Introduction.

Edition: 26/732E5 

USERS GUIDE PCD PG5

Workshop PG5 

Welcome 

© Saia-Burgess Controls Ltd.

Workshop PG5 

Welcome 

Introduction. 

Welcome 

Thanks a lot for your interest in our product. Soon from now you’ll discover 

how to write programs for the SAIA PCD as did many developers before 

you. In fact there are 250000 PCD’s running today! 

Programming a PCD is not hard at all. Although knowledge of PCD programming 

is of some help it isn’t required for this Workshop. You’ll learn how 

to solve simple problems step by step. Each chapter has some exercises at it’s 

end so you can check yourself the progress you have made. We believe that 

learning without practice is worthless. Therefore we strongly recommend to get 

a PCD with a digital input card and a digital output card before you start. Further 

you’ll need a cable PCD8.K111 for the examples. 

We wish you good fun. PCD Support Team 

What is PG5 all about? 

Much like the programming languages C++, Prolog, Assembler were built for 

special applications in science and industry, there are different kind of languages 

which are widely used in the automation industry. 

The languages are very similar from label to label, though the name for one and 

the same language may change. The languages are: 

• IL Instructionlist 

• Graftec 

• Fupla 

• Kopla also called Ladder 

We will see soon exactly how they work. PG5 now is a tool which allows us 

create programs for a wide range off applications. But PG5 not only is an editor 

for these different languages it will also help us to solve other problems we 

may encounter during a project. Tasks like: 

• Creating a documentation 

• Debugging the program once it runs on the PCD 

• Debugging the PCD 

• Set-up the configuration of the PCD 

• Write the program on an EPROM. 

During this course we will go through all these topics and do so by using a step 

by step approach. If you feel unsure about some points, then refer to the online 

help included in the PG5. You will see that you wont need much more then a 

little time and some cups of coffee to get familiar with the programming of 

PCD's. 


Workshop PG5 

Welcome 

Icons used in this book 

Each chapter contains pictures to help you make sense of the material you are 

reading. An other important graphical elements are the icons which highlight 

specific information so you can find the most important stuff at a glance. 

Warning or special 

help Never ignore this 

icon. Even if you skip 

the other icons, you 

don't want to miss this 

one. 

Technical stuff. If 

you are ready for 

some additional information, 

then read 

these points. 

Remarks. General 

information's about a 

topic. 


Workshop PG5 

Welcome 

System requirements 

Your PC: 

• SVGA or higher resolution monitor 

• Pentium 150MHz processor or better 

• 32MB of RAM or better 

• 30 MB free hard-disk space 

• Additional 5 MB free hard-disk space for HMI Editor 

• CD-ROM drive 

• Microsoft Mouse or compatible pointing device 

• TCP/IP Protocol installed for Online connections 

• TAPI 2.0 for modem connection 

• Microsoft Data Access Components (MDAC) 2.5 for HMI Editor 

and/or for Symbol Import/Export from/to Excel. 

MDAC 2.5 is automatically installed by the HMI Editor Setup or can 

be installed by running d:\pg5\mdac_typ.exe (assuming that d: is your 

CD-ROM drive) 

For Windows 98 Users: DCOM98 needs to be installed before installing 

MDAC 2.5. Run d:\pg5\dcom98.exe to install (assuming that 

d: is your CD-ROM drive) 

Supported operating 

systems: 

• Windows 95 B or higher 

• Windows 98 Second Edition 

• Windows NT 4.0 SP5 or higher 

• Windows 2000 Professional 

• Windows Me 


Workshop PG5 

Welcome 

Your PCD: 

You can write programs for any of the existing PCD’s: 

PCD1 

PCD2 

PCD4 

PCD6 

Have a look into the hardware manuals for further information about any of the 

PCD’s. Programs written with the PG5 will run on any of the PCD’s. 

All the examples are written for a PCD2 or PCD1 with: 

• 1 digital input card (E110 or E111 type) in slot 1 (equals address 0..7) 

• 1 digital output card (A400 type) in slot 2 (equals address 16..23) 

• 1 analogue input card (W100 type) in slot 3 (equals address 32..39) 

Further you’ll need a cable PCD8.K111 in order to download the program 

into the PCD. 

Further 

Documentation: 

For information about existing hardware refer to: 

Documentation CD-Rom: Ordernumber 26/801 


Workshop PG5 

Welcome 

1. Getting Started 

PROJECT MANAGER 1 - 1 

OPEN A NEW PROJECT: 1 - 3 

CONNECT YOUR PC TO THE PCD 1 - 6 

CONFIGURE THE HARDWARE (TABLE MEMORY CHIPSIZE): 1 - 8 

SUMMARY : 1 - 12 

ADDITIONAL NOTES: 1 - 13 

Exercise 

2. Write your first program 

MANAGE YOUR PROGRAM FILES. 2 - 1 

WRITE YOUR FIRST PROGRAM 2 - 5 

BUILD YOUR PROGRAM 2 - 6 

LOAD THE PROGRAM 2 - 7 

TEST YOUR PROGRAM 2 - 8 

SUMMARY 2 - 9 

ADDITIONAL NOTES: 2 - 11 

3. PCD Resources 

HARDWARE RESOURCES 3 - 1 

INTERNAL (SOFTWARE) RESOURCES 3 - 4 

SYMBOL EDITOR 3 - 13 

WORKING WITH SYMBOLS: 3 - 17 

ADD SEVERAL SYMBOLS AT ONCE 3 - 18 

IMPORT SYMBOLS FROM "EQU" STATEMENTS (PG3): 3 - 19 

ADD SYMBOLS DIRECTLY FROM THE PROGRAMEDITOR (ENTER): 3 - 20 

REPLACE A FIX ADDRESS BY IT'S SYMBOL (SHIFT + SPACEBAR): 3 - 20 

AUTO COMPLETE SYMBOLS (CTRL + SPACEBAR): 3 - 22 

AUTO ALLOCATION (WORK WITHOUT FIX ADDRESSES): 3 - 22 

FILTER THE SYMBOL VIEW: 3 - 25 

RESERVED NAMES: 3 - 26 

RESOURCE TABLE: 3 - 27 

Exercise 

4. FUPLA programming 

CREATE A NEW PROJECT AND A NEW FUPLA FILE 4 - 1 

THE FUPLA EDITOR 4 - 2 

EDIT YOUR FUPLA PROGRAM: 4 - 3 

EDIT PAGES 4 - 5 

BASIC INSTRUCTIONS: 4 - 7 

WRITE YOUR FIRST FUPLA PROGRAM 4 - 10 

BUILD AND DEBUG YOUR PROGRAM 4 - 13 

DEBUG YOUR PROGRAM ONLINE 4 - 14 

SOME RULES: 4 - 17 


Workshop PG5 

Welcome 

Exercise 

5. Program Structure 

CYCLIC ORGANIZATION BLOCK (COB 0 TO 15) 5 - 1 

PROGRAM BLOCKS (PB 0 TO 299) 5 - 3 

FUNCTION BLOCKS ( FB 0 TO 999 ) 5 - 5 

STRUCTURE VIEW AND EXECUTION PATH 5 - 6 

EXCEPTION BLOCK (XOB) 5 - 7 

TABLE OF XOB’S 5 - 8 

HISTROY TABLE 5 - 9 

SEQUENTIAL BLOCKS (SB 0 TO 31) 5 - 10 

6. GRAFTEC 

SEQUENTIAL BLOCKS (SB 0 ... 31) 6 - 1 

OPEN A NEW GRAFTEC FILE 6 - 3 

ORGANIZATION OF THE SB’S 6 - 6 

GENERAL STRUCTURE OF AN SB 6 - 7 

BASIC RULE: ALTERNATE STEPS & TRANSITIONS 6 - 7 

TRANSITIONS 6 - 8 

STEPS 6 - 9 

TYPICAL SEQUENTIAL BLOCK STRUCTURES. 6 - 10 

EDIT A SEQUENCE 6 - 11 

WRITE YOUR FIRST SEQUENTIAL BLOCK 6 - 15 


HOW TO STRUCTURE GRAFTEC USING PAGES. 6 - 23 

7. Instruction List Programming 

CREATE A NEW PROJECT AND A NEW INSTRUCTION LIST PROGRAM FILE 7 - 1 

THE INSTRUCTION LIST EDITOR "SEDIT" 7 - 3 

IL SYNTAX 7 - 5 

BASIC INSTRUCTIONS: 7 - 10 

WRITE YOUR FIRST IL PROGRAM 7 - 17 


DEBUG YOUR PROGRAM ONLINE 7 - 23 

SYNCHRONOUS VIEW 7 - 26 

Exercise 

8. Additional Tools 

DATA TRANSFER UTILITY 8 - 1 

CUSTOMIZE MENU 8 - 7 

WATCH WINDOW 8 - 9 

ONLINE CONFIGURATOR 8 - 13 

UPLOAD THE PCD CONTENT AND CREATE A PROJECT 8 - 17 

PROGRAM AN EPROM 8 - 22 

DOWNLOAD A NEW FIRMWARE VERSION 8 - 23 


1. Getting Started 

INTRODUCTION: 1 

1.1 PROJECT MANAGER 1 

1.2 OPEN A NEW PROJECT: 3 

1.3 CONNECT YOUR PC TO THE PCD 6 

1.4 CONFIGURE THE HARDWARE: 8 

1.5 SUMMARY: 12 

1.6 ADDITIONAL NOTES: 13 

Introduction: 

Welcome. 

In the first Chapter you will learn how to: 

♦ Open a new project. 

♦ Connect your PC to the PCD. 

♦ Configure the PCD. 

If you already have some experience with our other programming tools like PG4 

or PG3, we suggest that you do not skip this chapter because it will provide some 

basic information on how you can manage your projects today.

Workshop PG5 

Getting Started - Project management 


Workshop PG5 


1.1 PROJECT MANAGER 

PROJECT 

DEFINITION 

In contrast to PG4 or S5, PG5 doesn't handle one PCD, but a whole project 

with a multitude of PCD's and Networks. 

An entity of several PCD's is called a Project. Project files have the ending 

*.5pj 

Project 

Network 

© Saia-Burgess Controls Ltd Page 1-1

Workshop PG5 



Workshop PG5 


1.2 OPEN A NEW PROJECT: 

Before we start to write our first program we will have to open a new project 

with one or several PCD's: 

1. Open the PG5 Project manager. 

2. Click on File. 

3. Click on New Project. 

4. Enter a project name. 

5. Enter a description about the project. 

Enter a project 

name. 

Enter a description 

of 

the project. 

Click on OK 

to confirm 

entries. 

Don’t activate this 

option. We will 

manually add a CPU 

the first time. If it is 

active, just click on 

it to deactivate. 


Workshop PG5 


Now that you have opened a project, your project tree should match the display. 

The next step is to add a CPU. 

1. Highlight the Project, and right click on it. Then click on New CPU. 

2. Or, you can click on CPU in the menu bar, and then click on New. 

OR 

Enter a 

name 

Enter a description 

about 

the CPU. 

Click on OK 

to confirm 

ti 


Workshop PG5 


Your project tree should match the display below. 

Highlight Settings and double click on it. This shows you the three areas where 

you can configure your PCD. As you can see, there is Online, Hardware, and 

Software. 

The first setting is Online. Highlight Online and double click on it. 

Or Click on Online from the Tool Bar. 

OR 


Workshop PG5 


Select 

PGU 

Click on setup 

to select protocol 

The baudrate and protocol 

settings are fixed for 

PGU. The port depends 

on what is available on 

your PC. 

