted-pair cable
Cables with insulated leads twisted around each other. The twisting
suppresses to a certain degree disturbance from outside or from
neighboring pairs of leads.
Transmission rates of 100Mbps and more are possible. The maxi-
mum distance between the computer and a central component
(e.g. hub) is usually 100m.
Unshielded Cable with twisted pairs of leads without additional individual
twisted pair shielding.
(UTP)
„ More susceptible to disturbing radiation!

Shielded twi- Each pair of leads is shielded by a coat.

sted pair
„ Clearly less susceptible to electric disturbance.
(STP)
„ Data can be transmitted with higher transmission rates over long
distances.

Category Transmission rate Application

1 1 Mbps Analog language transmission,

alarm systems

2 4 Mbps IBM cabling type 3 (language), EIA-

232
3 10 Mbps 10Base-T, 100Base-T4 4-MBit
token loop, ISDN
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4 16 Mbps 16-MBit token loop

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 8.3 MAC Address

Category Transmission rate Application

5 and 5e 100 Mbps 100Base-Tx, ATM (155 Mbps),

SONET, SDH
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Table 8-1: Network cable categories

Further categories (6 and 7) in the gigabit transmission range are in

the process of being normed.

NOTE
If STP is used in a network, but one section uses UTP, the advan-
tage of the STP cables is cancelled.

Fiber-optic cable
Signals are transmitted unidirectionally via light impulses, i.e. only
in one direction, which is why at least two fibers (lanes) per cable
are needed. The light impulses are transmitted by means of a laser
diode or LED.
„ High transmission rates (gigabit range) and long distances

„ Good safety (against disturbing radiation and taping)

There are two different modes of fiber-optic cables:

Monomode The light runs practically parallel in the glass fiber core, so that light
reflections (dispersion) are minimal.
„ 100GHz x km

Multimode The core is thicker than the monomode fiber, dispersion increases.
„ 1GHz x km

8.3 MAC Address

A worldwide unique address is burnt into every network card.
Standardized structure of a MAC (media access control) address.

manufacturer network card

00 20 AF B7 32 29
Fig. 8-6: Structure of the MAC address

The MAC address is shown by entering ipconfig /all or GetMac at

the input prompt.
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8.4 Access Methods

8.4 Access Methods

8.4.1 CSMA/CD

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The access method of the Ethernet is CSMA/CD (carrier sense
multiple access with collision detection).
Each station can start sending whenever it wants. The individual
stations have competing access to the common transmission
medium at any time (multiple access).
Sending pro- When a station is sending, the signals are transmitted via the cable
cedure: in both directions. By means of regulation you try to minimize the
risk that two stations start sending at the same time and thus the
signals are destroyed on their way (collision). Regulation means
that, before sending, a station checks the transmission medium to
see if it is free. If there are already signals in the cable, the station
will not start sending in the first place.
Collision If there is a collision anyway because two stations find the cable
detection: “free“ and start sending at the same time, that collision must be
detected and a reaction must be triggered.
To detect a collision, all stations continue monitoring the transmis-
sion medium. The station that first detects a collision sends a so-
called JAM signal. Each station that registers the JAM signal stops
sending data immediately. When the line is free again, new
attempts to send can be started. Either a new attempt to send is
started after an arbitrary delay (non persistent CSMA), or the sta-
tion that wants to send continues monitoring the medium and starts
sending.
as soon as it finds the medium free (1-persistent CSMA).
„ The more stations are connected and trying to send, the more
often do collisions occur, and the lower is the effective data
throughput.
„ The time of sending cannot be calculated or determined, but is
arbitrary.
„ The method is therefore unsuitable for time critical applications.
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 8.4 Access Methods

8.4.2 Token Passing

Access method for token-loop networks (e.g. ArcNet).
Each client in the token loop is allowed to send in a given and thus
calculable time frame. This method is deterministic.
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Sending When a station wants to send, it has to wait until it receives the
method: token circulating in the loop (a bit pattern circulating in the network).
Within the bit pattern of a token, there is a digit that shows if the
token is actually free or busy.
When a station receives a “free“ token, it can change it into “busy“
and add information on the source and target addresses as well as
the data to the token. The whole package is now called a frame and
forwarded to the next station. That station checks the receiver
address and, if it is not the addressee, forwards the message.
Receiving When the message has reached its destination, it is copied there.
The destination acknowledges receipt by an entry in the frame and
forwards the modified package to the next station.
When this (acknowledged) package finally arrives at the former
sender station, that station recognizes that the message has been
transmitted. Now the station replaces the frame by a free token,
which it forwards to the next station.
Access rules Apart from this basic structure, token loop has further rules to
ensure data transmission. In each loop one station takes the role of
the “active monitor“. Usually it is the first station that becomes
active in a loop. When that computer is switched off, a new station
for that role is determined in a defined procedure (token claiming
procedure). The active monitor ensures, among other things, that
there is always a valid token or a valid frame (token plus data) in
the loop.
„ The network can be extended up to the maximum permitted
number of stations without impairing the regulated data through-
put.
„ With the NAUN procedure, token passing can find out relatively
quickly if a station is causing a problem, and which station in the
loop that is. The station can automatically be removed from the
loop.
„ Suitable for time-critical applications.
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8.5 Overview of Network Operating Systems

8.5 Overview of Network Operating Systems

8.5.1 Novell NetWare

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The proprietary IPX/SPX protocol is used. As of version 4.1, howe-
ver, the system also supports TCP/IP, which became the standard
protocol with version 5.0.

8.5.2 Microsoft Windows NT and Windows 2000

Domain concept in NT
The directory services in Windows NT are implemented in the
so-called domain concept. A domain is an administrative unit which
is eventually created by a single server, the so-called primary
domain controller (PDC).
Administration is done via (user) nodes stored in a user node data-
base on the PDC.
Administration of that database is also possible from other
computers.
Active Directory – further development of the domain concept in
Windows 2000.
Windows 2000 integrates the domain concept into ADS (active
directory services).
This makes the creation and administration of large networks signi-
ficantly easier than in Windows NT. Existing NT 4.0 domains can be
integrated in the active directory fairly easy.

8.6 TCP/IP

8.6.1 Comparison of Reference Models

TCP/IP proceeds from a four-layer architecture model and can be
reconciled with the seven- or eight-layer OSI reference model:

Layer OSI TCP/IP Layer

7 Application layer

6 Presentation layer Application layer 4

5 Session layer
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4 Transport layer Transport layer (TCP) 3

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 8.6 TCP/IP

Layer OSI TCP/IP Layer

3 Network layer Internet layer (IP) 2

2 Data link layer
Network layer 1
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1 Physical layer

Table 8-2: Comparison: OSI <-> TCP/IP

8.6.2 Important Protocols

In addition to the TCP and IP protocols, which give the protocol
family its name, there are a variety of other protocols (>100)

Protocol Name Description

TCP Transmission Con- For establishing logic connections
trol Protocol between applications. It is located
on the transport layer and, as a con-
nection-oriented protocol, serves for
secure data transmission.

UDP User Datagram Pro- Also located on the transport layer,

tocol but working without connection.
Therefore it is not as secure as TCP,
but faster.

IP Internet Protocol A connection-fee protocol, serves

for packaging and package swit-
ching via IP addresses.

IPSec IP Secure Extends the regular IP protocol by a

number of security mechanisms.

FTP File Transfer Proto- Serves for data exchange between

col computers and is located on appli-
cation level.

HTTP Hypertext Transfer Serves for the transport of HTML

Protocol (Hypertext Markup Language)
pages and is located on application
level.
Telnet Telecommunication Terminal emulation for host commu-
Network Protocol nication. Telnet is located on appli-
cation level.

SMTP Simple Mail Trans- For sending e-mails, located on

fer Protocol application level.

POP Post Office Protocol For receiving e-mails, located on

user level.
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8.6 TCP/IP

Protocol Name Description

ARP Address Resolution For resolving logic IP addresses into

Protocol physical MAC addresses.

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Table 8-3: Overview of important protocols

SMTP application
HTTP application

SNMP application
(Mail program)
FTP application

(Browser)

SNMP
SMTP
HTTP
FTP

4 TCP UDP

3 IP

2 data protection data protection

Ethernet (LAN) z.B. X.25 / HDLC
1 physical layer physical layer
e.g. Twisted Pair, 100 Mbit/s

Fig. 8-7: Structure of protocols and services and their location in OSI layers

Port number:
As different services such as FTP, Telnet, SMTP or HTTP can be
called at the same IP address in a computer that can be reached by
TCP, an additional marker is needed to make it clear which of those
services is requested.
This is done by means of the so-called port number.

Number Meaning

20 FTP data
21 FTP commands

23 Telnet

25 SMTP

80 HTTP

110 POP3

Table 8-4: Port numbers

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 8.6 TCP/IP

Socket:
Whereas the IP address unmistakably identifies a computer, the
port number determines which service on the computer is
addressed.
Both pieces of information together are called socket.
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8.6.3 IP Addressing
When using TCP/IP, an unambiguous IP address must be assigned
to each network card within a network. Thus logic IP addresses are
assigned to the physical network card addresses (MAC
addresses).
For computers that are connected to the Internet, this means that
their IP addresses are worldwide unique.

8.6.4 Subnet Mask

The subnet mask must be entered when installing the network
protocol.
When a computer in the network receives a data package, if first
checks with the help of the subnet mask if the package is at all
meant for a computer in the network segment. If there is a match, it
then checks if the node number is identical to its own. If this is also
the case, it reads the entire contents of the data package.
Example

Network ID Host ID

IP address
- decimal 192 168 10 1
- binary 1100 0000 1010 0000 0000
1000 1010 0001

Subnet mask
- decimal 255 255 255 0
- binary 1111 1111 1111 1111 1111 1111 0000
0000

Table 8-5: Correlation between IP address and subnet mask

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8.6 TCP/IP

8.6.5 IP Address Classes

The central authority for the assignment of IP addresses is called
InterNIC (Internet Network Information Center).
In Germany, the office in charge is DENIC (Deutsches Netzwerk-

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Informations-Center).
However, those centers do not issue individual IP addresses, but
only address groups, which providers then pass on to their custo-
mers. Providers can request different numbers of IP addresses.
This is why IP addresses were broken down into different address
classes.
Classes A, B and C are for addressing computers.

Number of
Subnet Number of
Class Network ID network
mask networks
nodes

A 0 to 126 255.0.0.0 126 16.777.216

B 128.0 to 191.255 255.255.0.0 16.384 65.536

C 192.0.0 to 255.255.255 2.097.152 256

223.255.255 .0

Table 8-6: Network address classes

Addresses starting with 127 must not be assigned, as they are

reserved for special functions, e.g. 127.0.0.1, which usually addres-
ses the so-called localhost, the internal loopback address.

8.6.6 Private IP Networks

For the creation of private networks, including many small LANs,
one section each was excluded from the network classes described
above.
The addresses in those three areas are never assigned as public
Internet addresses and generally not forwarded by routers on the
Internet.
10.0.0.0 to 10.255.255.255 in class A
172.16.0.0 to 172.31.255.255 in class B
192.168.0.0 to 192.168.255.255 in class C
If, however, a LAN is to be addressed via Internet, it must be gua-
ranteed that the IP address is unambiguous in the entire Internet.
In this case, a public IP address is needed.
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 8.6 TCP/IP

8.6.7 IP Address Assignment

Windows 2000 offers four methods for the assignment of IP addres-
ses to TCP/IP clients:
„ DHCP
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„ APIPA

„ Static IP addressing

„ Alternative IP configuration (multiple networking)

DHCP
DHCP permits the automatic configuration of IP addresses and
other configuration options for clients in a network with one or
several DHCP servers.
So-called IP segments (IP addresses to be assigned) are created
on the DHCP server and configured with options such as standard
gateway or DNS server. When booting, a client asks the DHCP ser-
ver for an IP configuration, which it can then use for a certain time
(lease time). When shutting down, the client logs off the DHCP ser-
ver, which then assigns the IP address to another client.

APIPA
APIPA is suitable for simple networks with only one subnet. If no
DHCP server is available, the computer automatically assigns itself
a private IP address via APIPA.(169.254.0.1 to 169.254.255.254)
Later on, when a DHCP server is available and determines an
address, the computer will change its IP address accordingly.

Static IP addressing
Static IP addressing permits the manual configuration of IP addres-
ses if DHCP and APIPA are not available or technically impossible.
Particularly in large networks, this method is very time-consuming
and prone to errors.

