CTIO not setting up correctly

[DueyDumore]

I'm using a CTRIO as a quad counter (A,B,Z on channel 1 and A Not, B Not, Z Not on channel 2). I've spent two days with AD tech support, and really have not gotten anywhere.

I originally set Ch 1 as a position counter, and  Ch 2 as a rate counter. On channel 1, I'm trying to count to specified # of pulses, the counter roll over to zero and keep counting. Ch 2 just keeps counting as FPM rate meter. I went through the set-up with the AD tech, 5 or 6 times with no success.

I cleared the module, and restarted. I finally got the unit to work the way I want, but in data view and the workbench the counter justs quits counting. I tried turning off data view and watching in workbench and vice versa with same results. Used the count value in compare statement in direcsoft, and fired and cyclical output. Some times it will miss two or three product spaces at a very slow process speed.

I'm hauling my scope there today, but could use some guidance.

Thanks

[ATU]

Which counter IO module do you have and which CPU?  Do you have the most current Firmware for the CPU?  What voltage levels do you have on the encoder with what type of driver ? Some encoders have differential outputs and don't really work well being connected as a single ended device.

[Greg]

(1) You say you have A, B, and Z connected to Channel 1;  are you connecting Z to Input C? And if so, what is this input configured to do?
(2) You say you have notA, notB, and notZ connected to Channel 2; are you connecting Z to Input C? And if so, what is this input configured to do?
(3) Do you have a Preset Table that fires a CTRIO output? Is this output then tied to Input C in order to do a Reset for the count?

If you try to catch the count in ladders you will always have problem simply because of the ladder logic scantime. If you could provide the details of your wiring and CTRIO configuration, then it would help greatly.

If I were going to do this, I think I might have a Preset Table that pulses the CTRIO output when the desired count is reached. This output would be wired to the Input C (instead of the Z or notZ), and I would use this pulse to reset the count. But that is if I have understood your application accurately.

[DueyDumore]

Greg: I have Z and Z Not tied to their respective C channels. I connected then because it showed the marker connected in a schematic.
Yes, you understand our application. Prior to this machine upgrade, we had an absolute encoder into a DC card, and converted to a rotary position,
which we compared to operator selected ON and OFF points to fire solenoids. If I understand you correctly, I shouldn't do any count comparisons in ladder, and should be using the actual outputs  to fire my solenoids? I will need to write the Output ON count and OFF count.  How do I do this?

I am using the preset table to roll the count over. I am not using an Output to reset the count on Channel C, but will give that a try. I will use
the outputs to fire some solid state relays for our outputs.

I scoped the encoder signals and they're perfect.

We're using a 1024PPR quad encoder, 4.5 -30VDC/ Complementary w/Short Circuit Protection. It is being powered from our 24VDC supply.

The CTRIO is running on the local rack (slot 7) of a DL-260 CPU.

Thanks for the help.

[ATU]

If you are controling solenoids on that same supply powering the encoder and CTRIO module. I would suggest purchasing another small power supply and powering only the encoder and CTRIO card with it.

[DueyDumore]

I've gotten the unit working properly. It resets at a specific count in my LENGTH preset.

I've gotten the outputs to turn ON and OFF at predetermined counts.

I want to use all four outputs, and they will all turn ON and OFF at different counts. So when the operator makes a product change, I'll recalculate the 8 different ON and OFF values, and then must load them. How do I go about doing this?

Thanks for all the help.

[ATU]

Section 6-23 of the Ctrio Manual.  I have never done it, but the capability is there.  I think you have to edit each entry in the table. If you have to make a lot of changes, it may be easier to use stored points in your PLC and just build the table.

[MikeS]

there are two ways to do this easily:

if the number of 'sets' of operator setpoints is limited to known values you could create a different preset table for each one -  you can have up to 255 preset tables - and then load the preset table that you need ...

or ...

you can create one Preset Table use the Edit Preset Table Ibox to change the values within that preset table as needed.

Editting preset tables was never hard, it was just complicated to get all the interlock logic right. With IBoxes, the interlock logic is already done for you, so it's much easier. The caveat is that you need to use IBoxes for everything you do to modify anything in the CTRIOs memory, to make sure that all operations on the CTRIO's memory is interlocked with all the others ...... if you mix IBoxes and 'regular' ladder logic you run the risk of 'un-interlocked' operations on the CTRIO ... and that almost never works out right.

[DueyDumore]

This thing is not working correctly. Occasionaly, we get that the CTRIO configuration is corrupted. Other times a warning comes up saying this is not the latest revision (presently 2.1.16, Booter 1.0.2).

I'm trying to use CTRIO Output #1 as a Registration Eye window (CTRIO Out1 drives Solid State Relay) The Operator will set a window on the web (material) that the registration eye can operate in (e.g. 1000 to 1048 counts), that we will allow the registration signal to be seen by our servo drives. This is Table #2  'REGISTRATION'. It contains a SET @ 100 and a RESET @ 200. I'm using a IBox-1003 (also tried IB-1002) to change the SET count (V3004) and another IB-1002 to change the RESET count (V3006).

If I change the PLC from run to program and back the output starts firing at 100 counts and stays on till 1024. This is very repeatable and fast. In Monitor I/O in Workbench I can watch the ON and OFF times and hear the solenoid turning on and off. I then go to the screen and change value of V3004 and use a differentail contact on a handshake bit between the screen and plc. I now see OUTPUT #1 turning ON at the correct time, and OFF at the correct time but the output is not turning ON and the OUTPUT display in the Monitor I/O turned Yellow instead of Green when it was running correctly. If I quit the workbench (all saved and in RUN) and come back in, it will say the Configuration is Corrupted.

I've got to be able to change these ON and OFF points with the machine running. Any ideas on what is going ON? Which I-Box is the correct one for changing one value at a time?

[Greg]

You should be using IB-1002 (CTREDRL - CTRIO Edit Preset Table Entry and Reload). The difference between the IB-1002 and the IB-1003 is that IB-1002 makes the change retro-active because it immediatly reloads the table for use. If you use IB-1003, then you will have to manually reload the table for use (using IB-1001 CTRLDPR).

I'm not sure what is happening with your Monitor I/O functionality in CTRIO Workbench, but keep in mind that when you go into Monitor I/O you have to option of suspending the I/O mapping between the PLC and the CTRIO. If you suspend it, then when the PLC tries to do certain functions with the CTRIO, it won't be able to because it is essentially "disconnected" from the CTRIO. If you do not suspend the mapping, then you can use Monitor I/O to watch what is happening, but realize then that any change you try to make in Monitor I/O can be overwritten by the PLC.

In any case, you should not even be able to corrupt the CTRIO configuration, so, as I said, I'm not sure what's happening there.

One other thing, it is important that if you use CTRIO IBoxes, that you use them exclusively and not try to use them as well as the examples in the manual that ATU mentioned. If you combine them, it may be that something is happening there to cause disfunctionality.

[Greg]

...If I quit the workbench (all saved and in RUN) and come back in, it will say the Configuration is Corrupted...

Regarding this specific error... Does your program use any WT/RD commands?

[DueyDumore]

Greg: I'm not using any WT or RD commands in my program. I have a second (new) CTRIO card that I will install and program into this PLC just to see....

I had tried this with the IB-1002, and then the IB-1003 just to get one to work. I'll redo it as an IB-1002 in my new card and give that a shot.

If that doesn't work, can you take a quick look at my program?

Thanks

[Greg]

Why certainly. Just send it to me: support@hosteng.com