Click on OK to 

confirm entries 

Now the communication protocol is set. Next, we will connect the PCD to 

your PC. 

1.3 Connect your PC to the PCD 

Basic connection: 

The standard connection is the direct connection between the PGU port on the 

PCD, and the Com1 port on the PC. Use SAIA cable #K111. There is other 

configurations available, but this is the one we are going to use with this 

workshop. Refer to your hardware manual for the power connection to the 

PCD. Now you should be connected to the PC and the PCD should be on. 


Workshop PG5 


Confirm 

connection: 

The simplest way to check the connection between the PCD and the PC, is by 

clicking on the Online icon. Click on this now. 

You will receive this message. 

Click 

on Yes. 

Displays the 

connection 

tt 

Run and Stop are 

active when you have 

a program downl 

Your display should have a HALT 

d d 

status. Halt is online, but since you have 

not downloaded a program, it goes into the halt mode. 

If you receive this message: 

1. Click on OK. 

2. Check that the PCD is on. 

3. Check the cable connection between the PCD & PC. 


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1.4 CONFIGURE THE HARDWARE: 

Default Hardware 

Settings: 

There is two areas you can use to enter the hardware settings. 

1. Default settings. (will be used if no individual settings are not downloaded) 

2. Individual settings. (Custom to the project that is currently active) 

To get to the default settings, click on Tools, Options, and then the General 

tab. 

General 

tb 

Click on 

Default 

Hardware 

Settings 

Enter the 

memory. 

Enter PCD 

type. 

Enter the extension 

memory, if 

Confirm with 

OK. 


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Individual 

Hardware Settings: 

We just covered the entry of the default hardware settings. These would be 

useful if you had several PCD’s with the same configuration. You could set the 

default settings once, and all the others would be configured via the default 

settings. 

For projects with one or several different PCD’s, we have the individual hardware 

settings. 

Highlight Hardware, and double click on it. 

Enter the PCD type, the memory and the 

extension memory. If you are not sure on 

on the memory, you can click on Upload 

and the PCD will fill in the memory and the 

extension memory for you. This is only available 

with the individual settings, it is not 

available when setting the default settings. 

If you are not sure of the 

memory of your PCD, 

click on Upload, and it 

will enter the data for you. 

Click on 

Upload 

again. 

When Upload 

is complete 

click on 

l 


Workshop PG5 


Download 

Settings: 

Once you have the settings entered, you need to download the settings. Follow 

the steps below: 

Once you have the 

settings entered, 

click on Download 

Click on 

Download 

again. 

When the Download 

is complete, 

click on Close. 

The PCD is now configured to your settings. 

The software settings file, will be covered in Chapter 3. The next step is to 

write your first program. Chapter 2 will take you through this procedure. 


Workshop PG5 


Important 

JUMPERS: 

There are several jumpers 

on the PCD where you 

can choose the kind of memory 

chip you are using. (Examples: 

EPROM, RAM and some times 

Flash). 

There is a jumper to indicate if 

the memory is > < 1Mbit. 

Before the settings are 

downloaded, the PG5 reads the 

position of these jumpers and 

compares it with the setting you 

have chosen from the list. 

2 

1 

2 

Example PCD2: 

If you use an additional memory 

chip in the socket 1 and you 

encounter problems at this stage, 

then check the position of these 

jumpers! 

2 

For further information, please refer to the hardware manual. 


Workshop PG5 


1.5 SUMMARY: 

In this chapter you have learned how to: 

♦ Open a new project. 

♦ Setup the communication between the PC and the PCD. 

♦ Set the default and individual hardware settings. 

Additional Notes: 

♦ Overview of the Project Manager structure. 

♦ Overview of the File Manager structure. 

♦ Some information about memory. 


Workshop PG5 


1.6 ADDITIONAL NOTES: 

Project Manager 

Structure: 

Tool Bar: 

All operations are 

handled from here. 

Message Window: : 

Displays Disdd error messages, and the 

entire protocol from the assembler. 

You can scroll in the protocol 

and edit it as you wish. 

Data Window: 

Displays the content of several 

files, such as the Symbol Editor 

files, listing files in 3 views: 

Data view, Block view, and 

Block structure view, and all 

map files. Displayed is the 

Symbol editor. 

File Manager: 

Stores all the program and configuration 

files for the project. Also can 

store files from other programs such 

as Word or ElektroCAD. When you 

backup the project, all the files are 

stored. 


Workshop PG5 


FILE MANAGER Structure: 

Contains all the program files, 

which are used by multiple 

CPU’s. The modifications in 

these files are automatically 

reported to all the CPU’s in the 

project which reference to the 

file in the “Common Files” 

folder. 

Project Title, and number 

of CPU’s in the 

Here you can set how 

you are going to 

communicate with 

your PCD. Default is 

“PGU direct connec- 

Active Project: 

There is always one CPU 

that is active at any given 

time. 

All the operations you 

execute (build, hardware 

settings, download, ect ) 

corresponds to this project. 

A project becomes active 

by right clicking on 

” 

the 

CPU and choose “Make 

Active” 

. 

Contains all your 

listing and map 

files. 

Configure your 

PCD 

hardware and softi 

Contains all your 

program files. 

Files which are 

only referenced are 

displayed as 

shown with 

..\filename 

© Saia-Burgess Controls Ltd. Page 1-14

Workshop PG5 


MEMORY INFORMATION: 

Chips you 

can use: 

Chips we 

support and 

supply: 

PCD 

type 

Memory chip 

PCD1 Empty socket 

1 RAM 256kBit 

1 RAM 1Mbit 

1 Flash 1Mbit 

1 EPROM 512kBit 

1 EPROM 1Mbit 

PCD2 Empty socket 

1 RAM 256kBit 

1 RAM 1Mbit 

1 RAM 4Mbit 

1 Flash 1Mbit 

1 Flash 4Mbit 


1 EPROM 1Mbit 

1 EPROM 4Mbit 

PCD4 2 RAM 62256 

2 RAM 1MBit 



2 EPROM 1Mbit 

Order 

number 

4 502 5414 0 

4 502 7013 0 

4 502 7141 0 

4 502 3958 0 

4 502 7126 0 

4 502 5414 0 

4 502 7013 0 

4 502 7175 0 

4 502 7141 0 

4 502 7224 0 

4 502 3958 0 

4 502 7126 0 

4 502 7223 0 

4 502 5414 0 

4 502 7013 0 

4 502 5327 0 

4 502 3958 0 

4 502 7126 0 

Usable Bytes 

in the PCD 

17 KB 

32 KB 

128 KB 

112 KB 

64 KB 

128 KB 

32 KB/128KB 

32 KB 

128 KB 

512 KB 

112 KB 

448 KB 

64 KB 

128 KB 

512 KB 

64 KB 

256 KB 

64 KB 

128 KB 

256 KB 

Extension 

memory 

(RAM) 

None 

13 KB 

13 KB 

13 KB 

13 KB 

None 

24 KB 

24 KB 

24 KB 

24 KB 

24 KB 

24 KB 

24 KB 

24 KB 

13 KB 

None 

128 KB if you use 

PCD2.M120 Version 

J or M150 

172 KB if you use 

the memory 

PCD7.R310 

If you order a chip of a certain size, you might receive different types of chips. 

Memory chip size Order number Chip type 

RAM 256kBit 4 502 5414 0 SRM 2B256SLCX70 

HY62256ALP-70 

GM76C256CLL-70 

M5M5256DP-70LL 

TC55257DPL-70L 

RAM 1Mbit 4 502 7013 0 LP621024D-70LL 

SRM20100LLC70 

HY628100ALP-70 

GM76C8128CLL-70 

M5M51008BP-70L 

RAM 4Mbit 4 502 7175 0 HM628512LP-5 

KM684000ALP-5L 

Flash 1Mbit 4 502 7141 0 AM29F010-70PC 

Flash 4Mbit 4 502 7224 0 chip AM29F040 on socket 

EPROM 256kBit 4 502 5327 0 UPD27C256AD-10 

M27C256B-10F1 

TMS27C256-10JL 

EPROM 512kBit 4 502 3958 0 AM27C512-15XF1 

AMC27C512-15XF1 

EPROM 1Mbit 4 502 7126 0 AM27C010-90DC 

NM27C010Q-90 

M27C1001-10F1 

EPROM 4Mbit 4 502 7223 0 AM27C040-100DC 

M27C4001-10F1 


Workshop PG5 


EXTENSION MEMORY? 

Although this point is handled automatically by the configurator, it might 

be interesting to know what extension memory is all about: 

All the PCD's have sockets where the user can place additional memory. 

The user has three options; RAM, EPROM, or FLASH. Some PCD's 

have RAM (PCD1 and PCD2 ) already soldered on the PC-Board itself. In 

the case of PCD2, the RAM has a content of 32kByte or 128kByte depending 

on the hardware version. Depending on your program size, it 

may not be necessary to place a memory chip into the empty socket. You 

can load your programs into this RAM and work without an additional 

RAM or EPROM chip. 

If you want your program to be stored on an EPROM, FLASH, or if you 

have a large program which is to large for the standard RAM, then you 

will have to add an additional memory chip. As soon you place a memory 

chip into the empty socket, this memory becomes the main memory and 

the small RAM becomes the extension memory. Complicated? A little? 

Why bother? Well for one, you now know what this extension memory is 

and, if for example, you have your program on an EPROM and you want 

to change the content of a DB in the run mode. In such a situation the DB's 

in the EPROM can't be changed and the only RAM you'll have will be this 

small extension memory. DB stands for Data Blocks, and will be covered 

in chapter 3. 


EXERCISE 


QUESTIONS 1-3: 1 

SOLUTION 1: 2 

SOLUTION 2&3: 3 


You have learned to setup a project and how to configure a PCD in the first chapter. 

You’ll need to consult the PCD hardware manual for some of the questions.

Workshop PG5 

Exercise Chapter1 

EX-01-E 

© Saia-Burgess Controls Ltd

Workshop PG5 


Questions 1-3: 

Memory Configuration 

1. You have a PCD 1 with a memory chip like: 

JAPAN 9845 

HM628512ALP-5 

1.1 What does HM628512ALP-5 say? 

1.2 What’s the order number of this chip? 

1.3 What are jumper settings on your PCD like? 

1.4 What are the settings you have to choose in the Hardwareconfigurator? 

Firmware 

2. Open the PCD and try to find the firmware chip: 

3. The label on the firmware chip is: 

PCD1. M.... 

V008 

3.1 What does it say? 

3.2 Control firmware version on your PCD online. 

EX-01-E © Saia-Burgess Controls Ltd. Page 1E-1

Workshop PG5 


Solution 1: 

1.1 

HM628512ALP-5 for : 

HM = Chip provider 

62 = RAM 

512 = capacity in kByte (Sometimes the capacity is given in kBits) 

5 = access time 50 nanoseconds 

1.2 

The order number is: 4 502 7224 0 

(List is in the hardware manual PCD2 and at the beginning of this chapter) 

1.3 

Memory Configuration 

HM62256LP- 

R E 

WP 

As this is a RAM, we have to put the jumper 

on R. The E stands for EPROM. 

The jumper underneath stands for WP = write 

protect. You can’t download your program 

anymore it this jumper is set. Set both 

jumpers as shown on the picture. 

1.4 


Workshop PG5 


Solution 2&3: 

Firmware: 

2. 

Take the hardware manual: 

PCD1/2 manual 26/737 

PCD 4 manual 26/734 

PCD 6 manual 26/735 

and you’ll find a drawing in the first 

chapter showing the PCD and the FW. 