Alternative IP configuration (multiple networking)

With the alternative IP configuration, several addresses can be
assigned to a network card. If connections need to be established
with different networks (e.g. different locations), one IP address
from each of the respective subnets is assigned to the network
card.
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8.6 TCP/IP

8.6.8 Name Resolution

A computer name is resolved into the corresponding IP address.
Windows 2000/XP offers four different methods for resolving
names in IP addresses.

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This includes DNS, WINS, name resolution with HOSTS or
LMHOSTS files and broadcast name resolution. Usually Windows
2000/XP uses a combination of the methods.

DNS
Queries are sent to DNS servers. The method is used for applicati-
ons and services requiring host-to-IP name resolution. This method
is needed if the computer wants to access the Internet.
DNS is the standard method for name resolution for clients in Win-
dows XP.
When the resolution service of Windows XP receives a positive or
negative reply to the query, it inserts that reply into its cache and
thus creates a DNS resource entry. Before the query to DNS ser-
vers, the resolution service always checks the cache first. If there is
a DNS resource entry in the cache, the resolution service uses the
entry saved there and executes no server query. This reduces the
queries and accelerates the network traffic due to DNS queries.
Show DNS ipconfig /displaydns
resolution
cache:
Manually Ipconfig /flushdns
clear DNS
resolution NetBIOS name resolution
cache:
Queries are sent to WINS servers. This method was added for
compatibility reasons for applications and services requiring Net-
BIOS-to-IP name resolution, e.g. the search function of Windows
NT 4.0, Windows 98/95.

8.6.9 IP Host and NetBIOS Name Resolution

Executed by HOSTS or LMHOSTS files.
Via manually managed local files, they provide host-to-IP and Net-
BIOS-to-IP name resolution.

NetBIOS name resolution (broadcast)

Executed by means of B-node broadcast. With the broadcast, the
name resolution is executed within the local subnet.
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 8.7 Coupling of Networks

8.7 Coupling of Networks

8.7.1 Additional Devices for Network Coupling

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To enlarge networks, additional devices are needed to overcome

existing limitations.
Only some of the devices are able to connect several segments
(parts of an individual network). Others can couple several inde-
pendent networks (subnets).

Repeater
A repeater (signal amplifier) is an active network component that
takes over a regeneration functionality.
A repeater receives signals, amplifies and forwards them.
In local networks, a repeater is used to increase the maximum
signal range and thus the maximum possible cable length. A repea-
ter can thus connect network segments of the same LAN type for
communication purposes.
A repeater works on layer 1 of the OSI model, i.e. the repeater only
regenerates bit streams that are sent via the media, but has no
insight into the messages. Therefore the same access method to
the medium must be used in all segments involved. A repeater
cannot mediate between e.g. Ethernet and token loop.
As a layer 1 device, a repeater is completely “transparent“, i.e. neit-
her other connected devices nor programs “know“ about the
device.
Repeaters no longer play any major role in new networks.

HUB
HUBs, like repeaters, work on layer 1 of the OSI model and are
completely transparent to other systems.
By connecting several hubs, the number of connected stations can
be increased fairly easily.
HUBs are connected to each other via a crossed cable - or if a
straight cable is to be used, a special input (uplink input) must be
used on the HUB.
The respective terminals are each connected to the HUB with a
cable of their own (straight). Such a connection point is known as
port.
As each connected device has its own decided connection and its
own cable to the HUB, HUBs can offer those devices the full band-
width of the local network at least up to the HUB port. Nevertheless,
the entire segment remains, i.e. the devices have to share the
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8.7 Coupling of Networks

transmission medium - every node receives every message - even

messages meant for other stations.

Bridge
A bridge already operates on layer 2 of the OSI model (MAC

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address level) and thus is transparent to higher protocol layers.
This means that all protocols based on layer 2 are forwarded by the
bridge without being processed. In contrast to the repeater, a
bridge can work with different transmission rates and different
access methods and thus can also be used e.g. between CSMA/
CD and token passing. A bridge connects network segments which,
in contrast to the repeater, can also represent different technologies
(e.g. Ethernet and token loop). If the bridge knows the recipient, it
will forward the data only to the appropriate network.
A bridge cannot narrow down circular messages in the form of
broadcasts to one segment, i.e. the broadcasts from one computer
to all others are forwarded to the other segments.
A bridge temporarily saves and prepares the data packages before
forwarding them on the basis of the MAC address. For this task, a
bridge uses address tables (bridge tables) in which the MAC
addresses of the connected stations are entered.

Switch
A switch is primarily the further development of a bridge. Just like a
bridge, a switch works on layer 2 of the OSI model and uses MAC
addresses to deliver the data.
A bridge can improve the bandwidth in the entire network by forwar-
ding data traffic only if it is a transmission from one segment to
another.
A switch, on the other hand, can improve the bandwidth within a
segment.
In contrast to the bridge, direct and decided connections are swit-
ched between the ports. Data packages are sent to the port of the
target station only. This reduces the network load substantially.
As the switch works on the MAC address level, a switch cannot
couple two network segments.
Several manufacturers are already offering high-capacity switches
that work not only on layer 2, but up to layer 3 or even higher.
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 8.7 Coupling of Networks

Layer 3 switch / layer 4 switch

Whereas a layer 2 switch only has the MAC address available to
forward the packages and a layer 3 switch additionally uses the tar-
get IP address, a layer 4switch can also steer the data traffic by
means of the port number.
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Router
A router is a device that can couple separate networks or divide
large networks into subnets.
The simplest form of a router is a PC with several network cards,
each of which has contact to different networks.
Routers work on layer 3 of the OSI model. This means that routers
can connect networks with different topologies and the layers 1 and
2 lying beneath them.
However, all networks involved always have to use the same way
of addressing their data packages.
The router unpacks arriving data packages up to layer 3 in order to
find out the target address in the header. This procedure takes
time, so that routers are usually slower than switches.
The allocation of routers to OSI layer 3 also means that a router
does not use the MAC address, but the address of the protocol
level (e.g. the IP address) as a target.
Routing The main function of a router is to find routes for packages from
tables source to target.
For this purpose, routers use so-called routing tables, where known
target addresses are listed.
When a package arrives and the router has read the desired target
address, it can check the routing table to see if that address is regi-
stered there.
If this is the case, it can forward the package. If this is not the case,
it forwards the package to another router (default router/gateway),
which then tries in its own way to deliver the package. This forwar-
ding is also called “hop“.
This means that the gateway to be entered in the Windows control
panel is actually a router.
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8.7 Coupling of Networks

Routing with Windows 2000

On each Windows 2000/XP computer, the static routing table of the
adjacent segments is created automatically. For this purpose, the
system evaluates the actual configuration information of the IP pro-
tocol for each network card that is installed and configured.The

Korrekturausdruck
service Routing and RAS must have been started (see PacDrive P
and Ethernet).
To test the routing properties of a Windows2000/XP computer,
there are various tools, which we will deal with later on.

Gateway
A gateway connects networks with completely different protocols
and address formats.
A gateway can connect actually incompatible networks. This is
made possible because a gateway can be active on all 7 OSI lay-
ers. In the extreme, it unpacks an incoming message up to layer 7
in order to re-pack it down to layer 1 in a way that is suitable for the
other network.
A gateway really converts one protocol into another.

8.7.2 Tools for Dealing with TCP/IP Problems

Ping (ping IP address)

Ping is a tool to check the connectivity on IP level. With the com-
mand ping, an ICMP echo request is sent to a target host. You
should always use ping when you want to check if a host computer
can sent IP packages to a target host.
Ping IP address of the remote host
Ping host name of the remote host
Ping uses name resolution to resolve a computer name into an IP
address. If the ping signal can be sent to an IP address suc-
cessfully, but sending the signal to a name fails, this is due to the
host name resolution, not the network connectivity.
If the ping cannot be used successfully at all, make sure that the
following prerequisites are fulfilled:
„ The IP address of the local computer is valid and is shown pro-
perly on the GENERAL tab in the dialog field Internet protocol
properties (TCP/IP) or when using IPCONFIG.
„ A standard gateway has been configured and the connection
between gateway and host is ready. Although several standard
gateways can be configured from Windows 2000, the gateways
after the first one are only used if the IP stack detects that the
original gateway is not working. In this case all other gateways
PD_UserMan_Netze_us.fm

should be deleted to make things easier.

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 8.7 Coupling of Networks

NOTE
If there is a connection with a long delay to the remote system to
which the ping signal is sent, the reply may take longer. The default
time limit of four seconds can be extended with the parameter – w
Korrekturausdruck

(wait).

Frequent error messages returned by ping:

Error message Meaning and action

Time to live exceeded The number of required hops exceed the time
during transmission to live (TTL).
Extend the TLL by means of the parameter
ping -i.

Target host cannot be The sending host or a router has no local or

reached remote route for the target host.
Update the routing table on the local host or
router (route add).
Request time excee- No messages for the echo reply received
ded within the given time (standard setting: 4
seconds).
Extend the time by means of the parameter
ping -w.

Ping request could not The name of the target host cannot be resol-
find host ved.
Check the name and availability of DNS or
WINS servers

Table 8-7: Meaning and action in case of error messages with “Ping“ command

Deleting the If a ping signal can be sent successfully both to the loopback
ARP cache address (127.0.0.1) and to the own IP address, but not to another
IP address, the ARP cache may have to be deleted.
The tool ARP is used for that purpose. The cache contents can be
displayed with the commands arp –a and arp -g. The entries are
deleted with the command arp –d IP address.
The complete ARP cache is deleted with the command netsh inter-
face ip delete arpcache.
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ELAU AG Programming Manual page 225

8.7 Coupling of Networks

Route print
The routing table is shown on the computer with the command
“route print“.
For two hosts to be able to exchange IP datagrams, they must have
a route to each other or use a standard gateway that knows a route.

Korrekturausdruck
Fig. 8-8: The command “route print“ at the MS-DOS prompt

The routing table shows a computer with IP address

10.201.17.124, subnet mask 255.255.0.0 and standard gateway
10.201.0.1. It contains the following entries:
Network tar- The network address in the routing table is the target address. The
get column for the network target can contain three different types of
entries, which are listed below in the order of their accuracy.
1) Host address (a route to a single, specific target IP address)
2) Subnet address (a route to a subnet)
3) Standard route 0.0.0.0 (This route is used if no other match
could be found)
4) If no match is found at all, the packages are deleted.
The entries of the routing table in detail:
1) The standard route used for forwarding packages to all locati-
ons outside the local subnet.
2) A subnet route for the local subnet.
3) A host route for the local host (route for packages sent to that
host computer).
4) A host route for a special IP broadcast address, the broadcast
address for all subnets.
5) The loopback route a host uses when sending packages to its
own address.
6) The IP multicast route the computer uses when sending pakka-
PD_UserMan_Netze_us.fm

ges to an IP multicast group.

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 8.7 Coupling of Networks

7) A host route for the limited broadcast address.

Network mask The network mask indicates which part of the target address must
match the network address so that a route is regarded as a match
with the target address of the forwarded package. If the mask is
given in binary format with ones and zeros, the value 1 stands for a
Korrekturausdruck

bit that has to match and 0 for a bit that does not have to match.
In a mask that consists only of ones (255.255. 255. 255) the target
address of the package to be forwarded must exactly match the
entire host address for this route in order to be regarded as a
match. In the example of the network mas 255.255.0.0 the first two
octets must match exactly. The last two octets need not match.
Gateway The IP address for forwarding is determined on the basis of the
address gateway address in the routing table. It is either the host’s own IP
address or that of a router in the local subnet. If the gateway
address of the route is the host IP address, the IP address for for-
warding is set to the target IP address in the IP datagram. This is
the IP address of the host to be contacted. It is insignificant whether
the host is located in the local subnet or in a remote subnet. If the
gateway address of the route is not the host IP address, the gate-
way address, usually the address of a router in the local subnet, is
used as the IP address for forwarding.

Route add
If a route is missing between two hosts that can be connected, a
route can be added with the command “route add“.
Example:
ROUTE ADD 192.168.3.0 MASK 255.255.255.0 192.168.2.2
The MASK option routes entire networks; i.e. if you want to address
a host in the network 192.168.3, then use router 192.168.2.2
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ELAU AG Programming Manual page 227

8.7 Coupling of Networks

Tracert
With the traceroute command (tracert) a route to a certain given IP
target can be traced via up to 30 hops (router/gateway).
The speed of data transmission on the respective sections is proto-
colled as well.