Firmware 

RAM 

uP 

68340 

User Memory 

24 VDC 

RUN 

ERR 

SPACE A 

SUPPLY 

3.1 The label says: 

PCD1. M.... 

V008 

The firmware is for a PCD1 and will run on any type of PCD1 ( M110,M120 

and M130) 

Further the firmware is an official one (indicated by the V) and it’s the version 

008. 

3.2 

Connect yourself to the PCD using the K111 cable as shown in the chapter1. 

Start the menu: “Online” “ PCDStatus” 

And you’ll get the 

firmware version: 

D1 = PCD1 

M1 = M110, 

M120 

Version 008 


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2. Write your first program 


2.1 MANAGE YOUR PROGRAM FILES. 1 

2.2 WRITE YOUR FIRST PROGRAM 5 

2.3 BUILD YOUR PROGRAM 6 

2.5 TEST YOUR PROGRAM 8 

2.6 SUMMARY 9 

2.7 ADDITIONAL NOTES: 11 


Now it's time to write our first program. A proper introduction to the FUPLA and 

IL programming will follow in the next chapter. It does not matter if you do not 

know the difference between FUPLA, KOPLA, IL, etc. (The names change 

from company to company ). The main goals of this chapter are: 

♦ See how easy a simple program can be done. 

♦ Write and download your first program. 

♦ Observe the states of your inputs and outputs on the PCD and your PC 

monitor.

Workshop PG5 

Write your first program 


Workshop PG5 


2.1 Manage your program files. 

There are a lot of different kinds of files in a project. Here, we will cover 

program files. There is three editors, and the format you choose to program 

in, determines the editor you will use. 

S-EDIT is the editor for programs written in IL ( Instruction list or AWL 

in German ). IL is a kind of assembler code with 127 different instructions, 

which work in combination with very powerful assembler directives. 

This will be your tool if you plan to make very fast programs or if 

you start to implement your own communication protocols into the PCD. 

FUPLA is the editor for all the guys who like to edit their programs in a 

graphical environment. ( Like ladder or logic) 

The only difference between LADDER and LOGIC is in the way you draw 

binary combinations. As soon as you use integer or floating decimal values, 

both LADDER and LOGIC become very similar to work with. We 

have implemented both LOGIC and LADDER into the same editor. 

In addition to the large basic library, a large number of libraries for applications 

like HVAC or communications via a modem, ( pager, modem … ) 

can be purchased. 

GRAFTEC is the name of the editor in which you can draw 

SEQUENTIAL BLOCS. It is a way to structure and display your program 

in a sequential format. This is useful if you want to solve sequential problems 

where you have to wait on some internal or external events before 

starting the next program step. 


Workshop PG5 

OPEN A 

PROGRAM- 

FILE: 


In order to start programming you have to know how to open a new program 

file: 

1. Highlight the folder called " Program Files" 

2. Click on the " New File" button or click the right mouse button 

OR 

3. Fill in the dialog-box as shown below: 

Add a name to 

your file 

Choose to open a new 

INSTRUCTION LIST 

program 

Activate this option 

in this example.. 

Don’t activate 

this option in 

this example. 

We will open 

the file later. 


Workshop PG5 


4. Look at the File Manager and you'll see this program file: 

Technical 

stuff: 

Highlight the file, click 

the right mouse button, 

then click on Linked to 

link or unlink the file 

LINKED/ 

NOT LINKED 

An arrow indicates that the file will be linked to the program. 

This means the file is part of your project and will be 

downloaded to the PCD. 

No arrow indicates the file will not be linked to the program. 

This can be useful if you have several program files, 

which you link for testing purposes, but will not be included in 

the final version of your program. 


Workshop PG5 



Workshop PG5 


2.2 Write your first program 

Goal: 

We will just program one simple equation: 

O 32 = I 1+ I 2 

(Turn the Output32 on if Input 1 or 2 has an input signal) 

Open the 

editor: 

Highlight and double click the file to open the editor. Enter the six program 

lines as shown. 

Enter the program 

code: 

The cursor will start in the 

upper left corner. Just type 

in COB 0 and enter. The 

editor will position the 

string for you automatically. 

Next don’t move the 

cursor, just type in 0 and 

enter. Follow this format 

for your entries. 


Workshop PG5 


2.3 BUILD your program 

What’s the BUILD 

function? 

BUILD your program: 

The functionality of BUILD is one of the most powerful features of the PG5 

package. It provides an automated and optimized procedure to take you from 

edit mode into online mode. The PCD system is updated with all the modifications 

that have been made to the project files. 

. 

Compile the program by clicking on the "Build Project" icon. 

As soon as you click on the "Build " icon, the program goes through all the 

files and assembles one after the other. This process is documented in the message 

window, so you'll always know which files are actually assembled. Once 

all the files are done, the linking starts. This also is documented in the message 

window. If everything is ok, the message window will tell you: 

Output to the 

MESSAGE 

WINDOW: 

The program " Inputoutput 

combination.src " 

has no errors. 

All the files that are 

linked. (We only 

have one file in this 

example plus the 

basic file called 

"~projpg4" which is 

always there.) 

The build was 

successful. 

Upon a successful build, your program is ready to be downloaded to the PCD. 


Workshop PG5 


Download your files 

Execute the download by clicking on the "Download" icon. 

DOWNLOAD 

YOUR 

PROGRAM- 

FILES: 

As soon as you activate Download, the memory settings and the program are 

downloaded into the PCD. The current program in the PCD will be erased and 

the new program will be downloaded. 

As soon as the program is downloaded, the status bar (see picture) will indicate 

“Complete. Press close to continue. 


Workshop PG5 


2.5 Test your program 

1. Go online. click on the icon and the start and stop icons will illuminate. 

2. Click on the start icon and the PCD is now in the run mode. Confirm 

that the run led is on. (The led is located on the front of the PCD). 

3. Click on the stop icon and the PCD is now in the stop mode. Confirm 

that the run led is off. 

4. Click on the start icon to go back into the run mode. 

5. Double click on the Input output combination file. 

View your program 

online: 

6. Click on the Asynchronous Data Mode icon. Your program is now 

displayed. 

7. Activate input 1 and confirm it’s state changes to a high, along with the 

state of Output 32. Deactivate Input 1 and activate Input 2. Output 32 

should go high again. 

8. You have completed your first program!!! 

Click on the “Asynchronous 

Data Mode” icon. 

If you turn on and 

off you input 1, the 

state will change 

on the screen 


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2.6 Summary 

You have learned how to: 

• Open a new program file. 

• Edit a very simple program with one program block. (Program blocks will 

be defined later). 

• Build your program. 

• Download your program. 

• Test the program online. 

Additional notes in the following pages.... 

• Build options 

• Download options 

• Code view mode 


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2.7 ADDITIONAL NOTES: 

You don't have to know or understand the build options in order to successfully 

make a program. However, they are 

available if you want to customize the way 

your program is built and documented. 

Technical 

stuff: 

To access the options window, activate Tools => 

Options. 

BUILD 

OPTIONS 

Each time you build the project you will be asked whether or not you want to 

save the project. (We recommend you keep this activated until you become 

familiar with PG5) 

Stops the build after the first error appears. (If disabled the build will finish the 

build process to the end and list all the errors {up to 100}. In any case a 

download will be refused). 

Downloads the program automatically after a successful build. 

Creates a *.MAP file. The MAP file contains statistical information about your 

project like lines of code from each program file and the number of text bytes. 

Creates a *.lst (list file) during the build process. ( Useful to debug tricky instruction 

list programs) 


Workshop PG5 


Technical 

stuff: 

You can: 

1. Download everything (default) 

2. Download only the program blocks that have been changed. 

3. Download only the Text or DB segments that have been changed. 

DOWNLOAD 

The download options can be called from the menu “TOOLS => 

OPTIONS” or from the “OPTIONS” button in the “Download Program” 

window. (the window above) 

DOWNLOAD 

OPTIONS 


3. PCD Resources 


3.1 HARDWARE RESOURCES 1 

3.2 INTERNAL (SOFTWARE) RESOURCES 4 

3. 3 SYMBOL EDITOR 13 

3.4 WORKING WITH SYMBOLS: 17 


It’s now time to give you a more global view over the elements you can make use 

of while writing your application. 

The first part is a summary over all the elements we know in SAIA PCD such as 

input/outputs or flags, their usage and their address range. 

The second part shows you how to use these elements inside the symbol editor.

Workshop PG5 

PCD Resources 


Workshop PG5 

Resources 

3.1 Hardware resources 

Each program is made up of functions, which allow the user to read, write, and 

manipulate different kinds of resources. The resources which allow us to interact 

with our environment, are called hardware resources. 

3.1.1 Digital 

inputs and 

outputs 

I / O 

1 bit (0/1) of information 

max. number of I/O 

PCD1 32 (*64) 

PCD2 64/96/128 (*265) 

PCD4 512 

PCD6 5120 

* Only if the PCD is equipped with the input modules E160 or output modules 

A460 

Inputs and outputs represent signals which are going to, or coming from the 

PCD. Inputs show the state of end-switches, pushbuttons, proximity detectors, 

sensors, ect. With outputs you can activate valves, lamps, turn on A/C motors, 

ect. 

You can read and write outputs. Inputs can only be read. 

Inputs and outputs are added to the PCD by placing I/0 cards into one of the 

designated slots on the PCD. The start address of a slot is defined either by it's 

position (PCD1/2 and 4 ) or by switches (PCD 6 ). 

The following example turns the output O 64 on if the inputs number I1 and I2 

are both high. 

Another way to show such functions is by using boolean equations: O 64 = 

I 1 * I 2 

Instruction list program: 

COB 0 

0 

STH I 1 

ANH I 2 

OUT O 64 

ECOB 

FUPLA program: 

(FBox: Binary, AND 2 to 10 inputs) 


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Resources 

3.1.2 Time 

Most of the PCD's have a built in RTC (real time clock ). ( PCD1.M120/130 

and all the PCD2/4/6). You can load the date and time into a register with a 

special instruction. 

The example shows you how to read the time in your program. 


COB 0 

0 

RTIME R 1 

ECOB 


(FBox: Time Related, Time ) 

This program reads the time from the clock and copies the value into register 

R1. Look what the value represents: 

R 1 = 093510 

09 o'clock 35 minutes and 10 seconds 

R 2 = 073990210 

week 07, day no. 3 ( Wednesday ), the 

10th of Feb 99 


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3.1.3 Interrupt 

inputs 

Some of our PCD’s have two inputs called INB1 and INB2. Each time you 

have a rising edge on one of these inputs, the normal program cycle will be 

interrupted and the PCD will execute a special program block called XOB20 or 

XOB25 ( XOB20 for INB1 and XOB25 for INB2 ). These interrupt inputs are 

on the following PDC's: PCD1.M120/130, PCD2.M120 and PCD6.M3. 

These inputs are capable of a frequency up to 1000 times per second. 



COB 0 ; Main program 

0 

ECOB 

XOB 20 ; interrupt INB1 

INC R 2 ; increment the register 

; R 2 

EXOB 

( FBox: Integer, Addition ) 

Normal input cards have special filters on their inputs. These filters protect the 

pin from noise with frequencies higher than 50Hz. Therefore you might have a 

situation where you can't react on a signal because it is either to short, or 

repeated to fast. In this situation, you can use these inputs as an interesting 

alternative to expensive special counter cards like the PCD2.H1XX or 

PCD4.H1XX. ( these cards count at speeds between 10 and 160 kHz ) 


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Resources 

3.2 Internal (software) resources 

3.2.1 Flags 

How to use 

Flags in your 

program: 

1 bit (0/1) of information 

F NV ( non volatile ) 

0 8191 

A flag memorizes one bit of information. There is 8192 flags. (0 is a valid 

flag). By default, the flags are non volatile. This means that if you turn off the 

PCD, and the flag is a 1, when you turn the PCD back on, it will still be a 1. 

(Considering that your battery is good). All volatile flags would be reset to a 0, 

if the PCD was turned off). If you want a volatile flag or flags, they can be 

configured in the software settings. This is explained below. 

The following example writes a high (1) into the Flag number 11 as soon as 

inputs 1 or 3 is high. Boolean equation: F 11 = I 1 + I 3 


COB 0 

0 

STH I 1 

ORH I 3 

OUT F 11 

ECOB 


(FBox: Binary, OR 2 to10 inputs) 

Setup flags: 

By default the flags aren’t volatile. If you want them to be volatile, then you 

have to specify so in the software settings. (See example) 


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3.2.2 Registers 

32 bit value 

Integer : -2 147 483 648 to +2 147 483 647 

Floating decimal : -9.22337E+18 to +9.22337E+18 

R 

NV 

0 4095 

A register can contain floating decimal or integer values. Registers are extremely 

useful for arithmetic operations or operations with analogue values like 

measurements and regulation tasks. You can have up to 4096 Registers. They 

are non volatile. 

In FUPLA, the lines connected to a register have different colors depending on 

their content. If they contain a floating decimal value the lines are yellow, if 

they contain an integer value, they are green. You can't interact an integer 

value, with a floating decimal values. For example you can't add the two together. 

One of the values has to be converted into the other’s value, and then 

added. 

How to use 

Registers in 

your program: 

The following example adds the number 113 to the content of register 12 and 

puts the result into register 54: 

R 54 = R 12 + 113 


COB 0 

0 

ADD R 12 

113 

R 54 


(FBox: Integer, ADD) 

Setup 

Registers: 

Dynamic resources allocation is a powerful feature introduced to free you from 

having to specify a fixed address for every resource that you need. 

Dynamic resources are used by defining a symbol name for a resource without 

specifying an address. You won’t need to change these settings until you start 

to write large programs with a large number of registers. 

You must increase the dynamic space settings in case of assembling errors like 

"Auto allocation overflow for type: R". 


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Resources 

3.2.3 Constants 

32 bit value 

Integer: -2 147 483 648 to +2 147 483 647 

Floating decimal: -9.22337E+18 to +9.22337E+18 

Constants are fixed values that do not change during the program. They are 

written into a register. 

Example: fix coefficients like PI = 3.1415. 

The next example loads the register R 4 with a fixed value of ( 100 ). Then the 

register R 4 is divided by 0.25. Because the register R 4 contains an integer 

value and we want to divide it by a decimal value ( 0.25 ), you have to convert 

R4 into a decimal value. We copy R4 into R3500 (register we are sure is not 

being used), convert R3500 into a decimal value, and then divide R3500 by 

0.25. The result of the division is placed into R 5. R5 is then copied into R 6, 

and R6 is then converted into an integer value. 

How to use 

constants in 

your program: 



COB 0 ;Cyclic organization 

0 ; block 

LD R 4 ;load 100 into R 4 

100 

COPY R 4 ;convert the integer value 

R 3500 ;from integer to 

IFP R 3500 ;floating decimal 

0 

FDIV R 3500 ;divide the value by 0.25 

2.5e-1 

R 5 ; and place the result 

;into R5 

FBoxes: Integer: Move 

Converter: Int to float 

Floating decimal: Divide 

Converter: Float to Int 

COPY R 5 

R 6 

FPI R 6 

0 

ECOB 

;convert the result back to 

; integer 


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Resources 

3.2.4 Counters 

& Timers 

31 Bit value ( 0 … 2 147 483 648) 

T/C V NV 

0 31 1599 

Timers and counters can have a value between 0 and 2 147 483 648 (31Bit) and 

they share the same address range: 0 to 1599. Usually addresses 0 to 31 is 

dedicated to the timers, and addresses 32 to 1599 are dedicated to the counters. 

Of course, you can configure this to your own personal settings. The timers by 

default, have a time-base of 100ms. (This means that the system will decrease 

every timer by one, every 100ms): The time base can be changed in the 

“Software Settings”, along with configuring the timer/counter addresses. 

Timers are volatile, counters are not. 

Timers and Counters can only contain positive values. Their value can be 

changed by loading a new value with the LD instruction. 

Timer values decrease only. Counters can count up or down, using the instruction 

INC/DEC. (Inc Dec ). 

Timers and counters can also be used with binary instructions 

When a timer or counter contains a non-zero value its state is High (1), when 

its content is zero its state is Low (0). 

Setup 

Timer/Counters: 

The distribution of the address range between timers and counters can be altered 

in the " Software Settings ". This is also where you can change the timebase 

of 100ms 

The more timers you declare, the greater the load on the CPU. This is 

also true if you lower the timebase. Take this into consideration before 

you change the number of timers or lower the timebase. 

Example: 100 timers will take about 2% of the CPU’s capacity. 


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Timer Example: 

You have a high signal on Input 4. On the rising edge of this signal you want 

to send a high signal out, output 65. This signal will have a duration of 2,5 

seconds. 

Integer value: 

Load the timer: 

LD T 1 

25 

Value displayed by the 

output "t" of the 

XPluse FBox 

Binary value: 

Value displayed by the output Q 

Instruction list program: FUPLA program: 

Solution: 

COB 0 ;organization block 0 

0 ; time out time 

STH I 4 ;If input 4 

DYN F 12 ;sees a rising edge 

LD T 1 ; load the timer1 

25 ; with 2,5 seconds 

STH T 1 ;copy timer state 

OUT 0 65 ;to the output O65 

ECOB 

(FBox: Time related, Exlusive Pulse) 

Technical stuff: 

Time constants 

Timers in the SAIA PCD are decremented at a rate defined by the “Software 

settings” “Timer” “Timebase”(normally 100ms). The actual time defined by a 

constant which is loaded into a Timer changes if the “Timebase” is changed. 

This means that if the “Timebase” setting is changed, then all Timer load values 

must also be changed. To overcome this problem, the “time” data type can 

be used to declare Timer load values. If a time value is used, then the linker 

calculates the actual Timer load value according to the “Timebase” settings. 

Format: 

T#nnnS|MS 

Examples: DelayTime EQU T#100MS ;100 milliseconds 

OneDay EQU t#86400s ;86400 seconds 


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Counter Example: 

We will program a counter which counts up each time the input 5 receives a 

signal. Each time input 6 receives a signal, the counter will count down. (the 

counts will be activated on the rising edge of the input signal). The counter can 

be set to zero with a high on input 2. We will load the initial count with 3. 

This is just an example. If you are a little confused, don’t worry you will understand 

it better once we start actually writing some programs. 

Load the counter: 

LD C 35 

3 

Integer value: 

Increment the counter: 

INC C 35 

Read the counter content 

and display it on the output 

LD C 35 

0 

Binary value: 

Q equals high if the counter content 

is not zero. 

STH C 35 

Solution: 

Instruction list program: FUPLA program: 

COB 0 ;Cyclic organization block 

0 ; 

STH I 1 ;If input 1 equals 1 

LD C 35 ;then load the counter 35 

3 ; with 3 

STH I 2 ; If input 2 equals 1 

LD C 35 ; then load the counter 

0 ; with zero 

STH I 5 ;If there's a rising edge 

DYN F 13 ;on input 5 

INC C 35 ;then increment the counter 35 

STH I 6 ;If there's a rising edge 

DYN F 14 ;on input 6 

DEC C 35 ;then decrement the counter 

ECOB 

( FBox: 

Counters, UP-Down pre-set and 

clear) 


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Resources 

3.2.5 Texts & 

Data blocks 

TEXT/DB 

Main memory 

NV 

0 3999 

Extension memory NV 

4000 (PCD4/6) 7999 

(PCD2) 5999 

(PCD1) 4999 

Texts and DataBlocks (DB's ) are non volatile. Texts ( string of characters ) are 

used for: Messages on displays, texts you want to send to a pager, initial 

strings for modems and so on. 

DB's are used for data logging, tables and so on. 


Where are 

Text/DB’s saved? 

Register, flags, timers, and counters are handled by the system and stored in a 

small RAM apart from the main memory. 

DB's and texts on the other hand are stored in the main memory, together with 

the user program. If you want to use a FLASH Eprom or a normal EPROM for 

your main memory, remember that if you are in run mode, you can read from 

this memory but not write to it. Therefore you can't alter the content of your 

DB’s ( for example your Data login ). In most cases you won’t bother with 

this, but if you know that you are going to read and write from your DB's, then 

make sure to use DB's which are stored in the extension memory => address 

4000 and up. (This is the extension memory and it is always RAM, which 

means you can read and write to it). 

See how a Text or DB is declared in a Instruction list program: 

Example: 

Declaration of 

BD’s & Text 

TEXT 10 "Bonjour!" 

TEXT 11 [7]"Hello" 

DB 12 45,46,78,999,0 

DB 13 [10] 

DB 14 [4] 2,3 

;Text number 10 contains the string Bonjour! 

;Text number 11 is 7 characters long were from 

the last 5 are Hello and the first two are spaces. 

;DB number 12 with the 5 integer values: 

;45.46,78,999,0 

;DB number 13 is 10 values long and they are 

zero at start up. 

;DB 14 is four values long. The first two are 2 & 

3 the second ;two are 0 


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Resources 

Example: 

Data-logger in 

FUPLA 

See how you can easily log values from an analogue card into the DB 4010. 

Every time the signal "Store" comes up, the analogue value is read and then 

written into the DB with the number 4010. 


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3. 3 SYMBOL EDITOR 

Before we start programming we have to make a list of all the elements we are 

planning to use (number of inputs and outputs, number of timers and so on). 

All these elements have to be known by PG5. This is very helpful to find 

elements inside the program files, tell us we have committed a programming 

error, or help during the debugging process. Therefore we list all the elements 

we are going to use in a central tool called “Symbol Editor”. 

We use the expression Symbol rather than element because we want to emphasize 

that each element has a name (a symbol). Also, giving all your resources 

a name makes it easier to read the program. 

Elements of a 

resource: 

Name of the resource: 

(can be up to 80 

characters long) 

Type of the symbol: 

Here you specify what 

kind of resource you 

are using. For example 

Input or Register…. 

Comment: 

ADD a long comment 

to every resource. 

It makes the 

program easier to 

read. 

Filename where 

your symbols belong 

too. The symbols 

are not known 

to files other then 

this one. 

Address/Value: 

You have to tell the PG which input or 

output you want to assign to this Symbol. 

In the case of internal resources (everything 

but inputs and outputs) you don’t 

have to specify an address. The system 

will choose one for you. This is called 

auto allocation. 


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Resources 

Group your Symbols: 

You can group your symbols if you would like to. It makes the program easier 

to read. Just use the right mouse button to add a new group to your symbol 

editor and then drag ‘n’ drop the symbols you want into this folder: 

EXAMPLE: The Group named “Wastepump” contains several symbols: 

Within the program file the group name 

will be added in front of the symbol 

name. The group name and the symbol 

name are separated by a dot (see picture): 


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Resources 

Scope of symbols: 

Symbols are normally known to one file only (their scope is local). As soon as 

you open a program file in an editor, the symbol editor with the appropriate 

symbol list is opened too: 

Example: 

Opening the program file named “Pump Management.src”, automatically 

opens the “Pump Management” Symbol Editor. 