Korrekturausdruck
E.g. tracert 10.205.0.1 (shows the package route to the target
10.205.0.1)

Pathping
The command pathping sends data packages to each router on the
way to the last network target IP address and then reports via the
path of the packages from one router to the next.
As pathping indicates the extent of package loss in route segments
or connections, it can be detected exactly which routers or connec-
tions may be overloaded and are causing network problems.

Connection order
If several network cards and several network protocols are installed
on a computer in Windows XP Professional, you can define the
connection order of the respective network cards and protocols for
the services using the respective protocols.
The connection order defines which protocol a service uses for the
connection to another service or client and which network card is
used for the connection.
To reduce the time for searching the necessary clients and ser-
vices, place the most frequently used network card and protocol
first.
Many services can establish connections with any protocol.
Network access, however, is controlled by the service Client for
Microsoft Networks. The connection order is shown on the tab Net-
work cards and connections on the properties page Extended
settings (right mouse button - Network environment | Advanced |
Advanced settings) of a selected network adapter.
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page 228 Programming Manual ELAU AG

 8.7 Coupling of Networks
Korrekturausdruck

Fig. 8-9: Configuring the order of connection for the network card and the order of
protocol creation

Display of events
Window order:
Workplace | Settings | System programs | Events | Safety
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ELAU AG Programming Manual page 229

8.7 Coupling of Networks

Korrekturausdruck
Fig. 8-10: Dialog window “Properties of Event“

The display of events enables you to monitor events in the system.

Windows XP starts the event protocol service by default.
A typical protocol entry is composed of the header and a
description.
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page 230 Programming Manual ELAU AG

 9 System Data

9 System Data

Size Value
Korrekturausdruck

IEC tasks max. 64

IEC program code (code size) 2 MByte

IEC data area (data size) 2 MByte

(in versions < V00.07.00 1 MByte)

IEC variable area data size - 3 x 64 kByte

markers 64 kByte
inputs 64 kByte
outputs 64 kByte

IEC retain variable

NvRam MAx-4
- size 1 kByte
- data retention max. 7 days

flash Disk MAx-4 with UPS object

- size 64 kByte
- data retention > 100 years
- write cycles max. 100 000

NvRam with PN-4 module

- size 101 kByte
- data retention max. 7 days (without battery)
- battery buffer can be done internally or externally

Maximum variable sizes

Array 128 kByte (32 kByte < V00.12.00)

Struct 128 kByte (32 kByte < V00.12.00)

global variable list 128 kByte (32 kByte < V00.12.00)

size of all variables of a POU of the type 128 kByte (32 kByte < V00.12.00)
FB (including POUs called up)

stack depth for functions 10 kByte

nesting depth if instruction 15

SERCOS cycle time

accuracy < 0.01 %

resolution 1, 2, 4 ms (can be set with

parameter CycleTime)

System clock

accuracy < 0.1 %

PD_UserMan_Kennwerte_us.fm

resolution 250 µs

ELAU AG Programming Manual page 231

9 System Data

Size Value
real-time clock on the PN-4 module
- accuracy ±1 minute in 12 days.
- data retencion max. 7 days
- battery buffer can be done internally or externally

Korrekturausdruck
Table 9-1: Data of the PacDrive™ M system

NOTE
Bit variables declared with the keyword AT can only be placed on
the first 4096 bytes. Otherwise there will be a syntax error in the
declaration.
The initialization behavior can be influenced with the object
parameter MAx-4.General.RetainInit.
After successful compilation of a project, the sizes Code Size and
Data Size are shown.

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page 232 Programming Manual ELAU AG

 10.1 Switching on Enable

10 Time Diagrams - MotorController

10.1 Switching on Enable

Korrekturausdruck

Switching on enable results in the following behavior over the time:

1
1
Hardware- and
ControllerEnable 0
0 t

AxisState 0/1 2 ≥3
0x03 /
MC4State 0x10
0x20 0x30

current speed

0
0 Brake t
Disconnection
Time
1
brake relay
closed 0
0 t

1
motor
torque 0
0 t

1
Ready
closed 0
0 t

Fig. 10-1: Time diagram: Switching on enable

Before switching on enable, AxisState and/or MC4State depend on

the enable signal that is being awaited. If hardware enable is mis-
sing, AxisState stands at 0 and MC4State at 0x03. If the drive is
awaiting enable with ControllerEnable, AxisState is at 1 and
MC4State at 0x10.
When switching on hardware enable and ControllerEnable (time 1),
the brake relay is closed (brake lifted) and the motor torque is swit-
ched on, if there is no error message, the DC-circuit is loaded and
all phases are connected. After the BrakeDisconnectionTime (time
2; default value: 100 ms), positioning jobs can be sent to the drive.
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ELAU AG Programming Manual page 233

10 Time Diagrams - MotorController

10.2 Lifting Enable

When lifting enable, three events may occur.

Korrekturausdruck
10.2.1 Ramping-down within Maximum Ramping-down
Time
When lifting enable, the following behavior over the time occurs if
the drive is ramped down within the maximum ramping-down time:
1
1
Hardware- and
ControllerEnable 0
0 t

AxisState ≥3 0

MC4State 0x30 0x05 0x06 0x03 / 0x10

current speed 2

nmin
0
0 t

1
brake relay 4
closed 0
0 StopTimeLim t

3
1
motor
torque 0
0 t
BrakeCouplingTime

1
Ready
closed 0
0 t

Fig. 10-2: Time diagram: Ramping down within maximum ramping-down time

When lifting enable (time 1), the drive ramps down with maximum
current. The drive comes to a stop before expiry of the maximum
ramping-down time StopTimeLim (time 4). As soon as the acutal
velocity drops below the velocity limit (time 2: actual velocity < nmin
(10 min-1)), the brake relay drops. After expiry of the BrakeCou-
plingTime (time 3), the motor is switched torque-free. The ready
contact remains closed.
Thus error-free ramping-down is executed if CoastOption is not
PD_UserMan_ZeitDiag_us.fm

active for lifting enable (bEnableCoast = FALSE).

page 234 Programming Manual ELAU AG

 10.2 Lifting Enable

10.2.2 Stop Time Limit Exceeded, Drive Is Brought to a

Controlled Stop
When lifting enable, the following behavior over the time occurs if
the drive is not ramped down within the maximum ramping-down
Korrekturausdruck

time, but the drive can still be brought to a controlled stop:

1
1
Hardware- and
ControllerEnable 0
0 t

AxisState ≥3 0

MC4State 0x30 0x05 0x08 0x06 0x02

current speed
3

nmin
0
0 t

1
brake relay 2
closed 0
0 StopTimeLim 2* StopTimeLim t

4
1

motor torque
0
0 t
BrakeCouplingTime

1
error 5
reaction "B" 0
0 t
StopTimeLim

1
Ready
closed 0
0 t

Fig. 10-3: Time diagram: Ramping down (stop time limit exceeded, bringing to a
stop)

When lifting enable (time 1), the drive ramps down with maximum
current. However, the drive does not come to a stop before the
maximum ramping-down time StopTimeLim (time 2). For this rea-
son, the error message “Stop time limit exceeded“ is triggered with
error reaction "B". In case of error reaction "B", the ready contact is
opened and the drive is still brought to a controlled stop with maxi-
PD_UserMan_ZeitDiag_us.fm

mum current. If the drive comes to a stop (time 3) within the stop
time limit of error reaction "B" (time 5), the brake relay is opened

ELAU AG Programming Manual page 235

10 Time Diagrams - MotorController

(brake drops) and the motor is switched torque-free after the Brake-
CouplingTime (time 4).
Thus, the drive is ramped down in a controlled way as long as the
drive comes to a stop within the double stop time limit plus the
brake coupling time and CoastOption is activated neither for lifting

Korrekturausdruck
enable nor for error reaction "B" (bEnableCoast = FALSE; bError-
Coast = FALSE).

10.2.3 Stop Time Limit Exceeded, Drive Brought to an

Uncontrolled Stop
When lifting enable, the following behavior over the time occurs if
the drive is not ramped down within the stop time limit and the drive
cannot be brought to a controlled stop:

1
1
Hardware- and
ControllerEnable 0
0 t

AxisState ≥3 0

MC4State 0x30 0x05 0x08 0x06 0x02

without brake

current speed

with brake
nmin
0
0 t

1
brake relay 2
closed 0
0 StopTimeLim 2 * StopTimeLim t

4
1
motor
torque 0
0 t
BrakeCouplingTime

1
error 3
reaction "B" 0
0 t
StopTimeLim

1
Ready
closed 0
0 t
PD_UserMan_ZeitDiag_us.fm

Fig. 10-4: Time diagram: Ramping down (stop time exceeded, drive coasts to a
stop)

page 236 Programming Manual ELAU AG

 10.3 Error Reaction "B"

When lifting enable (time 1), the drive ramps down with maximum
current. However, the drive does not come to a stop within the
StopTimeLim (time 2). For this reason, the error message “Stop
time limit exceeded“ is triggered with error reaction "B". In case of
error reaction "B", the ready contact is opened and the drive is still
Korrekturausdruck

brought to a controlled stop with maximum current. If the drive does

not come to a stop within the stop time limit of error reaction
“B“(time 3), the brake relay is opened (brake drops) and the motor
is switched torque-free after the BrakeCouplingTime (time 4).
Thus, the drive is ramped down in a controlled way as long as the
drive comes to a stop within the double stop time limit plus the
brake coupling time. This applies only if CoastOption is neither
active for lifting enable nor for error reaction "B" (bEnableCoast =
FALSE; bErrorCoast = FALSE). The uncontrolled stop stop will not
trigger any error message.
The behavior of the drive in case of an uncontrolled stop depends
on whether the motor has a holding brake or not.

10.3 Error Reaction "B"

In case of an error reaction "B", two procedures may occur.

10.3.1 Ramping down within Stop Time Limit

In case of an error with error reaction "B", the following behavior
occurs if ramping-down is completed within the stop time limit:
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ELAU AG Programming Manual page 237

10 Time Diagrams - MotorController

1
1
error
reaction "B" 0
0 t

Korrekturausdruck
AxisState ≥3 0

MC4State 0x30 0x08 0x06 0x02

current speed 2

nmin
0
0 t

1
brake relay 4
closed 0
0 StopTimeLim t

3
1
motor
torque 0
0 t
BrakeCouplingTime

1
Ready
closed 0
0 t

Fig. 10-5: Time diagram: Error reaction B / Ramping down within stop time limit

In case of an error with error reaction "B" (time 1), the drive ramps
down with maximum current and the ready contact is opened. The
drive comes to a stop before expiry of the StopTimeLim (time 4). As
soon as the actual velocity drops below the velocity limit (time 2:
actual velocity < nmin), the brake relay drops. After expiry of the
BrakeCouplingTime (time 3), the motor is switched torque-free.
Thus, the drive is ramped down error-free if CoastOptionis not
active for error reaction "B" (bErrorCoast = FALSE).