LOCAL, CPU Global 

& Symbols from a 

Network Editor: 

Local Symbols are only know to the one file they belong to. 


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Resources 

Global symbols: 

CPU 1 

GLOBAL SYMBOLS 

Global symbols are know to all the files in the CPU. 

Make locak symbols 

global: 

If you want to use the same symbols in several files, then you have to move the 

symbols from the local list to the “GLOBAL” list (just mark some symbols in 

the list use the “Make Global” function (right mouse click)). Once a symbol is 

listed as “GLOBAL”, you can access it from any file within your project. 

Sharing data between two different PCD’s is more complicated than sharing 

information between files. You need some kind of network connection between 

the two PCD’s. This network connection can be designed in our network editor 

(to date we support: Sbus, Profibus DP, Profibus FMS and LON Networks). 

The “Network Editor” lists all the symbols in the “Network” list, and you can 

use them in your program in order to move data from one PCD to the other. 


Workshop PG5 

Resources 

3.4 Working with symbols: 

Writing a Symbol 

list: 

Open the file you are going to work with. This will also open the Symbol 

Editor. Click on Group/Symbol, and then press the “INSERT” button. A new 

symbol field is added to the list instantly. Enter the symbol name, type, 

address/value, and a comment. Press Enter to confirm your entry, and then for 

the next symbol, simply press the insert button. Note: The editor automatically 

enters the previous symbol name and address but increments them by 1. 

(See the picture below). You can change the comment and accept the name, 

type, and address/value, or you can overwrite the entry with a new name, 

type, address/value, and comment. 

If you already have a list started, and would simply like to add a symbol, just 

click on the last symbol, press the “INSERT” button and this will open another 

symbol field. 


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Add several symbols 

to the Symbol 

editor: 

You can add a range of symbols to your list if you want. Just enter the symbol 

name with the first and the last element number as shown, (Drainpumps1..8 O 

32 ;Pumps in building F). 8 is the number of symbols, O is for output, and 32 

is the starting address of the range you are entering. Press the “Enter” button, 

and the symbol editor will complete the list. 

Another option is to enter a symbol 

and address in the symbol editor, 

open the options window, (click on 

Symbols, then Options) enter the 

symbol and select “ Create reference 

for symbol”. 

Click OK, and then highlight the 

symbol in the editor. Press the 

Insert button, the symbol is entered 

but incremented by one. This can be 

helpful if you have a string of inputs 

or outputs and you want or need to 

change the physical address location, 

in the software, you would just 

change the first one, and all the 

others would follow. 


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Resources 

Import the Symbols 

from the 

“EQUATE” statements: 

If you have old PG4/3 “Instruction List” files with “equ” statements, then simply 

mark the statements and import the elements by clicking on the right mouse 

button and choose the option: 

The symbols are then moved from the program file into the symbol list. 

Import the Symbols 

from an other 

application: 

Or you can import your symbols from another program (Electro CAD) and use 

these symbols inside your project. This makes your documentation consistent 

over the entire project, and your electrical drawings will have the same labels 

in electrical drawing as well as in the program code. Simply use the export 

function in your CAD to export the symbols into a text file and import them 

into the symbol editor again. 


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Resources 

Add a symbol 

while typing your 

program in Instruction 

list: 

You can simply write your program and each time you use a new symbol, add 

type address and comment to the program (The option in „Tools“ => „Options“ 

must be activated). Once you press “ENTER” the symbol will be moved into 

the list.Example: 

ENTER 

An other nice thing you can do in Instruction List is replacing an element with 

a fix address by the symbol from the table: 

SHIFT+SPACEBAR 


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Add a symbol 

while typing your 

program in 

FUPLA: 

The FUPLA Editor works exactly the same. You can enter new symbols to the 

Symbol List directly from the FUPLA input/output field. 

SYNTAX: 

 

Write the Symbolname, the 

type, a comment and press 

“ENTER” 

And evidently you can also replace fix addresses by the symbol name by using 

the “SHIFT + SPACEBAR” key shortcut. 


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Drag-n-drop symbols: 

Resources 

You can drag-n-drop symbols from the symbol editor into any editor. 

Auto complete 

symbols: 

If you use long symbol names your program will become easier to read. On the 

other hand it will be annoying if you have to re-enter the long symbol name 

each time you use it in the program. Therefore you can simply enter the first 

letters of a symbol, and then lookup all the symbols which match those letters, 

by using the keys “CTRL and SPACEBAR”: 

Example: 

ENTER 

CTRL + SPACE 

This works in Instruction list as well as in the FUPLA editor. 

Auto allocation: 

Until now weve always declared the elements like this: 

Symbol name Type Address 

Comment 

Example: Pumpspeed R 2000 ;Speed in l/min 

If you are entering any symbol type, other than an input or an output, you do 

not have to enter an address for them. If you don’t enter an address then the 

PG5 will give an address to your element at build time. We call this autoallocation. 

The PG5 will look up in the software settings the address range 

configured for that element, and assign one during the build process. 

Example: 

You declare a register in your program and you don’t give an address to it: 

The register will get a number between 3500 and 4095 during the build process 

because in the “Software” settings we declared the dynamic space between 

3500 and 4095 for registers. 


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Enter Texts: 

In order to add a text to your PCD you have first to declare a text. You can do 

so by entering x after the symbol name. Example: 

Double click on the symbol icon to open the text editor: 

Don’t forget to use “ “ otherwise your text won’t be valid. 

Enter DB’s: 

DBs have a special editor too. Read the help for more information 


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Search for a 

symbol: 

Often a symbol will be used several times inside the program file or even in 

several different files. After a successful build of your program you can “right 

mouse button click“ on any symbol and start the “Cross reference” function. 

The cross-reference will 

list you the 

(filename and line number) and how many times a certain symbol was used. 

Double-click on any of the listed locations and the program file will open and 

the cursor will be on the symbol. 

The place where the 

symbol was defined. 

(Normally 

the Symbol editor) 

Program filename and 

line where the symbol 

OILPUMP was used. 

Written means 

that the symbol 

on this line contains 

the result of 

an operation 

The cross-reference tool not only works in SEdit and Fupla but also in the different 

views which are available in the project manager. 

Example: Block-Structure view 


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Arrange your 

symbols: 

Rearrange in the 

“List View”: 

Symbols are listed in the order you enter them. This way, the symbols you enter 

at the same time will stay together even if you add new symbols some time 

later. 

You can rearrange your symbols by simply changing from “Group view” to 

“List view”. Simply click on one of the tabs in order to arrange them by: Name, 

Type, Address or Comment 

Display with filter: 

Once you change back to “Group View” the old order is re-established. 

If you have a lot of symbols in your list it’s sometimes convenient to display 

only certain types or only symbols with a certain name. 

The filter function selects the view. As soon as the filter is active your symbols 

will have a different icon. 

Example: Symbol editor shows all Elements 

Filter is active>Not all the symbols are displayed 


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Symbol names: 

Symbol names are names which can be assigned to elements in the PCD (inputs, 

outputs, flags, registers, COBs etc). Symbol names can be up to 80 characters 

long and are not case sensitive unless they contain foreign characters. 

MotorOn is the same as MOTORON, but GRÜN is not the same as grün. 

Symbols have to start with a letter ( a-z, A-Z) a number won't be accepted. 

Within the symbol you can mix numbers, letters and underlines "_" as you 

wish. You cannot have a space in a symbol name. 

Reserved Words cannot be used as symbol names. 

Reserved Words: 

The following words are reserved, and cannot be used as symbol names: 

♦ Assembler declarators, e.g. PUBL, EXTN, EQU, DEF, LEQU, LDEF, 

MACRO, ENDM, EXITM etc. 

♦ Medium control codes and data types (I, O, F, R, C, T, K, M, COB, FB, 

TEXT, X, SEMA, DB). 

♦ MOV instruction special codes (N, Q, B, W, L, D). 

♦ Condition codes (H, L, P, N, Z, E). 

♦ All instruction mnemonics. 

♦ Pre-defined symbols. 

♦ Internal symbols used for automatic resource allocation, which begin with 

underscores, e.g. 

______TEXT, _________F. 

Internal __CSTART__ symbol, used for $$ assignments. 


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Summary: 

In the PCD we have the following elements to work with : 

Element: 

Shortform: 

Amount: 

Specialities: 

Inputs I Depends on PCD. 

Max = 8191 

Outputs O Depends on PCD. 

Max = 8191 

Registers R 4095 

Share the same addresses 

Flags F 8191 You can set a range of 

volatile flags if you like 

to. 

Constants K 16383(32Bit) or 

8191 (13Bit(##) 

Timers T 0 to X 

Counters C X to 1599 

Texts X 0 to Y 

DataBlocs DB Y to 3999 

RAM Texts RAM X 3990 to Z 

RAM Data RAM DB Z to 4999 

Blocs 

Share the same addresses. 

First timers 

then Counters 

Share the same addresses. 

First texts then 

DB’s 

Share the same Address 

range. 

PCD 2 goes up to 5999 

PCD 4/6 go up to 7999 

Every element ( input / output / register / timer/ ect) in your project can have a 

name, these names are called SYMBOLS. There are: 

• Symbols from a Network editor 

These symbols are known to all the PCD’s in the Workspace. They are created 

in one of the network editors like “S-Net”. 

• GLOBAL Symbols 

These Symbols can be used in every file of the current project. Each project 

has it’s own project-shared symbols. 

• LOCAL Symbols 

These symbols can only be used inside the active program file. Each program 

file has it’s own local symbols. 

You can search for symbols. You can drag and drop symbols from one editor to 

the other. And you can import/export symbols. 


Workshop PG5 

Resources 


EXERCISE 


GENERAL QUESTIONS “RESOURCES” 1 


You have learned a lot about resources now. We will start using them right away 

in the next chapters. Therefor we will limit ourselves to three questions of more 

general nature.

Workshop PG5 



Workshop PG5 


General questions “Resources” 

Question1: 

What’s the difference between a counter and a timer once you load them with a 

value? 

Question2: 

What happens if you decrement a counter which contains the value 0 ? 

Question3: 

What went wrong when you build your program and you’ll get the error message: 

Fatal Error 368: Auto-allocation overflow for type: R 

Solution2: 

Timers are decreased by the system every X milliseconds. (Time can be set in 

the Softwaresettings). 

Counters are decreased/increased in the user program using the DEC / INC 

instruction. 

Solution: 

Nothing. Timer/Counters only contain positive values. Therefore the counter 

value will stay unchanged at 0. 

Solution: 

The dynamic range for registers in the “Software” settings is too small. 

There are too little 

addresses in the dynamic 

space. Put the 

first address to 3000. 

In such a situation the 

field called “Free” 

will be at 0. 

© Saia-Burgess Controls Ltd. Page 3E-1

Workshop PG5 



4. FUPLA programming 


4.0 CREATE A NEW PROJECT AND A NEW FUPLA FILE 1 

4.1 THE FUPLA EDITOR 2 

4.2 EDIT YOUR FUPLA PROGRAM: 3 

4.3 EDIT PAGES 5 

4.4 BASIC INSTRUCTIONS: 7 

4.5 WRITE YOUR FIRST FUPLA PROGRAM 11 

4.6 BUILD AND DEBUG YOUR PROGRAM 14 

4.7 DEBUG YOUR PROGRAM ONLINE 15 

4.8 SOME RULES: 19 


The most straight forward way to introduce someone to the world of PLC programming is to start 

with Fupla programming. Fupla (FUnction PLAn) is a graphical environment which enables you 

to draw your programs rather then write them. 

Every instruction is represented by an icon which we call an FBox (Function BOX). The programming 

itself is simply done by drawing the connection between these different FBoxes. We 

do have several hundred of these boxes available. These boxes are organized by libraries. The 

basic library is installed standard with the PG5. Other libraries can be added later: 

The other libraries you can buy are: 

HVAC library: A set of over 200 FBoxes for heating applications. 

MODEM library: Enables you to use one or several modems with your PLC. This enables 

you to build a network of PLC’s, exchanging data over the telephone line. You can 

send SMS or pager messages, and you can even use a remote control with your PLC 

using the dial tone of your telephone. 

FBoxes for special I/O modules. A lot of our I/O cards such as motor control cards 

(Hxx) are delivered with a set of Fboxes. With the help of these FBoxes you can set up 

your hardware within minutes. 



Workshop PG5 

FUPLA programming 

4.0 Create a new project and a new FUPLA file 

Choose to open a 

new project: 

Open a new program 

file: 

To open a new program file in this project, click on the " New File" button or use 

the right mouse button. 

OR 


Workshop PG5 


Open the editor: 

Double-click the new file and the “FUPLA” editor will open. 

4.1 The FUPLA editor 

Note: FUPLA files have the extension “filename.FUP” 

The editor: 

Let’s have a quick look at the editor. The program is executed from the top to the 

end and from left to right. The input symbols are on the left and the results are written 

to the right. Each FUPLA file can have several program blocks and up to 200 

pages total. 

Program page: 

You can draw your programs 

inside this field. The program is 

organized by pages. The 

FUPLA file can have up to 200 

pages. 

Input fields: 

All the input values 

are listed on the left. 

Output fields: 

All the results are 

transferred to the 

symbols on the right. 

The block type (COB, PB, 

XOB, ST or TR) and number 

are shown on the top. 

The page name and number 

are shown also. 

Symbol Editor : 

The input and output 

fields interact with the 

symbol editor. 


Workshop PG5 


4.2 Edit your Fupla program: 

Toolbar: 

File handling and 

FBox editing tools 

Drawing tools 

Build your program 

and change to project 

manager 

Block, Page and Symbol 

organisation windows 

Go Online, 

Run, Stop, 

Step-by- 

Step 

Go from page to page. 

Insert page. Grid. Zoom 

Page 

Edit a contact: 

1. Click on the "LADDER" icon 

2. Choose your function. 

3. Place your contact on the drawing area and 

click the left mouse button in order to release it. 

4. For more information double-click on the 

specific function. 

1. 

2. 

4. 


Workshop PG5 


Edit a FUPLA 

function: 

1. Start the Fbox mode by clicking on the "FBox" icon. 

2. Choose a family and then a function within 

the family. 

3. Place the Fbox on the drawing area by 

clicking the left mouse button. 

2. Family 

1. 

4. For further information right-click the Fbox 

or the FBox Name on the selection window 

Function 

4. 

Connect the 

functions 

(first solution) 

Connect the 

functions 

(second solution) 

Erase a line or 

a function. 

1. Click on the “Select” icon. 

2. Move your pointer on the Fbox and push the left 

mouse button. ( keep the button pressed ) 

3. Now you may move the Fbox to the desired location. 

4. Once two connection points touch each other they 

are connected. 

1. Click on the “Lines” icon. 

2. Place the pointer on the departure point of your 

connection and click the left mouse button. 

3. Click the left mouse button each time you want to 

change direction. 

4. Once you arrive to the other connection point just 

press the left mouse button a last time and the two 

points are connected. 

5. If you want to stop editing the line then just press the right 

mouse button. 

Click on the "Eraser" icon, and click on the part you 

would like to delete. 

3. 

2. 3. 

1. 

2. 

4. 

1. 

4. 


Workshop PG5 


4.3 Edit Pages 

The FUPLA editor organises it’s programs in pages. Each file can have up to 

200 pages. 

Adding a page to 

your program: 

When you need to add a page to your program click on Page of the tool bar or 

place the curser in the middle of the page (in a blank area) and click the right 

mouse button. The pull down menu’s are displayed below. There is two options 

here, you can insert the page before the current page, or you can insert a 

page after the current page. Simply click on the one you want. 

You can also use the PageNavigation Window. 

Document 

your pages: 

Document the pages as you 

complete them. It only takes a moment, and can really be useful when you want to 

move between different areas of the program file. You will activate the pull down 

menu’s as you did to add a page, then highlight and click on Page Properties. 

Give the page a name and a comment that lets you know what part of the program is 

on the page. Under description you can go into a little more detail about the operation 

of the page. 


Workshop PG5 


Navigate 

from page to 

page: 

There is a couple of ways to move from page to page in a program file. 

The last three icons on the far right of the tool bar are for this process. 

The 2 arrows will scroll you through the pages one at a time. The arrow pointing to 

the left goes to a previous page, and the arrow pointing to the right goes to the next 

page. When an arrow is white, this is an indication that there is another page in that 

direction. If the arrow is gray, than that means there are no pages in that direction. 

If you have many pages, then it’s easier to use the Page Navigation Window. 

If you have documented your pages, they will be listed in the Page Index. Our display 

only shows one page, but if you have several pages, simply highlight the one 

you want to bring up and either double click on it, or click on Goto. 


Workshop PG5 


4.4 Basic Instructions: 

It would take too long to explain each and every instruction inside the Standard Library 

(there are over 200 FBoxes). With time you’ll get to know more and more of 

these FBoxes. Read the Technical Information 26/367 E1 for a complete overview. 

Still there are two or three Families you have to know right from the start. 

The Binary functions: 

Word functions: 

Analogue values: 

You will learn, that there are two different ways to 

draw your Programs. (Using FBoxes from the binary 

family “FUPLA” or using Contacts “Ladder”) 

You’ll learn to know the most important families for 

basic register handling and basic arithmetic. 

Read and write analogue values from and to your 

Wxxx cards. 

FBoxes are grouped in different libraries and each library has different families with 

FBoxes. 

FBOX Selection: 

The family selection lists five to twenty 

FBoxes in logical order. 

PG5 is delivered with a standard library containing 

over 200 FBoxes. You can add other 

libraries such as Modem or HVAC 

Binary Instructions: 

Today every PLC Company has some kind of graphical programming tools. There 

are basically two different ways to write your programs in graphical environment: 

FUPLA or LADDER 

(FUPLA vs. 

LADDER): 

There are no differences between FUPLA and LADDER (also known as Contact 

and Logic). FUPLA and LADDER are just two different ways to represent the 

same functionality. Whereas LADDER comes from the time we use to work with 

relays and hard wire our functions. FUPLA shows the same thing in a logical approach. 

In Anglo-Saxon countries you'll usually find that LADDER is more common. 

In the continental countries FUPLA is more common. PG5 has implemented 

the two into the same editor. 


Workshop PG5 


FUPLA 

LADDE R 

In FUPLA you always have all the inputs 

of an operation on the left side of the 

drawing and the outputs on the right side 

of the drawing. Boxes then represent the 

function inside the drawing area. These 

boxes are called FBoxes (FUNCTION 

BOX) 

In LADDER you'll find a power rail on 

the left side and a ground rail on the right 

side. The inputs and outputs are represented 

by contacts and coils, which are 

situated inside the drawing. The logical 

functions then are realized by the way you 

connect the contacts. 

Although the power rails are not shown in 

the editor, the LADDER works like 

every other LADDER editor. As soon as 

you connect a contact to the left, the 

input box is considered as a power rail. 

Turn on the output number 32 (O 32) as soon as the inputs number 1 (I 1) and 0 (I 0) 

are high. 

Input 

fields 

Program 

area 

Output 

fields 

The input field is 

considered as a 

power rail as 

soon as a contact 

is connected to it. 

If you wish 

you can connect 

the coil to 

the right 

These two examples have the same functionality. As soon as it comes to data types 

other than binary, you won’t have this distinction anymore. (This is also true for RS 

Logic or S7). 

Note: Lines and connections which represent binary values are always drawn red. 


Workshop PG5 


Besides binary, the most important families are: 

INTEGER: 

All the FBoxes you’ll ever need for arithmetic with integer values. Also functions 

such as compare values or move register content from one register to the next. 

Note: Lines which contain an integer value are green. 

FLOATING 

DECIMAL: 

FBoxes for arithmetic operations such as Sinus Log etc. Note: Lines which contain 

decimal values are yellow. 

CONVERTER: 

COUNTERS: 

These FBoxes not only convert Integer values to decimal values and vice versa, but 

also convert the content of your register into formats such as BCD, IEEE, decimal 

and so on. 

Groups all the basic counters as specified in the norm IEC 1131. 

TIME RELATED: 

Groups all the basic timers as specified in the norm IEC 1131 plus some nice additional 

timers time related FBoxes like “Chronometer”; “Cycle Time measurement” 

and functions for the build in real time clock. 


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Workshop PG5 


4.5 Write your first FUPLA program 

Open the file: 

At the beginning of this chapter (4), we made a new file called: "Blink with output". 

We will write our first code in this file. 

GOAL: 

We will turn on a pump (Oilpump signal O 32), if the oil level becomes too high 

(OilHigh signal Input I 0) and if the machine is in conditional Run (Cond_Run signal 

Input I 2) or normal run (NormalRun signal Input I 1). The pump must not run if 

there is a emergency stop (Emergency signal Input I 7). 

As long as the pump is running a signal lamp will blink. The lamp is connected to the 

output 33 (PumpRun_Signal O 33) 

Double-click on the file called: "Blink with output.fup" and the FUPLA editor will 

open. 

Prepare the symbols: 

Before we start to write our program, we have to make a list of the symbols we are 

planning to use. Enter the following symbols into the Symbol Editor: (Refer to page 

3-13 if you need help on entering symbols) 

Now the programming 

begins: 

The pump runs if the machine is in conditional run OR normal run: 

Select the “OR” FBox from the family “Binary” and draw the first combination: 


Workshop PG5 


Now we make the connections to turn on the pump if one of the above signals is 

active, AND if the oil level is too high, AND if there is NO emergency signal. 

Select the “AND” FBox from the “Binary” family and place the FBox behind the OR 

function and click ONCE with the left mouse button: 

The “AND” FBox is now placed behind the OR function. Move the mouse pointer 

downward and the FBox stretches, giving you the choice of two to ten inputs. If 

you click a second time the FBox is drawn to the board. Draw a FBox with three 

inputs: 

Add the symbols to the drawing and connect the missing links: 

Drag-n-Drop these 

from your symbol 

list. 


Workshop PG5 


Invert binary signals: 

In the event of an emergency stop, the motor must not run. To achieve this, 

we have to invert the emergency stop signal. 

Activate the “Invert” tool and click on the line pin of the AND FBox: 

Calling the help on 

FBoxes: 

The only thing missing, is the blinking lamp. 

Add a blinker from the “Blinker” family (For more information on the different blinkers, 

right click on the FBox Name in the FBox Selection Window or place the 

FBox on the drawing board and double click on the FBox: 

Take the FBox “Blink dely T” and add it to the drawing. 

The "Time Value" is always given in 100 

ms. 

Example: If you enter a 10 in the column 

“Address/Value", of your symbol list that 

means that the Blinker will blink in 1.0 second 

intervals. Add this to your symbol 

editor list. 

An “En” input on a FBox 

always stands for Enable. 

Example: 

The output Q will only blink 

if the signal connected to En, 

stays high. 