10.3.2 Stop Time Limit Exceeded

In case of an error with error reaction "B", the following behavior
occurs if ramping-down is not completed within the stop time limit:
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page 238 Programming Manual ELAU AG

 10.3 Error Reaction "B"

1
1
error
reaction "B" 0
0 t
Korrekturausdruck

AxisState ≥3 0

MC4State 0x30 0x08 0x06 0x02

without brake
current speed

with brake
nmin
0
0 t

2
1
brake relay
closed 0
0 StopTimeLim t

3
1
motor
torque 0
0 t
BrakeCouplingTime

1
Ready
closed 0
0 t

Fig. 10-6: Time diagram: Error rection B / Stop time limit exceeded

In case of an error with error reaction "B" (time 1), the drive ramps
down with maximum current and the ready contact is opened.
However, the drive does not come to a stop before expiry of the
StopTimeLim (time 2) (actual velocity < nmin). Therefore the brake
relay is opened and the error message “Stop time limit exceeded“ is
triggered. As an error with the same error reaction is already active,
this error message has no effect on the drive. After the BrakeCou-
plingTime (time 3), the motor is switched torque-free.
Thus, the drive is ramped down in a controlled manner for the stop
time limit period plus the brake dropping time and then brought to
an uncontrlled stop (drive coasts to a stop). This only applies if
CoastOption is not active for error reaction "B" (bErrorCoast =
FALSE). The uncontrolled stop generates no error message.
The behavior of the drive in the event of an uncontrolled stop
depends on whether the motor has a holding brake or not.
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ELAU AG Programming Manual page 239

10 Time Diagrams - MotorController

10.4 Error Reaction "A"

An error with error reaction "A" results in the following behavior:

Korrekturausdruck
1
error
reaction "A" 0
0 t

AxisState ≥3 0

MC4State 0x30 0x07 0x02 BrakeCoast = FALSE

MC4State 0x30 0x07 0x06 0x02 BrakeCoast = TRUE

n with brake and

BrakeCoast = TRUE

current speed
3 4
with brake
without brake
nmin
0
0 t
with BrakeCoast = TRUE

1
brake relay 2 5
closed 0
0 Brake t
Coupling Brake
Time Coupling
1 Time
motor
torque 0
0 t

1
Ready
closed 0
0 t

Fig. 10-7: Time diagram: Error reaction A

In case of an error with error reaction "A" (time 1), the drive is swit-
ched torque-free immediately, the brake drops and the ready
contact is opened. When the BrakeCouplingTime is over and the
drive comes to a stop (actual velocity < nmin) (time 3), the
MC4State is switched to 0x02. From that state, the drive can be
controlled again after quitting the error message.
With the CoastOption for the brake, the brake will not drop until the
drive is standing (time 4: actual velocity < nmin). After the Brake-
CouplingTime the MC4State is switched to 0x02.
The same reaction is activated if the CoastOption for enable is acti-
vated when lifting enable (bEnableCoast = TRUE) or the
CoastOption for error reaction “B“ is activated for an error with error
PD_UserMan_ZeitDiag_us.fm

reaction "B" (bErrorCoast = TRUE).

page 240 Programming Manual ELAU AG

 10.5 Overload Switchoff

The behavior of the drive depends on whether the motor has a hol-
ding brake or not.

10.5 Overload Switchoff

Korrekturausdruck

In principle, two procedures may occur in case the system switches

off due to overload.

10.5.1 Overload Switchoff within Maximum Switchoff Time

In case the system switches off due to overload, the following beha-
vior over the time occurs if the overload position is reached within
the maximum stopping time:
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ELAU AG Programming Manual page 241

10 Time Diagrams - MotorController

1
1
Overload
0
0 t

Korrekturausdruck
AxisState ≥3

MC4State 0x30 0x31 0x32

current
position
Overload
position

0
0 800ms t

current speed

nmin
0
0 800ms t
-nmin
2

1
brake relay
closed 0
0 t

1
motor
torque 0
0 t

1
Ready
closed 0
0 t

Fig. 10-8: Time diagram: Overload within maximum stopping time

When the system switches off due to overload (time 1), the drive is
controlled with reference to the overload position. The overload
position is the actual position at the time when the overload switch-
off occurs. If the drive reaches the overload position within the
maximum stopping time of 800 ms and the motor comes to a stop
(time 2: |actual velocity| < nmin), the MC4State is switched to 0x32.
After overload was quitted in this state, the drive follows the set
values again.
PD_UserMan_ZeitDiag_us.fm

This is a way to bring the motor to a stop without any error in case
the system switches off due to overload.

page 242 Programming Manual ELAU AG

 10.5 Overload Switchoff

10.5.2 Overload Switchoff with Transgression of Maximum

Stopping Time
In case the system switches off due to overload, the following beha-
vior over the time occurs if the overload position is not reached
Korrekturausdruck

within the maximum stopping time:

1
1

Overload
0
0 t

AxisState ≥3

MC4State 0x30 0x31 0x08 0x06 0x02

current
position
Overload
position

0
0 800ms t

current speed
2

nmin
0
0 800ms t
-nmin

1
brake relay 4
closed 0
0 t
BrakeCoupling
Time
1
motor
torque 0
0 t

1
error
reaction "B" 0
0 t

1
Ready
closed 0
0 t
PD_UserMan_ZeitDiag_us.fm

Fig. 10-9: Time diagram: Overload / Maximum stopping time exceeded

ELAU AG Programming Manual page 243

10 Time Diagrams - MotorController

When the system switches off due to overload (time 1), the drive is
controlled with reference to the overload position. The overload
position is the actual position at the time when the overload switch-
off occurs. If the drive does not reach the overload position within
the maximum stopping time of 800 ms (time 2), the error message

Korrekturausdruck
“ramping-down time exceeded“ is triggered with error reaction “B“
and the motor is brought to a controlled stop. As soon as the actual
velocity drops below the velocity limit (time 3: |actual velocity| <
nmin), the brake relay drops. After the BrakeCouplingTime (time 4)
the drive is switched torque-free.
The drive is brought to a stop in this way if CoastOption for error
reaction "B" is not active (bErrorCoast = FALSE).

LEGEND
Absolute values are noted directly on the axes. They give a value
referring to the zero point of the axis.
Differences are noted in curly brackets. The bracket gives the cor-
responding range.

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page 244 Programming Manual ELAU AG

 11.1 Version Designation in General

11 Version Numbers and Compatibility

11.1 Version Designation in General

Korrekturausdruck

VXX.YY.ZZ
XX - incompatible changes
YY - upwardly compatible changes
ZZ - compatible changes

11.2 Compatibility EPAS-4 - MAx-4

„ EPAS-4 XX must be equal to MAx-4 XX
„ EPAS-4 YY must be greater than or equal to MAx-4 YY
„ EPAS-4 ZZ has no significance

11.3 Compatibility MAx-4 - MC-4

„ MAx-4 XX must be equal to MC-4 XX
„ MAx-4 YY must be greater than or equal to MC-4 YY
„ MAx-4 ZZ has no significance

11.4 Compatibility MAx-4 - IEC-Libraries

„ MAx-4 XX must be equal to Lib XX
„ MAx-4 YY must be greater than or equal to YY
„ MAx-4 ZZ has no significance
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11 Version Numbers and Compatibility

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 12.1 Function of the ENI

12 ENI-4
This chapter will give you an overview of the function, structure and
operation of the engineering interface (ENI).
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Further documentation:
„ ENI Server user manual

„ Online help for ENI Server, ENI Admin, ENI Control (parts of the
ENI Server Suite) and ENI Explorer
„ EPAS-4 Automation Toolkit online help

12.1 Function of the ENI

The world of automation is so multifarious that it is impossible to
enforce one standard for all software and hardware products. Users
do not want to be committed to a small number of manufacturers,
but demand the best solution to every problem.
Systems should become more transparent, they have to offer open
interfaces to which users can connect their software and hardware
without any problem. Within the PacDrive system, there are several
interfaces offering that opportunity. Via OPC server, for example,
you can directly access the data of the PacController. The most
recent interface of the PacDrive system is the EPAS-4 Engineering
Interface (ENI).
The ENI was developed as a client/server system. The server is an
independent program based on a data storage system, preferably a
version management (e.g. Microsoft Visual SourceSafe or MKS
Source Integrity). All engineering data, such as program function
blocks, variable lists, visualizations or configuration are stored via
the server. The data storage format is XML. With this interface,
other tools can now access all data of a project developed with
EPAS-4. Those tools can read, generate and manipulate data.
Three examples are to help you better understand the ENI:
„ Multi-user operation

„ Version management

„ Access by external clients

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12.1.1 Multi-User Operation

The ENI permits multi-user operation in the implementation of
PacDrive projects. In the past it was very difficult for several
developers to work together on projects developed with a

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development environment for controllers. Although individual parts
of a project could be exchanged by means of export and import
functions, developers had to rely on verbal arrangements in order
to coordinate their work.
The ENI offers a much more elegant solution to that problem. The
project is stored entirely in the ENI. When a developer wants to
work on a component, he loads it to his local working environment
and edits it there. Other developers cannot edit that component at
the same time. They can only access it after it has been released
by the programmer. This strategy permits coordinated and thus
effective work with several developers on the same project.

12.1.2 Version Management

The ENI supports the use of a source code version management
program. Software is usually developed in several phases. The
programmer will therefore implement the modules of a program
step by step. Changes often have to be discarded because the way
taken turned out not to be right after all. In the past, the developer
saved his version and then made changes to a copy. If the changes
were successful, he kept the copy; if they were not so successful,
he returned to the original version. Everyone who has worked with
this method knows that it needed improvement.
At least in the EPAS-4 development environment and modern
development environments for many high languages, a solution
has been found. Developers can now store different versions of
their program or even individual components in the ENI database.
The developer can retrieve those versions at any time, provided
that the ENI uses a database that supports version management.
The use of a version management does not interfere with the
workflow, as it integrates smoothly with the EPAS-4 development
environment.
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 12.2 Structure and Communication of the ENI

12.1.3 Access by External Clients

In the past it was not possible to directly access the data of the
development environment with other tools. With the ENI, any
clients now have access to the data of the automation project.
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Those data can be read and even manipulated by the external

client. For the programming language C++ there is a client interface
(C++ DLL) to program a client for the ENI Server.

12.2 Structure and Communication of the ENI

The ENI operates a data storage system for PacDrive project data
objects. This can be an existing database system or a local file
system. The ENI interface is divided into a server and a client part,
so that the storage system can also be located on another
computer (otherwise multi-user operation would not be possible).

Client 2
EPAS-4 (Vis, Config. etc)
programming
system
Client Interface
(C++ DLL)

HTTP / XML HTTP / XML

ENI Server

Database Interface

e.g. file system,

DB SourceSafe, etc

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Fig. 12-1: ENI server concept

ENI Server
Engineering Interface Server runs as a separate service. The
communication protocol is HTTP with XML as useful data.
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12 ENI-4

ENI Client
The clients of the ENI Server are e.g. EPAS-4, a CoDeSys
programming system or other applications that need to access the
data storage. All clients are equal.

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Connection between ENI Server and database system (DB)
The ENI defines no own storage format. It is connected to an
existing data handling system via drivers (database interface).
Drivers are available for the database systems 'Visual SourceSafe
6.0', 'MKS Source Intergrity' and a local file system. For connection
to other storage systems, please contact us.
Which data storage system an ENI Server is actually serving is
defined in the ENI Server administration (See also „The ENI in
EPAS-4“ on page 251.). The clients of the server can then access
exactly that system.

HTTP as communication protocol, XML as data format

The ENI Server is accessed via the HTTP protocol; the transmitted
data (objects) are shown in the universally accepted standard
format XML. The HTTP protocol makes it possible to work across
firewalls and execute certain operations by means of standard
tools.
There is a client C++ DLL (client interface) to encapsulate the
protocol in C++ classes, so that it is not a must to use only HTTP
and XML software to access the ENI Server.

12.3 Structure in the Data Storage System / ENI

Explorer
The ENI Server manages components created by EPAS-4 or other
clients in a folder structure in the data storage system. There they
are held as objects characterized by a type and access rights.
Moreover, a version history is kept for each object. Within a folder,
objects must be unambiguous by name and type.

ENI Explorer
ENI Explorer exists analogous to Windows Explorer as an
independent program that can be connected to the desired ENI
Server by means of suitable ENI access data. The folder/object
structure in the ENI and the desired database functions can be
called up right there, independently of the data handling system
used and of EPAS-4. Object type, access rights, actual check-out
status and users are shown as well.
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 12.4 The ENI in EPAS-4
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Fig. 12-2: ENI Explorer

12.4 The ENI in EPAS-4

The EPAS-4 programming system is a possible client of the ENI
Server. Every part of a PacDrive project can be created as an
object in the data handling system. For that purpose it is assigned
to one of the four object categories that are possible in EPAS-4
(see below). The object storage is complete, i.e. the properties of
the component, such as access rights, are transmitted in XML
format along with the contents of the component. An automatic
exchange with the data handling system can be defined for each
object category.

XML format for EPAS-4 objects

The example below shows the depiction of a component in XML
format. It includes e.g. the name of the component (<name>), its
type (<pou>), its path in the EPAS-4 Object Organizer structure
(<path>), access rights for the eight possible workgroups
(<accesslevels>) and the contents of the component in the
declaration part (<interface>) and the program part, which in this
case is created in structured text (<st>,<body>).
<?xml version="1.0" encoding="ISO-8859-1"?>
<pou>
<accesslevels> rw,rw,r,rw,r,rw,rw,rw </accesslevels>
<path> \/languages </path>
<name> ST_EXAMPLE </name>
<flags> 4 </flags>
<interface>
<![CDATA[PROGRAM ST_EXAMPLE
VAR
YVAL: INT := -250;
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BOTTOM: INT := -250;

RUN_STRING: STRING(20) := 'Start';

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12 ENI-4

OFFSET: INT := 2;
END_VAR
]]>
</interface>
<st>

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<body>
<![CDATA[RUN_STRING:='Start';
IF (YVAL < 0) THEN
YVAL := YVAL + OFFSET;
BOTTOM := YVAL + OFFSET;
END_IF;
]]>
</body>
</st>
</pou>

Categories for EPAS-4 ENI objects

There are four kinds of data objects for management via the ENI
interface:
1. Project-specific objects: Components created specifically for
a certain project.
2. Common objects: Components that are commonly used in
several projects, e.g. function block libraries.
3. Automatically generated compilation objects: This has
currently no significance and is not supported.
4. Local objects (not managed in the data handling system)
An object is assigned to one of the categories in the EPAS-4 project
options and object properties.
The ENI parameters can be configured separately for each of the
categories 1-3 (see below, Operation...).

Structure of the PacDrive project in the data storage system

One or several paths are created for a project in the connected data
storage system and thus "in the ENI" under the "root" configured in
the ENI control - folders where e.g. project components are shown
as objects (for example, you could define a separate folder for each
ENI object category).
Every project object receives a data type. Every component name
taken over from EPAS-4 receives a type-specific extension and a
type symbol and thus represents the object outside the
programming system.
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 12.4 The ENI in EPAS-4

Operation of the ENI interface in the programming system

In EPAS-4, the ENI can be activated as a project option. Then the
following functions are available for dialogs:
1. Definition in the project options if and to which ENI object
category a newly created object is to be assigned.
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2. Configuration of the ENI connection type in the project options

for each of the three ENI object categories (project objects,
common objects, compilation files; see above):
„ Access data: port, access rights, project in the ENI storage to
which the actual project is connected
„ Definition which exchange with the data storage system is to
take place automatically, and when (e.g. always call up objects
from the database when a project is opened or check out
whenever a change is begun in EPAS-4, etc.)

Fig. 12-3: ENI settings

3. Individual assignment of an object to an object category (see

above) in the object properties of each object
4. Entry of username and password via a database login dialog
(project menu) for access to the data handling system
5. Database commands in the project menu, for individual objects
or for the entire project:
- Call / call all
- Check out / check out all
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- Check in / check in all

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12 ENI-4

- Undo check out / ... for all objects

- Version history for object / project
- Show changes
- Label version

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- Insert common objects (from the database system into the local
project
- Update status

12.5 ENI Admin and ENI Control

Certain settings can only be made locally on the ENI Server. The
programs 'ENI Admin' and 'ENI Control' are available for that
purpose. Like ENI Server and ENI Explorer, they are installed with
the ENI Server Suite, which is shown with an icon on the system
bar of your computer.
ENI Admin (ENIAdmin.exe) requires the entry of the administrator
password to start. Users, user groups, access rights and the
administrator password are defined here, licenses are managed
and object data types shown.

Fig. 12-4: ENI Admin

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 12.5 ENI Admin and ENI Control

ENI Control (ENIService.exe) also requires the ENI administrator

password to start. It is used to set the desired database driver even
during the installation via setup. Moreover, it offers the opportunity
to deliberately stop and restart the ENI service, which is usually
started automatically, or to let the service run via another user
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account. In addition, certain communication parameters

(communication timeout, port, etc.) of the server-client connection
can be changed. An event log is available as well.

Fig. 12-5: ENI Control

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12 ENI-4

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 13 Frequently Asked Questions

13 Frequently Asked Questions

What are VAR_IN_OUT variables?
VAR_IN_OUT variables are transmitted as pointers. Thus, the data
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need not be copied into and out of an instance. Located boolean

variables cannot be transmitted as VAR_IN_OUT.

Are there pointers?

IEC 61131 knows no pointers. However, pointers are supported in
the PacDrive M system. If you use pointers, we cannot assume any
warranty that the programs work correctly - the user is entirely
responsible himself.

Are there structuring possibilities for the validity range of

variables?
You can create local and global variables.

What language can be used for what purpose?

There is no clear method. Here is just a recommendation:
„ SFC for step-by-step procedures

„ ST for algorithmic calculations

„ FBD for program calls

„ LD e.g. for locks

„ IL for bit processing

Which programming language is the fastest one?

The execution speed of the programming languages differs only
marginally.

Is there an oscilloscope function?

Yes, there is trace recording.

How can I display an instance of an FB in online operation ?

The instance of an FB can be shown under PROJECTS | OPEN
INSTANCE. To do this, the cursor in the Object Organizer (left win-
dow) must stand on the FB or the FB must already be opened.

Are there partial compilations or do I always have to compile

the entire program?
PROJECT | COMPILE ALL always compiles the entire project. An
online exchange only generates and loads the changed code. After
a rebuild, online exchange is no longer possible. You have to load
the entire program.
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13 Frequently Asked Questions

What happens in case of online change?

This method permits changes while the PLC is running. In case of
online change, the delta code, i.e. the latest modifications, is crea-
ted. Directly after login this code is loaded into the the control (in
the runtime system) and stored there. When the changes are acti-

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vated, the code is added at the end of a cycle. As the code now
exists twice, the memory will be reorgnized during the following
cycles.

What is OPC?
OPC stands for OLE for Process Control and represents a standard
interface for the connection of various hardware components to
HMI/SCADA applications.
For further details, see Operating Manual OPC Server (article num-
ber 17130073-001)

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 14 Glossary

14 Glossary
Absolute position encoder
Every point of a journey is marked by an unambiguous signal. For
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systems with absolute position encoders, no homing drive is requi-

red after switching on.
Normally the encoder information is recorded with an additional
code disk which records a maximum of 4096 encoder revolutions.
An easier variant is to store the infomration with a built-in battery.

Acceleration time
Acceleration time of the servomotor/amplifyer combination without
external inertia from standstill to rated speed at peak torque.

ActiveX
The designation ActiveX is a general term. It comprises the techno-
logies known as OLE Control (OCX). However, the terms were
rearranged in the scope of the definition of ActiveX. ActiveX is a
technology developed by Microsoft in order to support interactive
contents for the World Wide Web. To be regarded as ActiveX con-
trol, a COM object must offer certain interfaces.

Analog signal
Many process data are available as analog values. We differentiate
bewtween a voltage or current signal. To enable a computer to read
in an analog value, it requires an analog digital converter. The reso-
lution of the signals depends on the accuracy of hte AD converters.

Applet
An applest is a program used primarily on Internet sites. It is written
in the Java programming language and can therefore run on all
platforms.

AS interface
AS interface (ASI) is designed for very easy networking in automa-
tion technology. ASI was optimized for the lowest field bus level and
offers the opportunity to connect not only binary, but also intelligent
slaves and simple, analog units. With regard to the data volume,
ASI has a lower capacity than field buses and is no competition for
them.
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14 Glossary

ASCII
ASCII is the abbreviation for American Standard Code for Informa-
tion Interchange. It is represented in 7-bit mode.

Axis identifier

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Logic address of an MC-4 MotorController (not RealTimeBusAdr!)

Baud
The transmission speed baud is defined as the number of bits
transmitted per second.

Baud rate
The baud rate is the speed of data transmission and gives the num-
ber of bits transmitted per second (baud rate = bit rate).

Booting
The start procedure of a computer (e.g. PC) and operating system
is also called booting.

Browser
A "Web browser" is a program that permits access to and display of
Internet pages. The main purpose of web browsers is to download
HTML documents and the corresponding pictures from the Internet
and display them.

Bus
Common transmission channel to which all participants are connec-
ted; it has two defined ends.

Bus connector
Physical connection between station and bus line.

Bus system
All stations that are physically connected via a bus cable form a bus
system.

Cam laws
See set value generation
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 14 Glossary

CAN
CAN stands for Controller Area Network and was originally
developed by Bosch and Intel as a bus system for vehicles. In the
meantime, CAN has also proven suitable as a field bus in automa-
tion technology. Like practially all field buses, CAN is based on the
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OSI 7 layer model. CAN is normed in ISO 11898 only for OSI layers
1 and 2 and is based on a bus structure. The transmission speed
can be selected in a range of 20 kBit/s to 1 Mbit/s. The application
layer is defined by the layer-7 protocols based on CAN, e.g.
DeviceNet over CANopen. Due to the access method CSMA/CA
and object-oriented addressing, CAN is particularly suitable for set-
ting up very efficient event-controlled systems. In the multimaster
system CAN, data can be exchanged directly between any number
of clients.

CE
The CE sign documents that the product meets all requirements of
the applicable European directives.

Client
An application that turns to a server to have certain tasks carried
out.

CLSID (with OPC)

The class ID is a worldwide unambiguous code for a certain COM
object. Via the CLSID, a client can address a certain COM object. A
CLSID consists of 128 bit. To receive an unambiguous CLSID, the
time of generation and hardware information of the computer used
for generation are included in the CLSID.

CNC
An abbreviation for computerized numerical control. CNCs are
used primarily in machine tools.

Cold restart
Program start at which all variable ranges are (re-)initialized. In
case of certain events, such a cold start can be initiated automati-
cally or manually by the user.
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14 Glossary

COM
The Component Object Model is used by Microsoft to define a
mechanism for the cooperation of software components within the
Microsoft Windows operating systems. By means of COM, an appli-
cation can use the services of other applications or components.

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COM is the technological basis for ActiveX, OLE and DCOM. COM
describes accurately to the bit how components work together and
thus, in principle, is not tied to a programming language or a certain
operating system. By now, the COM standard is also available on
other operating systems.

COM objects
COM objects are software components that comply with the COM
component model and make their functionality available to a client
via COM interfaces. COM objects are defined unambiguously by
their CLSID.

Commentary
Text enclosed between brackets and asterisks (cannot be nestet!)
to explain a program; not interpreted by the programming system.

Communication
Here: data/information exchange between configurations.

Consistent data
Data that belongs together in terms of content and must not be
separated are called consistent data.

Control
A system in which signals are given only in forward direction from
the input to the output. It is not checked and corrected if the actual
values of the system match the set values.

ControlNet
ControlNet is an open control network fulfilling the requirements of
real-time applications with high data throughput. It is used to con-
nect controls, I/O modules, PCs, visualization systems (HMI) and
other intelligent devices. ControlNet transmits data with 5 MBit/s
and enables a deterministic, reproducible transmission of time-criti-
cal control data. Network access is controlled by the time slice
algorithm "Concurrent Time Domain Multiple Access" (CTDMA).
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 14 Glossary

Continuous Function Chart (CFC)

Continuous Function Chart (CFC) is a programming language
which, similar to SFC, has Boolean and arithmetic elements that
work simultaneously. The continuous function chart uses no net-
works. The elements can be placed freely. The elements in the
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processing list include function block, input, output, jump, label,

return and comment. The inputs and outputs of those elements can
be linked by dragging the mouse. The connecting line is drawn
automatically.
An advantage of the continuous function chart CFC is that feed-
backs can be inserted directly.

CPU
Central Processing Unit, micro processor

CUL
Products bearing the CUL sign meet the safety standards for the
Canadian market. Canadian safety standards may differ in detail
from the US standards of UL.

Current regulator
The current regulator regulates the difference between set current
value and actual current value to 0.

Cv
Designator for the rated speed -> see VDI 2143
Meaning:
Cv lower -> required drive torque due to static strain (spring force,
gravity, usable force) lower

Cycle
One round of the application program (which is checked
periodically).

Cycle time
The time an application program needs for a cycle.

DC-circuit
Rectified and smoothed power supply.
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14 Glossary

DCOM
The Distributed Components Object Model expands the COM stan-
dard, so that COM objects can be used across computer limits.
DCOM is an optimized protocol which enables a client to use a
COM object on another computer. For this purpose, the calls to the

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COM object are “packed“ in data packages, transported via a net-
work, unpacked again and finally the COM object is called. The use
of remote objects is transparent to a client.

Declaration
Definition of variables and FB instances in a declaration block,
giving the designator, the data type or FB type and, where applica-
ble, the start values, value ranges and field properties.
The definition or programming of POUs is also called declaration
because they are declared with their properties in the programming
system.

Declaration block
Summary of declarations of a variable type at the beginning of a
POU.

Derived data type

With the help of a type definition, you can create a user-specific
data type the elements of which consist of its elements or of ele-
mentary and/or derived data types.

DeviceNet
DeviceNet is an open, manufacturer-independent field bus stan-
dard in automation technology for the connection of PLCs with
“intelligent“ devices such as sensors, push buttons, I/O assembly
units, simple operating interfaces and drives via one single cable.
DeviceNet is an application protocol (OSI layer 7) based on the
Controller Area Network (CAN). It offers high reliability for deman-
ding applications with a high number of I/O assembly units.
Depending on the kind and length of cable used, the transmission
speed is 125 kBit/s to 500 kBit/s.