Workshop PG5 


4.6 BUILD and debug your program 

BUILD: 

Once you have finished the drawing, you can compile the entire program by clicking 

on the BUILD button. 

You can use the build button from the 

program editor or from the 

Project Manager. It is on both tool 

bars. 

Message Window: 

The message window will show you all the information you'll need: 

If you have entered the 

program correctly then the 

message window should 

now tell you: 

Build successful. Total 

errors: 0 Total warnings: 0 

If there are any errors in the drawing, then it will be displayed in red letters. Click 

on the red letters, and it will take you to the error in your program. 


Workshop PG5 


4.7 Debug your program online 

Believe it or not but programs tend to have errors. ( this is also true for our competitors 

). Therefore we have prepared a number of online functions which come in 

handy when you debug your program. Following is an explanation of these functions. 

Start/Stop your 

PCD: 

1. Download your program 

2. Go online. 

3. Start and stop your PCD. 

As you start and stop the PCD, 

observe the run led on the front of 

the PCD. 


online: 

The logical state of binary values is displayed by thick and thin lines. Highlighted 

(thick) lines are high and logic zero is displayed by a thin line. 

You cannot edit your program while you are online. 


Workshop PG5 


Display values 

while your online: 

If you have programs with integer or decimal values, you can monitor the content of 

the line by inserting a probe. 

Just click on a line and the actual value will be displayed. 

By double clicking on a probe you can activate the "Probe Display Format" window, 

where you can choose the format you would like to have displayed. 

Step by step 

Tests: 

Once your online with a program, you can also set break points in your program. 

1. Go online 

2. Choose the menu "MODE" and switch from "Set Probe " to " Set Breakpoints" 

3. Your pointer changes and you can set breakpoints where you wish. The program 

will stop at the break points and will wait for further instructions. 

4. Each time you press "F11" or the menu "Online" "step by step", the PCD executes 

one single instruction. 


Workshop PG5 


F11 

F11 

5. F12 will start the PCD and will execute nonstop all the instructions until the 

next break point. 

6. Clicking on the breakpoint for a second time makes the breakpoint disappear. 


Workshop PG5 



Workshop PG5 


4.8 Some rules: 

1. Each type has it's own color. Binary => Red 

Integer => Green 

Floating decimal => Yellow 

2. You cannot connect different data types together but, you can convert 

values from one type to the other.( see FBox Family " Converter" ) 

3. You cannot draw loops. 

4. Your not allowed to define outputs without connecting them to a function. 

5. You cannot connect an input field directly to an output field. To do this, 

you would use a "MOVE" FBox. 

There are "MOVE" FBoxes for binary, integer and decimal values. 

( See corresponding family ) 


Workshop PG5 


6. Dynamic inputs are marked with a triangle on the inputs: 

Dynamic inputs are inputs which only react on a rising edge. If you want 

an input to react on the rising edge and the specific input isn't dynamic, 

then you can add a "Dynamize" FBox in front of the input 

( Family Binary ) 

In LADDER a dynamic contact looks like this: 

( rising edge ) 

7. The program is read from the top left corner of the 1 st page, to the bottom right 

corner of the last page. You can never jump inside a FUPLA program. If you wish 

to execute program parts conditionally then you have to structure your program in 

blocks. (Read the chapter Program structures) 

If you want to know which FBox is executed in which order then click the menu 

"Page" "FBox Priorities” 

8. A couple of notes on the symbols in the left and right columns of the program page 

(input and output fields). As space is limited, the details of the symbol cannot be 

displayed all the time. You can view the details by placing the cursor on the symbol 

field for one second. 

Also, if you change the symbol name in the drawing (input or output field) then the 

symbol in the symbol editor won’t be affected. If you change the symbol name, 

type, address, or comment in the symbol editor, then this will change the name, 

type, address, or comment of all the input/output fields which hold this symbol 

name. 


EXERCISE 


FUPLA PROGRAMING EXAMPLES: 1 

TIMERS AND COMPARE FUNCTIONS 13 

COUNTERS AND BLINKER : 17 


The time has come to start with the real programming. In each example we'll try to 

reach a new goal. Refer to the manual if you run into problems.

Workshop PG5 Exercise Chapter 4 



Fupla Programing Examples: 

In chapter 4, you learned how to open a Fupla file, and enter the program content. 

The following is some examples to help you get comfortable with drawing a program, 

and to introduce you to a few of the F-boxes and their function. 

AND Gates: 

1. Open the project “Chapter 4” ( this is the project you opened at the begining of 

chapter 4). 

2. Create a new file and name it AND_GATES. Then open it. 

3. Enter the following symbols into the Symbol Editor list: 

4. Click on the F-box selector. 

Available F- 

box families. 

Click here to display 

all the available 

functions of active 

the family. 



Highlight and 

click on Binary 

Hightlight and 

click on “And” 

You should now have the “And” symbol on the program page. You can move it to 

any location on the page by moving your mouse. When you have it where you want 

it, click the left mouse button one time, and this will paste the symbol to this location. 

Move the mouse vertically to choose the number of inputs you want. Minimum 

is 2 and maximum is 10. Once you have the inputs you want, click on the left mouse 

button, and the symbol is set. You can now highlight the symbol, and move it horizontally 

but only horizontally. (You have to click and hold the button on) 

Place one AND gate with 2 inputs and one AND gate with 4 inputs on the program 

page. 



In the symbol list, highlight each symbol and drag and drop them in the columns on 

the sides of the program page. Left side or column is for inputs and the right side is 

for outputs. 

You should now have a display that matches the one above. 

Now we can draw the connections. Click on the Line Mode Icon 

This will activate a black dot on the page. You can move this dot to the starting 

point of your connection, click the left mouse button one time, this will paste the 

beginning point. Move the mouse to the next point where you want to make a connection 

or change direction. Click left mouse button. (note: you can only move horizontally 

or vertically). Follow this format until you get to the final destination of the 

connection. Double click the left mouse button and the connection is complete. 

Follow this format until all the connections are complete. Your display should be 

similar to the one below. 



Next: 

1. Build and donwload the program. (If you need a little help with 

building or downloading, refer back to chapter 2). 

2. Go on line. 

3. Activate the run mode. (refer to chapter 2 for help) 

Observing the led’s on your PCD, activate input 0 and input 1. Led 0 and led one 

should be on. Also, Output 0 (led 32) should be on. 

Turn input 0 and input 1 off, and activate input 2 and input 3. Led 2 and led 3 

should be on, but no output leds should be on. 

Leave input 2 and input 3 on, and activate input 0 and input 1. Now input led 0, 

led 1, led 2, and led 3, should be on, along with output 0 and output 1. (led 32 

and led 33) 

Binary Inverter: 

Using the same program, we will introduce the binary inverter. The binary inverter, 

converts the logic 1 or high, to a logic 0 or low, and vice-versa. 

1. Deactive the run mode, and go offline. 

2. The binary inverter is located on the toolbar of the Fupla editor. The icon is 

. 

3. Click on the icon and this symbol will be displayed. 

4. Position the tip of the arrow where you would like to insert the inverter. 

Click the left mouse button one time and this will paste the invert symbol 

to the pin. Position the pointer on the symbol and click the left button to 

remove the symbol. 

Place an inverter symbol to the AND gate of your program to match the display 

above. Build and download the program, go online, and activate the run mode. In 

the previous exercise, All the inputs had to be high to activate output 1. (Led 33). 

Now, input 1, input 2, and input 3 have to be high, and input 0 has to be low, to 

activate output 1. (Led 33) 

Spend a little time inserting the inverter symbol, creating different scenarios. 

Confirm the operation of the different scenarios by testing your programs. You will 

find that this symbol is a very useful and commonly used symbol. 

Below are a few examples. 



Comparaters: 

Comparaters are used to compare two values. These values can be two integer 

values, or two decimal values. The output is a binary value of a 1 or a 0. 

There are several options for comparaters: 

1. two values are equal 

2. one value is greater than another. 

3. one value is greater than or equal to another. 

4. one value is smaller than another. 

5. one value is smaller or equal to another. 

These are your choices. 

Create a new file, and name it Comparaters. Open the file, and click on the F- 

box selector icon. (If you don’t remember this icon, refer back to the AND gates 

segment). Now activate the pull down menu for the F-box family selections. 

(again, refer to the AND gates segment for help). 

Highlight and click on integers. Next, activate the pull down menu for the funtions. 

Highlight and click on “is equal to”. Your display should look like this: 

Position and paste four comparaters on the program page. Do this in a vertical 

format. 

Now the symbols are in place, so we need to create the symbol list. 

Enter into the list the following: 

Drag and drop the MainControl symbol and all the input symbols into the left column 

of your program page. Drag and drop the output symbols into the right column 

of your program page. 



Draw your connections, to match the drawing below. 

Position these in the center of 

the page. We will be adding 

to this program 

Build and download the program. (Make sure that the AND_GATE file is unlinked). 

Go online and observe the ouput Leds. Led 32 and 35 should be on. 

Led 33 and 34 should be off. The comparaters are comparing their value to 0. If 

their value is equal to zero, then their output is high. 

Counters: 

Using this same program, we will add a counter to it. 

1. Make sure you are offline. 

2. Click on the Eraser icon 

Place this on what you want 

to delete and click the left 

mouse button. 

3. Erase all the lines that connect to the left column. (there should be no lines 

left of the comparaters). 

4. Open the pull down menu for Families, and select “Counters”. 

5. Open the pull down menu for function and select “Up wrap around with 

clear” 

6. Paste the counter where all the lines were, left of the comparaters. 

7. Add to the Symbol list, Input4 and Input5. Both will be inputs, with there 

address being the same as their input number. Comment for Input4 is “resets 

counter to zero” and for Input5, “toggle to activate count”. Change the 

Address/Value of Input3 from 0 to 3. 



8. Remove MainControl from the left column. This can be done by highlighting 

the symbol in the left column and pressing delete. It will still be listed in the 

symbol list. If you highlight it in the symbol list and delete, it will delete it 

completely. (Note: symbols in the symbol list, do not have to be used in the 

program). 

9. Click on the line mode icon and make the connections as follows: 

A. Connect input4 to Clr of the counter. 

B. Connect input5 to Up of the counter. 

C. Connect input3 to Max of the counter. 

D. Connect Cnt of the counter to the top pin of all 4 comparaters. 

E. Connect Input0 to the other pin of the first comparater, Input1 to the 

open pin of the second comparater ect. Yes, Input3 goes to both Max 

of the counter and to the comparater. 

Your program should look similar to the drawing below. 

Build and download the program. Go online and activate the run mode. 

Toggle input 5 on and off, and observe the Leds, 32, 33, 34, and 35. 

Every time you toggle input 5 on and off, the counter increments and the comparater 

that matches the counter number, activates it’s output. The counter is set up to 

count 0, 1, 2, 3, 0, 1, 2, 3, 0, 1, 2, 3, ect, 

XOR Gates: 

The next function we are going to cover, is the exclusive OR gate. This is in the 

binary family. Open the F-box selector, and activate the exclusive OR symbol. 



The function of the exclusive OR gate is that when one of the inputs are high, 

then the output is high. If more than one of the inputs is high, then the output is 

low. You can have 2 to 10 inputs, but only one can be high, to activate the output. 

Erase the lines that are connected to the right column. Paste 2 exclusive OR 

gates between the comparaters and the right column. Each gate should have 2 

inputs. Delete Output1 and Output3 from the right column. Connect the outputs 

from the 2 top comparaters to the inputs of the top exclusive OR gate. The outputs 

from the bottom 2 comparaters should then be connected to the bottom exclusive 

OR gate. The output of the top exclusive OR gate should be connected 

to Output0 and the bottom one should be connected to Output2. Something 

similar to the drawing below. 