Dezentralized technology
In converter technology, one differentiates between centralized and
decentralized technology. The difference lies in the power supply. In
centralized technology, one supply module generates the power for
the individual amplifyers. In decentralized technology, each
amplifyer or MotorController has its own power supply.
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 14 Glossary

Directly shown variable

Variable without further designator; corresponding to a hierarchic
address.

Drive bus
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Modern, leading-edge systems transmit the information between

control and drives in digital form. The most important technical
requirement for the drive bus is a strictly deterministic transmission
of the positioning data.

Edge
A “rising“ edge means the 0 -> 1 transition of a logic variable.
Accordingly, a “falling“ edge is the 1 -> 0 transition.

Electronic packaging machine

In an electronic packaging machine, a mechanical main shaft is
replaced by an electronic main shaft with individual flexible electric
motor drives.

Elementary data type

A standard data type defined by IEC 61131-3.

EMC
EMC (electromagnetic compatibility) is the ability of an electric or
electronic device to function satisfactorily in its electromagnetic
environment. Limits for interference emission and interference
proofness are set in norms.

EN
Abbreviation for European norm. In the course of European harmo-
nization, national norms (e.g. DIN or VDE) are replaced by
European norms .

Erasing unit
Assembly units to reduce induced voltages, which occur when swit-
ching off power circuits with inductivities.
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14 Glossary

Ethernet
Ethernet has been around since the early 1980s and is nowadays
found in all network technologies. An end of the dominance of the
Ethernet is not in sight. It is available for various cable media, fiber-
optic cables and radio and offers data rates of 10 Mbit/s to 1 Gbit/s.

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All kinds and generations of components cooperate in a network
with no problem. The principal disadvantage of the restricted deter-
ministic transmission behavior is usually meaningless for most
applications (e.g. HMI) and can be neglected in view of the
immense transmission capacities.

FBL
Function block language, essentially equivalent to the classical
function block diagram.

Field
Sequence of elements of the same data type.

Field bus
Conventionally, sensors and actuators are connected with a control
or evaluation unit via an analog or digital signal. This technology
requires a multiwire cable for each connection between sensor or
actuator and control. In addition, a facility for switching on and off (I/
O) must be provided in the control for each sensor or actuator. If a
field bus system is used, all devices are connected to one bus
cable. Instead of facilities for switching on and off, an interface
module is used. The resulting advantages are obvious. Commis-
sioning and service become easier, the plant is more flexible. As a
rule, this means cost advantages compared with conventional solu-
tions. The different requirements for field bus systems, the variety
of techical soltions and last, but not least, aspects of corporate
policy, resulted in a large number of different field buses and pre-
vented one single international standard. The devices of ELAU AG
support the following international standards: CANopen, PROFI-
BUS DP, DeviceNet and ControlNet.

Following error
The following error is the dynamic distance between the computed
set position value and the actual position value. The following error
depends on the regulator structure and the amplifications of the
individual regulator circuits. Minimal following errors can be achie-
ved by means of feed forward for speed and current.
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 14 Glossary

FTP
"FTP" (short for "file transfer protocol") is a transfer protocol used in
the World Wide Web or in local networks using TCP/IP as network
protocol. "Anonymous FTP" is offered by several thousand Internet
computers as a way for everybody to access data, even if the
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respective computer has no user entry.

Function block diagram (FBD)

The function block diagram is a graphically oriented programming
language. It works with a list of networks. Each network contains a
structure representing a logic or arithmetic expression, the call of
function blocks, a jump or a return instruction.

Function call hierarchy

This function displays the call stack if there is an actual diagnosis
message from the message logger.

global
extensive; here: within the entire configuration

Ground conductor
One or several conducting parts that have very good ground
contact.

Ground contact
Electrically conductive connection between a phase and PE.

Grounding
Grounding means connecting an electro-conductive part to the
ground conductor via a grounding system.

GSM
GSM is a European mobile communication standard for cellphones
in the 900 MHz range, defined by the CEPT (Conférence Euro-
péenne des Administrations des Postes et Telecommunications).
Due to their digital data transmission technology, the GSM data ser-
vices permit the remote diagnosis of packaging machines via
cellphone.

Hierarchic address
Physical connection address of the I/O modules of a PLC system.
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14 Glossary

HMI
HMI (Human Machine Interface) are systems to operate plants, to
monitor processes and to save data in industrial production proces-
ses. Smaller packaging machines use simpler operating units, but
complex machines often use efficient visualization systems on the

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basis of industrial PCs. Such systems depict the operational proce-
dures in a machine as flow diagrams and thus facilitate
transparency for their monitoring. Important operating data are
recorded and shown graphically. If something should not run
smoothly, an alarm will be triggered immediately.

Holding brake
Brake in the motor; may be used only if the motor is standing.

Hot restart
Program start at the same place where a power failure occurred,
while the PLC was in “RUN“. All buffered data ranges of the pro-
gram are retained and the program can continue running as if there
had been no interruption. In contrast to a hot start at the beginning
of a program, the duration of the interruption must lie within a cer-
tain interval, depending on the process. For this purpose, the PLC
system must have a separately secured real-time clock, so that the
program can calculate the duration of the interruption.

Hot start at program start

Program start like hot restart with the only differenece that the unit
starts from the beginning of a progrm if a maximum duration time
has been exceeded. With the help of a state flag, the application
program can recognize this situation in order to be able to prepare
a special setting of its data.

HTML
HTML means HyperText Markup Language. It describes the logic
components of a document. As a markup language, HTML contains
commands for marking typical elements of a document, such as
headers, text paragraphs, lists, tables or graphic references.

Id
see Identifier

Identifier (Id)
Identifier of an object
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 14 Glossary

IEC 61131
IEC 61131-3 is an international standard for programming langua-
ges of programmable logic controls (PLCs). Instruction list (IL),
function block diagram (FBD), ladder diagram (LD), structured text
(ST) and SFC (sequential function chart) are different languages of
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this norm.

Instruction list
IL (instruction list) is a widely used programming languages for PLC
systems, similar to Assembler.

Indirect FB call
Call of an FB instance, the name of which was transmitted as
VAR_IN_OUT parameter in a POU.

Incremental encoder
Encoder that reports its position by two signals offset by 90°.

Instance
Structured data set of an FB by declaration of a function block,
giving the type of FB.

Instancing
Instancing means the allocation of variables, including name and
data type, during declaration by the user. By declaring different
variables for the same type of FB, a data copy of the FB is formed n
the control memory for each instance thus created.

Interface
interface

Interfaces (OPC)
COM interface, non-equivocal by an identification code - collection
of connected functions. COM object can have one or several inter-
faces. Must not be changed after publication.
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14 Glossary

Internet
The Internet is a decentralized network, i.e. it does not depend on a
single computer. The network consists of a number of sub-nets; the
network protocol is TCP/IP.
The Internet consists primarily of the following services:

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„ e-mail, the most widely used service

„ World Wide Web, the second-most widely used service

„ Usenet, also called newsgroups

„ FTP, a data transmission service

Inverter Enable
Inverter Enable is a switching unit in the MC-4 MotorController and
enables the operating mode “safe stop“. In this operating mode, the
unintentional start of a stopped drive due to an error is prevented.

IP 20
Protection means according to DIN 40050: Protected against finger
touch and against the intrusion of solid foreign objects with a dia-
meter of more than 12 mm.

IP 65
Protection means according to DIN 40050: Protected against
touch, dust and the intrusion of spraying water from any directions.

IP 66
Protection means according to DIN 40050: Protected against
touch, dust and against the harmful intrusion of powerful water jets.

IP 67
Protection means according to DIN 40050: Protected against touch
and the intrusion of water with a certain pressure when
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 14 Glossary

ISDN
ISDN (Integrated Services Digital Network) is a telecommunication
standard that is widely used in Germany and Europe. In ISDN, all
information is transmitted in digital form. This makes it possible to
transmit the signals for language, text, pictures and data through
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the same telephone line. ISDN not only offers the possibility of
using conventional telecommunication services. It also supports
new types of communication, e.g. picture phones. The high trans-
mission speed makes ISDN the ideal transmission medium for
remote diagnosis of packaging machines.

Ladder diagram (LD)

LD (ladder diagram) is a programing language to describe networks
with simultaneously working boolean electromechanical elements
such as contacts and coils.

Limit switch
Limitation switch in the travel of a machine.

Logic address
Each object and each parameter in the control configuration has an
unambiguous address by which it can be addressed.

Main shaft
See electronic packaging machine

Mains filter
Facility to educt distortions from the power lines to PE.

Mass
Mass is the total of all connected inactive parts of an operating
means that cannot take on a dangerous contact voltage even in
case of an error.

Master
Master devices determine the data traffic on the bus. If it has bus
access rights, a master is allowed to send messages without exter-
nal request. Masters are also known as active participants.

Master cam
Main or basic cam

Moment of inertia
Mass moment of inertia of a servomotor in the unit kgcm2.
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14 Glossary

MotorController
An electronic unit containing an amplification and control circuits for
position, speed and current of a servomotor. The output size, the
power connection of the servomotor, are modified in dependence
on the set input value, the set positioning value.

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Multi-element variable
Variable of the type Field or Structure, composed of several data
types.

Network
Unit which is marked by the fact that the content of the actual result
is not retained beyond the network boundaries.

OCX
The term OLE Control Extension marks COMobjects which can
depict themselves via a user interface. Such COM-based control
elements are additions to the known Windows control elements
such as button, checkbox, etc. The term “OCX“ has been replaced
by the more general defintion “ActiveX Control“ and is no longer
used.

offline
without connection

OLE
Object Linking and Embedding is a COM-based mechanism for
integrating different document types within a document. OLE
makes it possible e.g. to embed a spreadsheet in a text and use the
functionality of that spreadsheet program within the text processing
program.

OLE Automation
OLE Automation defines a COM-based mechanism that enables
script languages (macro languages of applications, Java script,
Visual Basic, etc.) the easy use of COM objects.
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 14 Glossary

OPC
OPC is the abbreviation for "OLE for Process Control". The OPC
Foundation has the aim of transforming the different interfaces
used in process control and automation applications into a standar-
dized form in order to enable a smooth collaboration between
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control applications, the fiels systems and components and the

business and office applications and thus enable a simple, quick
and inexpensive system integration. Based on Microsoft’s OLE and
COM/DCOM technology, the OPC standard offers manufacturers of
hardware and software a possibility to develop a standard driver for
data exchange with other systems, e.g. HMI or SCADA.

OPC groups
An OPC group is a logic unit for structuring OPC items used by a
client. Groups are created by a client and can contain one or
several OPC items. Group calls can be applied to the OPC items of
a group.

OPC items
The OPC items represent the process variables. OPC items are
identified by an ItemID and have a value, a state information and a
time stamp.

OPC server
An OPC server is a COM object offering the interfaces of the OPC
specification of the OPC-Foundation.

Open Control
The Open Control Foundation wants to develop future-oriented
concpets for the standardization of PC-based automation solutions.
For an automation solution, usually different hardware and software
components have to be integrated in an overall system, e.g. a field
bus connection for decentralized I/Os, a control, a visualization
system and various projecting tools for PLC, field bus and HMI. By
using a common data pool, the Open Control Foundation tries to
achieve a usefulness of the projecting data throughout the system,
to avoid errors and in general enable cost reductions in projecting.

Operand
Language element with which an operation is effected, e.g. %IX1

Operator
Symbol that represents an action with which an operation is execu-
ted, e.g. AND
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14 Glossary

Opto-coupler
Optical connection between two electrically independent systems.

PacDrive
The PC-based automation system PacDrive is ideally suited for the

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complete automation of packaging machines. The IEC 61131 PLC
and motion tasks (VarioCam) are realized with a central PC-based
intelligence. There are interfaces to all commercially available
HMIs. The I/O level of the PLC is realized by standard field buses.
The highly dynamical servo drives are connected via SERCOS.
The built-in Ethernet interface with TCP/IP enables remote diagno-
sis via modem or Internet down to the motor current.

Peak torque
The maximum torque which the combination of servomotor and
amplifyer can emit to the drive shaft of the servomotor for a short
time.

PLC
Programmable Logic Controller

PLC
Abbreviation for Programmable Logic Control.

Plug-In
Plug-Ins (PI) extend an Internet browser by additional features,
which make it possible to display varous file formats which the
browser does not support by default.

POU
Program organization unit; IEC 61131-3 component of the type
Function, Function block or Program, from which PLC programs
are created hierarchically.

Position resolution
The position resolution says how many increments are available
per 360 degrees motor revolution. In principle, positioning accuracy
and regulating quality are the better, the higher the position
resolution.
In general, resolvers have a position resolution of 4,096 to 65,000
increments per motor revolution. High-resolution SinCos encoders,
as used in the PacDrive™ system, have a resolution of 1,000,000
increments per motor revolution.
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 14 Glossary

PROFIBUS
PROFIBUS is a manufacturer-independent, open field bus stan-
dard for applications in manufacturing, process and building
automation. Manufacturer-independence and openness are gua-
ranteed by the international norm EN 50 170. PROFIBUS enables
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the trouble-free communcation between devices of different manu-

facturers without any special interface adjustments. PROFIBUS is
suitable both for fast, time-critical data transmission and for com-
prehensive and complex communication tasks. PROFIBUS
consists of a family of 3 compatible variants: PROFIBUS-DP, PRO-
FIBUS-FMS and PROFIBUS-PA.
The PROFIBUS connections of ELAU AG are based on PROFI-
BUS-DP. PROFIBUS-DP is specially designed for the
communication between automation systems and decentralized
peripheral units on field level and is characterized by high speed
and low connection costs. PROFIBUS-DP is based on a bus struc-
ture and uses a transmission technology according to RS-485 or
fiber-optic technology. The transmission speed can be selected in
the range of 9.6 kBit/s to 12 Mbit/s.

ProgID
The Program ID is a plain-text substitute for a CLSID. ProgIDs have
the format “library.class.version“ and, in contrast to CLSID, are non-
equivocal only by convention. Example of a ProgID:
„OPC.Producer.20“.

Protocol
The rules for data transmission between computer systems and
other devices are called protocol. A protocol defines the packeting
of data, i.e. how many data bytes are transmitted at once, the treat-
ment of data that were transmitted faulty (kind of error protocol), the
channels availble for transmission (full duplex or half duplex
method), giving the beginning and end of a transmission and the
kind of compression of the data packages.
The ISO (International Standards Organization) created the OSI
model (Open Systems Interconnection) as a reference model for all
data transmission between electronic systems. According to the
OSI reference model, a transmission protocol has seven leves.

Position regulator
The position regulator regulates the difference between set position
and actual position to 0. Output: set speed.

Rated speed
Usable speed at rated torque. Idle-running speed and mechanical
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limit speed of the servomotor are higher.

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14 Glossary

Rated torque
The rated torque is the permanent torque in Nm of a servomotor/
amplifyer combination at rated motor speed. Due to the losses,
which are related to the speed, it is less than the standstill torque at
speed 0. With an ambient temperature and depending on the ther-

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mal motor time constant, an overtemperature of 40°C occurs on the
motor casing.

Real-time operating system

In real-time operating systems, like in conventional operating
systems, several parallel jobs, i.e. tasks, threads or processes, are
processed simultaneously. To fulfill the real-time requirements in
the control job, real-time bus systems use special methods of com-
puting time allocation. The predictability (determinism) of the
system behavior, i.e. the guarnteed processing of a job within a
given time frame, is an essential criterion for real-time systems.
Moreover, the administration of system resources, such as com-
mon or exclusive memory ranges, IO devices, ports and time
services as well as the task communication via semaphore, mail-
box and event-queues put particularly high demands on the real-
time operating system.

Real-time process
The tasks of the real-time process include e.g. processing the
master and logic encoders, processing the motion tasks including
calculation of set values, processing the measuring inputs, recor-
ding trace values and of course exchanging real-time data via the
real-time bus (SERCOS).

Real-time system
According to a DIN definition, a real-time system is a system that
replies in a defined way to an external event under all circum-
stances, with the reply being generated within a certain time frame
(scan time). If a time frame is exceeded, this is regarded as a
failure of the whole system. If the process is less critical, it may be
admissible to exceed that time frame. In this case, we speak of “soft
real time“. A soft real time system is only acceptable if exceeding
the time frame causes no risk to man or machine. As a rule, pak-
kaging machines are systems that represent “hard“ real-time
requirements for the control used.

Reference potential
Potential from which the voltages of the circuits involved are regar-
ded and/or measured.
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 14 Glossary

Regulation
A set value of a proces size is compared with the actual value and
amplified and regulated in such a way that the difference is zero, if
possible. In contrast to a control, the influence of a distortion is
regulated out in a regulation. In principle, there is control and distur-
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bance variable behavior. In a servo drive, position, speed and

current are regulated.

Reset
Procedure that triggers the boot of a computer (e.g. activating the
reset button, switching on the control voltage).

Resource
As a rule, the ressource is equivalent to a CPU.

RS-232
The RS-232-C interface is a standardized serial interface which is
largely identical with the V.24 interface (CCITT). It is designed for
asynchronous data exchange between a computer system and a
peripheral unit.

RS-422
In functional terms, the RS-422 interface is equivalent to the RS-
232 interface, but it uses a differential signal transmission and thus
makes it possible to bridge greater distances even at higher trans-
mision speeds while being little prone to distortion.

RS-485
The RS-485 interface is a standardized serial interface. In functio-
nal and electrical terms, it is largely equivalent to the RS-422
interface and permits the connection of several terminals to a con-
nection cable (bus).

Restart
Summary term for hot restart and hot start at program start.

SCADA
SCADA systems (Supervisory Control and Data Acquisition) con-
tain components for the control, analysis, monitoring, storage and
administartion of the information flow between the systems of the
field level and the management level of a company. This ensures
the connection between the decentralized I/O units and the
machine controls on the one hand and the office computers of the
mangement level on the other.
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14 Glossary

Scan rate
Time in millseconds which tells in which time the set values of an
axis are calculcated and compared to the actual values and then
the differences are processed in the controller.

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Sequential function chart
SFC (sequential function chart) is a programming language to des-
cribe sequential and parallel control procedures with time and result
control.

Server
A server is a service provider. In connection with COM, the server
is a COM object whose functionality (services) can be used by a cli-
ent via its interfaces.

Servomotor
A servomotor nowadays is a brushless, permanently excited syn-
chronous motor. A servomotor has a position encoder and is
characterized by its extremly low internal inertia and high power
density.

Servo amplifyer
see MotorController

Set value generation

Nowadays the motion functions of the individual axes of an electro-
nic packaging machine are realized with intelligent software in the
PacController. All motion laws known in VDI 2143 and some self-
defined motion laws can still be modified online.

Short-circuit
Is a conducting connection arising due to an error between two
conductors under operating voltage if there is no useful resistance
in the fault current circuit.

Single-element variable
Variable that is based on one single data type.

Slave cam
Overlaying cam. A slave cam can only be started if a master cam is
active.

Speed regulator
The speed regulator regulates the difference between set speed
and actual speed to 0. Output: set power value.
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 14 Glossary

Spline interpolation
Connection of individual points in space with a 3rd-grade
polynomial.

Step
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State knod in an SFC program in which commands of the action

belonging to a step are triggered.

Standard functions
Number of functions defined firmly by IEC 61131-3 to realize PLC-
typcial functionality.

Standard function block

Number of function blocks firmly defined by IEC 61131-3 to realize
PLC-typical functionality.

Structured text
Structured text is a programming language for the description of
algorithms and execution control by means of a modern high
language.

Symbolic variable
Variable with designator to which a hierarchic address is allocated.

Syntax
Structure and structural cooperation of the language elements of a
programming language.

TCP/IP
"TCP/IP" (abbreviation for "transmission control protocol/internet
protocol") usually describes a whole family of protocols to connect
computers in different networks. Nowadays TCP/IP is used in many
LANs and is the basis for the worldwide Internet.
The IP takes over the transport of data, while the TCP takes care of
their delivery.
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14 Glossary

Telecommunication connection
Telecommuncation in this case means the transmission of data bet-
ween electronic data processing units or systems over a longer
distance e.g. with the help of electric cables, fiber-optic cables or
radio waves.

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Teleservice
Teleservice enables the remote connection of controls of packgaing
machines via telecommunication networks (ISDN, GSM) for ser-
vice, maintenance, commissioning or machine conversions. For the
machine builder, teleservice can guarantee worldwide short service
reaction times and thus a high availability of packaging machines.

Terminal resistor
is a resistor to adjust the performance on the bus cable; terminal
resistors are necessary at the ends of cables and/or segments.

Thermo protective contact

Temperature-sensitive switch built into the motor winding.

Torque constant
Quotient of standtsill torque and standstill current in the unit Nm/A.

Transition
Transition from one SFC step to the next by evaluating the transi-
tion condition.

Translation of functions
A function can be applied to entries of different data types.

Type definition
Definition of a user-specific data type on the basis of existing data
types.

UL
Underwriter Laboratories Inc. (UL) is an independent testing and
certifying organization in the USA. Products bearing the UL sign
comply with the safety standards of the UL.

Ungrounded structure
Structure without galvanic connection to the ground. In most cases
an RC module is used to carry off parasitic currents.
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 14 Glossary

Variable
Name of a data storage, which can take on values determined by
the data type and entries in the variable declartion.

VarioCam®
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The VarioCam® Online Toolbox provides you with extensive

functions, including standard cams. Lengthy modificatin and restart
is not required, as the cams are simply reshaped by
parameterization.

VxWorks
ELAU AG’s MAx-4 PacController is based on the real-time opera-
ting system VxWorks® by Wind River Systems. VxWorks® is the
market leader in the field of real-time bus systems and meets high-
est requirements with regard to real-time behavior, robustness,
runtime and memory efficiency.

Windows
A strong trend towards Microsoft operating systems can be obser-
ved in automation technology. This development confirms the
direction towards open, scalable automation solutions on the basis
of the fast-developing PC hardware. Software becomes a decisive
factor for automation solutions. The driving force in this develop-
ment is the 32-bit world of the Windows operating systems, on
which many producers of industrial software are now betting. The
products usually include standard interfaces for graphic imports,
data exchange (DDE, ODBC) and for the integration of applications
(OPC). By means of interfaces, the communciation between diffe-
rent software products can be effected easily.
However, these standard operating systems from the office domain
cannot fulfill the strict real-time requirements for a driving system.
Windows CE, Windows NT and Windows NT Embedded in their
original version can only be used for automation projects with “soft“
real-time requirements. Therefore ELAU AG’s MAx-4 PacController
is based on the real-time operating system VxWorks®, which gua-
rantees absolutely deterministic behavior.Thanks to the integrated
OPC interface, the MAx-4 PacController can easily be integrated in
Windows environment.

WWW
The "WWW" (abbreviation for "world wide web") is a multi-media
hypertext information system in the Internet.
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14 Glossary

Zero pulse
The zero pulse is issued by incremental encoders once per revolu-
tion. It helps to zeroize the machine.

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 14 Glossary
Korrekturausdruck
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ELAU AG Programming Manual page 283

14 Glossary

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page 284 Programming Manual ELAU AG

 15.1 Contact

15 Appendix

15.1 Contact
Korrekturausdruck

For repair
Please send the components to be repaired or checked, along with
the error report, to this address:
ELAU AG
Abt. Kundendienst house address:
Postfach 1255 Dillberg 12
97821 Marktheidenfeld 97828 Marktheidenfeld
Phone: +49 (0) 93 91 / 606-142
Fax: +49 (0) 93 91 / 606-340

Service team
Should you need to talk to a member of our service team or require
on-site service, please contact:
ELAU AG
Dillberg 12
D-97828 Marktheidenfeld
Phone: +49 (0) 9391 / 606 - 0
Fax: +49 (0) 9391 / 606 - 300
e-mail: [email protected]
Internet: www.elau.de
ELAU, Inc.
4201 West Wrightwood Avenue
Chicago, Illinois 60639 - USA
Phone: +1 773 342 8400
Fax: +1 773 342 8404
e-mail: [email protected]
Internet: www.elau.com
ELAU SYSTEMS ITALIA S.r.l.
Via Tosarelli 300
I-40050 Villanova di Castenaso (BO)
Phone: +39 051 / 7818 70
Fax: +39 051 / 7818 69
e-mail: [email protected]
Internet: www.elau.it

NOTE
Further contact addresses you can find on the ELAU homepage
PDM_AnhangStd_us.FM

(www.elau.de).

ELAU AG PacDrive page 285

15 Appendix

15.2 Further Literature

ELAU can provide you with these manuals and instructions on the
PacDrive™ System:1
Project Manual

Korrekturausdruck
Art.No. 17 13 00 58 - 00x (DE, EN, FR)
Programming Manual
Art.No. 17 13 00 61 - 00x (DE, EN)
Operating Manual MC-4 MotorController
Art.No. 17 13 00 62 - 00x (DE, EN, IT, FR)
Operating Manual CAN L2
Art.No. 17 13 00 66 - 00x (DE, EN)
Operating Manual PROFIBUS-DP
Art.No. 17 13 00 67 - 00x (DE, EN)
Operating Manual SM Motor
Art.No. 17 13 00 68 - 00x (DE, EN, IT, FR)
Operating Manual EPAS-4
Art.No. 17 13 00 70 - 00x (DE, EN)
Operating Manual MAx-4 PacController
Art.No. 17 13 00 71 - 00x (DE, EN, IT, FR)
Operating Manual OPC-Server
Art.No. 17 13 00 73 - 00x (DE, EN)
Operating Manual Device Net
Art.No. 17 13 00 76 - 00x (DE, EN)

Operating Manual HMI Libraries

Art.No. 17 13 00 77 - 00x (DE, EN)

Operating Manual INC-4 Incremental Encoder Module

Art.No. 17 13 00 78 - 00x (DE, EN)

Operating Manual CANopen

Art.No. 17 13 00 79 - 00x (DE, EN)

Operating Manual VarioCam® Editor ECAM-4

Art.No. 17 13 00 80 - 00x (DE, EN)

Operating Manual PacNet Module PN-4

Art.No. 17 13 00 81 - 00x (DE, EN)
PDM_AnhangStd_us.FM

Operating Manual SR Motor

Art.No. 17 13 00 82 - 00x (DE, EN)

1. Art.No. -000 (DE) german -001 (EN) english -002 (IT) italian -003 (FR) french
page 286 PacDrive ELAU AG
 15.2 Further Literature

Operating Manual BusTerminal BT-4/DIO1

Art.No. 17 13 00 83 - 00x (DE, EN)

Operating Manual TTS

Art.No. 17 13 00 88 - 00x (DE)
Korrekturausdruck

User Manual Automatic Controller Optimization

Art.No. 17 13 00 89 - 00x (DE, EN)

Operating Manual PacDrive SCL

Art.No. 17 13 00 93 - 00x (DE, EN)

Operating Manual PacDrive PS-4 und PacDrive PD-8

Art.No. 17 13 00 94 - 00x (DE, EN)

Operating Manual Evaluation Kit

Art.No. 17 13 00 95 - 00x (DE)

Operating Manual PacDrive Controller P600

Art.No. 17 13 00 96 - 00x (DE)
PDM_AnhangStd_us.FM

ELAU AG PacDrive page 287

15 Appendix

15.3 Product Training

We offer practical workshops and seminars.
Our experienced seminar leaders will enable you to make optimum
use of the vast possibilities of the PacDrive™ system.

Korrekturausdruck
NOTE
Please contact us for further information or to order our seminar
program. See also our homepage (www.elau.de).

PDM_AnhangStd_us.FM

page 288 PacDrive ELAU AG

 15.4 Modifications

15.4 Modifications

07 / 1999
„ Terms e. g. MAx-4, MC-4 and PacDrive™ M modified
Korrekturausdruck

„ Sales Regions updated

„ Manual revised

12 / 1999
„ Separation of the programming manual in reference and user
part
„ Revised to 00.06.00

01 / 2001
„ Chapter „The Basics of IEC-61131“ new
„ Revision of Chapter „Programming Guidelines“
„ Revision of Chapter „Teleservice“
„ FAQs new
„ Glossary widens

10 / 2003
„ Chapter "Networks" new
„ Chapter "Teleservice" modem recommendation extended
„ Chapter "Teleservice" "Settings on Remote PC" extended for
Windows 2000
„ Chapter "Programming Guidelines" extended
„ Chapters "Characteristics", "Time diagrams" and "Version desi-
gnations" taken over from Reference Manual
„ Chapter "ENI-4" new

NOTE
The latest documentation and modification service on this product
are available on the ELAU Homepage (http://www.elau.de).
PD_UserManAen_us.FM

ELAU AG Programming Manual page 289

15.4 Modifications

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page 290 Programming Manual ELAU AG

 Index

15.5 Index

A contents 3
Absolute position encoder 259 Continuous Function Chart
acceleration time 259 (CFC) 263
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Action in SFC 61 Control 262

Active step 61 ControlNet 262
ActiveX 259 CPU 263
Alternative branch 64 CSMA/CD 212
Analog signal 259 CUL 263
APIPA 219 current regulator 263
applet 259 Cv 263
Arbeitsgruppe 203 cycle 263
ARP 216 cycle time 263
AS interface 259
ASCII 260 D
Axis identifier 260 Datendurchsatz 213
DC-circuit 263
B declaration 264
baud 260 declaration block 264
Baud rate 260 delete log file ... 147
Benutzerverwaltung 204 Derived data type 264
Bindungsreihenfolge 228 DeviceNet 264
booting 260 dezentralized technology 264
Bridge 222 DHCP 219
browser 260 direct shown variable 265
Bus 205, 260 DNS 220
Bus connector 260 Domäne 214
Bus system 260 Domänen-Konzept 214
drive bus 265
C
cam laws 260 E
CAN 261 edge 265
CASE instruction 56 ELAU AG 2
CE 261 electronic packaging machine
client 261 265
Client-Server 204 elementary data type 265
CLSID 261 eMail
CNC 261 ELAU AG 2
coil 69 EMC 265
cold restart 261 EN 265
COM 262 ENI-4 247
COM objects 262 Erasing unit 265
commentary 262 ethernet 266
communication 262 EXIT instruction 59
configuration 29
Consistent data 262 F
PDM_UserMan_usSIX.fm

contact 68, 285 FBL 266

ELAU AG Programming Manual page 291

Index

field 266 instancing 46, 269

field bus 266 instruction list 49, 269
following error 266 instruction type in ST 53
FOR instruction 57 interfaces 269
FTP 215, 267 internet 270

Korrekturausdruck
function 43 ELAU AG 2
function block 43 inverter enable 270
Function block diagram (FBD) IP 215
267 IP 20 270
function blocks IP 65 270
in LD 69 IP 66 270
Function call hierarchy 267 IP 67 270
funktion block language (FBL) IP- Adressierung 217
66 IP- Adressklassen 218
funktion blocks IP- Adresszuweisung 219
in ST 55 IPSec 215
ISDN 271
G
Gateway 224 J
Glasfaserkabel 211 jump 64
global 267
Ground conductor 267 K
ground contact 267 Koaxialkabel 210
Grounding 267 Kontaktplan (KOP) 271
GSM 267
L
H lader diagram (LD) 67
hierarchic address 267 languages
HMI 268 function block diagram
holding brake 268 (FBD) 66
homepage ladder diagram (LD) 67
ELAU AG 2 Sequential Function Chart
hot restart 268 (SFC) 59
hot start at program start 268 structured text 52
HTML 268 LD as FBD 69
HTTP 215 limit switch 271
HUB 221 literature 286
load from file ... 147
I load log file ... 147
Id 268 logic address 271
identifier (Id) 268
IEC 61131 269 M
IEC step 62 MAC- Adresse 211
IF instruction 56 MAC-Adresse 211
IL 49 main shaft 271
incremental encoder 269 mains filter 271
indirect FB call 269 manuals 286
PDM_UserMan_usSIX.fm

input action in SFC 61 Mass 271

instance 269 Master 271

page 292 Programming Manual ELAU AG

 Index

master cam 271 position regulator 275

message logger 146 position resolution 274
delete log file ... 147 POU 274
filtering 149 Präfix 114
load from file ... 147 PROFIBUS 275
Korrekturausdruck

load log file ... 147 ProgID 275

reset log entries 147 program 43
save and load a log file 147 protocol 275
save as file ... 147
save log file 147 Q
modifications 289 qualifier 63
modifiers in IL 50
moment of inertia 271 R
MotorController 272 rated speed 275
multi-element variable 272 rated torque 276
real-time operating system 276
N Real-time process 276
Namensauflösung 220 real-time system 276
NetWare 214 Reference potential 276
network 272 regulation 277
Netzwerke 203 repair 285
REPEAT instruction 59
O Repeater 221
OCX 272 reset 69, 277
offline 272 reset log entries 147
OPC 273 resource 29, 277
groups 273 restart 277
items 273 RETURN instruction 55
server 273 Ring 207
OPC server 273 risk
Open Control 273 classification 12
operand 273 Route print 226
operating manual 286 Router 223
operation in ST 53 Routingtabelle 226
operator 273 RS-232 277
opto-coupler 274 RS-422 277
output action in SFC 61 RS-485 277

P S
PacDrive 274 safety notes 12
parallel branch 64 save and load a log file 147
Pathping 228 save as file ... 147
peak torque 274 save log file 147
Peer to Peer 203 SCADA 277
Ping 225 Scan rate 278
PLC 274 seminare 288
plug-in 274 Sequential function chart 278
PDM_UserMan_usSIX.fm

POP 215 Sequential Function Chart

Portnummer 216 (SFC) 59

ELAU AG Programming Manual page 293

Index

server 278 U
service Übertragungsmedien 210
-personnel 285 UDP 215
servo amplifyer 278 UL 280
servomotor 278 Ungrounded structure 280

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set 69
set value generation 278 V
Short-circuit 278 validity 40
single-element variable 278 variable 281
slave cam 278 VarioCam 281
SMTP 215 version numbers 245
Socket 217 VxWorks 281
speed regulator 278
spline interpolation 279 W
standard function block 279 WHILE instruction 58
standard functions 279 Windows 281
step 279 WWW 281
step in SFC 60
Stern 206 Z
structured text 279 zero pulse 282
structured text (ST) 52 Zugriffsverfahren 212
Subnet Mask 217
Switch 222
symbolic variable 279
syntax 279
system data 231
system overview 19

T
tasks 29
TCP 215
TCP/IP 214, 279
telecommunication connec-
tion 280
teleservice 280
Telnet 215
Terminal resistor 280
thermo protective contact 280
time diagrams 233
Token Passing 213
Topologien 204
torque constant 280
trademarks 2
training 288
transition 61, 280
transition conditions 61
translation of functions 280
PDM_UserMan_usSIX.fm

Twisted-Pair-Kabel 210
type definition 280

page 294 Programming Manual ELAU AG

 15.6 Form for Error Report

15.6 Form for Error Report

This error report is absoluteley necessary in order to enable
efficient processing.
Send the error report to your ELAU representative or to:
Korrekturausdruck

ELAU AG, Abt. Kundendienst

Dillberg 12, D-97828 Marktheidenfeld
Fax: +49 (0) 93 91 / 606 - 340

Sender:
Company: City: Date:
Department: Name: Phone:

Details on the defective product

Product name: ..................................................................................
Article number: .................................................................................
Serial number: ..................................................................................
Software version: ..............................................................................
Hardware code: ................................................................................

Parameter enclosed: yes [ ] no [ ]

IEC program enclosed: yes [ ] no [ ]

Details of the machine on which the problem occurred:

Machine producer: ...........................................................................
Type: ................................................................................................
Hours of operation: ...........................................................................
Machine number: ..............................................................................
Date of commissioning: ....................................................................
Producer/Type of machine control:
.........................................................................................................
ELAU_FoStoerung_us.FM

ELAU AG PacDrive error report page 1

 Description of the problem:
..........................................................................................................
..........................................................................................................
..........................................................................................................

Korrekturausdruck
Additional information:

Problem state: Causes: Concomitant phenomena:

[ ] persistent [ ] unknown [ ] mechanical problems
[ ] when commissioning [ ] wiring error [ ] failure of mains supply (24V)
[ ] occurs sporadically [ ] mechanical damage [ ] failure of PMC-2
[ ] occurs after about.....hours [ ] moisture inside the unit [ ] motor failure
[ ] occurs in case of shocks [ ] encoder defective [ ] broken cable
[ ] depends on temperature [ ] insufficient ventilation
[ ] foreign object inside unit

Does the switching cabinet have an air conditioning system?Y/N [ ]

Have similar problems occurred before on the same axis?

How often: ..............................
Did the problems occur on certain days or times of day?
..........................................................................................................
further information:
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ELAU_FoStoerung_us.FM

error report page 2 PacDrive ELAU AG