Build and downloadBuidBuild 

Build and download the program. Go online and activate the run mode. Toggle 

input 5 on and off. When the counter is at 0 or 1, Led 32 will be on. When the 

counter is at 2 or 3, the Led 34 will be on. 

FLIP-FLOPS: 

The last F-box family we are going to cover, is the Flip-Flop. 

Open the file AND_GATES, make sure to link this file, and unlink the Comparaters 

file. 

Open the F-box selector, and choose the Flip-Flop family and the function of the 

Type RS dynamized. 



The function of the RS dynamized Flip-Flop is that of a latch. When there is a 

signal going from low to high on the R input, the latch is said to be reset, and the 

output Q will be low, and stay in this state, until a signal going from low to high 

on the S input occurs, and then the latch is said to be set, and the output Q will 

be high. If both receive a low to high signal at the same time, the output will be 

low. 

Erase all the connections to both the right and left column. You will have just two 

AND gates on the page. Change the AND gate that has 4 inputs from 4 to 2. 

(you will have to erase it and put a new one on the page) Remove any binary 

inverter symbols from the inputs of the AND gates. Paste the RS Flip-Flop between 

the AND gates and the right column. Connect Input0 and Input1 to the 

top AND gate and Input2 and Input3 to the bottom AND gate. Connect the 

output of the top AND gate to the R input of the Flip-Flop and the output of the 

bottom AND gate to the S input of the Flip-Flop. Connect the Q output of the 

Flip-Flop to the Output0 of the right column. Delete Output1 from the right column. 

Your program should look similar to the drawing below. 

Build and download the program. Go online and activate the run mode. 

When Input0 and Input1 go high, this will reset the flip-flop and Q will be low. 

Turn on Input2 and Input3, and Q will be high. Led 32 should be on. Turn Input0 

and Input1 on again, and Q will go low. Set and reset the Flip-Flop several times 

to see the operation. Remember this is a dynamized Flip-Flop, so it operates on 

the rising edge of the signals. There are a few different versions of this Flip-Flop 

available. 

FINAL 

PROJECT: 

The purpose of this project is to give you some practice writing/drawing a program. 

Create a new file and give it a title. Open the file and fill in the symbol editor list to 

match the list below. 



Here is a list of the F-boxes we are going to be using: 

Integer………… “is equal to” comparater 

Binary………… “AND” gate 

Binary………… “XOR” gate 

Flip-Flop……… “Type RS dynamized” 

Blinker………… “Blink Delay T” 

Counter………… “Up Down with preset and clear” 

This program will be a counter that counts 0 – 50 and when it reaches 50, it will 

reset back to 0 and continue to count, each time reaching 50 and resetting. You 

can also select to have it count from 50 – 0, and resetting to 50 each time it 

reaches 0. 

A drawing of the program is on the next page. Draw the program, build and 

download it. Go online and activate the run mode. Activate count up or count 

down, depending on which direction you wish to count. Activate Count_Run. 

The counter is now running. To see the counter working, click on Mode in the 

tool bar, and activate “Set Probes” Then take the curser and place it where you 

want a probe, and then click the left mouse button. A probe will display the value 

of the selected location. 







Timers and Compare functions 

Working with registers, constants, timers and flags 

This time the types are not limited to binary values and you can use all the resources 

we saw like Registers, flags and so on. 

Open a new FUPLA file in the Project Manager and call it TIMER. 

This is what we are going to do: 

Example: 

Daily-Timer 

Create a small program where you can turn on and off a machine every day at the 

same time. 

Use the following symbols: 

HMS = hours, minutes and seconds (current time) 

ONTime =Time where you want to turn the machine on 

OFFTime=Time where you want to turn the machine off 



In the Family “Time related” you will find a Fbox called “TIME” this Fbox reads the 

time from the PCD. The output shows the time as an integer value off six digits. 

HHMMSS. The color off the output is different to the color off the lines we had in 

our first example. That is because each and every type has its own color like: 

• RED lines are binary value 

• GREEN lines are integer and so on. 

You can’t connect two lines that have different types and you can’t connect two 

outputs either. 

Goal: 

You learn the difference between different types ( binary, integer,…. ) 

You learn how to read the time from the internal clock 

You learn to how to compare values. 

You learn to work with symbols rather then with fix addresses. 

You learn how to document your program. 

You learn to set the internal clock. 

Quite a lot for one example I know. 



Solution: 

1. Open a new FUPLA file ( You don’t need to open a new project ) called 

Time.fup 

2. Add a comment to your file!!! 

3. If there are any other files in your project, then mark them as "notlinked". This way 

the file will not be taken into considerations and will not be downloaded to the PCD. 

4. Open the FUPLA editor and place the FBox "Time related: Time" and copy the 

time to a Register called HMS. You have now the time as an integer value in a register 

called HMS 

5. Now you have to compare the content of this register with the time where you 

want to turn the heating on ONTIME and the time you want to turn the heating off 

again OFFTime. ONTime and OFFTime are for the moment just constants. Turn the 

heating on at 1 o clock PM => (ONTime=10000) and turn it of at noon (OF- 

FTime=120000) 

There are several ways to solve the problem. I used the FBox ( "Integer: Is greater 

or equal to" and Binary: Xor 2-10 inputs ) 

I first compare the actual time with the ONTime. If the actual time is bigger than then 

the ontime, then you know that its later than OnTime and can basically start the 

heating. Except if its already too late, and the OFF time has come. This is then tested 

in the next FBox (TurnOFF ) ON_OFF Turns the heatin only on, if TurnON command 

is there but the TurnOff command has not arrived yet. 

DAY_NIGHT then inverses the signal in the case were you turn on the heating in the 

evening but you turn off the heating in the morning. 

6. You can add nice names on every FBox if you like to. Just move the pointer on 

the FBox press the right mouse button and click on "FBox Properties" and add a 

name. 

OFF 



7. Build and download your program. 

8. In order to test your program, you have to go online and set the clock to different 

times. 

8.1 Go online. 

8.2 start the Online configurator from the project manager 

Click on the button called “Clock” and the second window comes up. 

On the left you'll see the time of your PC on the right the time of the PCD. You can 

edit PCD time 

directly in the 

fields. Once 

you press ok, 

the time is 

downloaded 

into your PCD. 

Try it and test 

your 

program. 



Counters and blinker : 

Example: 

Parking lot 

Output 17 

(red light) is 

lit as soon as 

the parking 

lot is full 

(Lot_full) 

Input 0 

( NewCar ) 

Input 1 

( Car_leaving ) 

You have a parking lot with 8 parking slots. 

You have to sensors : One at the entrance gate which gives a pulse each time a car 

enters. Input 0 (NewCar ) a second one tells you when a car is leaving (input 1 

Car_leaving ). 

A signal ( output 17 Lot_full ) starts blinking as soon as 8 cars are in the parking lot. 

Cars can enter the lot even if the lot is already full !! 

Set the counter to 0 when you start up. 

Goal: 

You learn to know the different types of counters we have. 

You learn to document the program. 

You'll use a blinker. 

You learn how to create a reset signal at start up. 





Solution: 

1. Open a new FUPLA file ( You don’t need to open a new project ) called 

Lot.fup 

2. Add a comment to your file!!! 

3. If there are any other files in your project, then mark them as "notlinked". This 

way the file will not be taken into considerations and will not be downloaded to 

the PCD. 

4. Open the FUPLA and enter the input signals at the left and the out put signal at 

the right. 

5. Place a up- down counter on your sheet and make it count up with each pulse 

from Input 0 ( NewCar ) and down with each pulse from input 1 ( Car_leaving 

). 

FBOX: 

Counters: up down with preset 

Binary : Dynamize 

When you start up your PCD, the counter might already contain a value. So we must 

reset the counter at start-up. 

The small FBox on the side may be found in the family: ( Binary: Dynamize ) 

If you start up your PCD, then the input of the FBox "Dyn" goes from 0 to 1 ( When 

the constant 1 is loaded into the input ) and stays at one from then on. This change 

from 0 to 1 makes the output go to 1 at start-up. The signal is connected to the input 

"Set" which then loads "0" into the counter. Cool trick he? 



Double-clcking on a FBox with triangle on the lower left side always opens a parameter 

window. 

Inside this parameter window you can set the behaviour of the FBox (Example: PID 

regulator or Communication ) . In the case of the "Dynamize" FBox we can choose 

how exactly we want the FBox to behave. Set the option "Accept power up edge " 

to "Always" 

6. Read the counter value and compare it with 8. 

7. If the counter value is higher then 8, then make the output 17 blink. 

FBox: integer :Is greater than 

Blinker:Blink delay T 

8. Add a long comment to the Fupla page, explaining what your program does. 

9. Print your file 


5.Program structures 


5.1 CYCLIC ORGANIZATION BLOCK (COB 0 TO 15) 1 

5.2 PROGRAM BLOCKS (PB 0 TO 299) 3 

5.3 FUNCTION BLOCKS ( FB 0 TO 999 ) 5 

5.4 STRUCTURE VIEW AND EXECUTION PATH 6 

5.5 EXCEPTION BLOCK (XOB) 7 

5.6 SEQUENTIAL BLOCKS (SB 0 TO 31) 10 


The key to fast programs, lies in the structure of a program. The structure is the 

most important part of your entire project, because it makes your program readable 

to others, makes it portable, easier to extend and to maintain. Before you start to 

write your program you need to have an idea about all the different tasks your installation 

will have to solve. PG5 organizes the program parts in different kinds of 

blocks, each with it's special function: 

There are five different types of blocks: 

CB's ( Cyclic Organization Blocks) 

FB's ( Function Blocks ) 

PB's ( Program Blocks ) 

XOB's ( Exception Blocks ) 

SB's ( Sequential Blocks ) called Graftec

Workshop PG5 

Program structures 

© Saia-Burgess Controls AG

Workshop PG5 


5.1 Cyclic Organization Block (COB 0 to 15) 

What’s a COB: 

COB's (Cyclic organization blocks) are foreseen for program parts which are 

executed nonstop, without ever waiting stopping. (For example in order to wait 

for internal or external events to happen). After Startup of the PCD, the program 

starts executing the first COB in the program file and then executes one COB after 

the other. If needed you may create up to 16 COB’s. All the COB's are called 

automatically one after the other in a never ending cycle. 

All signals which need to be treated on a regular basis (for example end-switches for 

motor movements, external power-cut or emergency-stop signals, human protection 

devices ect) have to be inside a COB. 

There has to be at least one COB in the PCD! 

It is very important to understand, that the notion of the blocks which 

are always executed, is the most important aspect of all PLC's. The 

lack of waiting loops is not a failure in the concept of PLC programming, 

but a very important security feature. It's the only way you can 

guarantee your client that important signals are checked on a regular 

basis. 

If you write your programs with the “FUNCTION BLOCK EDITOR”, a new file in 

a COB is automatically opened for you. 

You can then change the block type or comment as you wish. 

In instruction list programs, the block is defined by instructions which surround the 

program code. 

© SAIA-Burgess Controls AG Page 5-1

Workshop PG5 


Example COB: 

Here you have an example program ( once in IL and once in FUPLA) which makes 

the output 64 blink at a rate of 1,5 seconds. The program is written in the COB 0. 

The COB 0 is followed by the COB 15. 


LADDER or FUNCTION BLOCK program: 

COB 0 ;COB 0 starts here 

0 

STL T 1 ;If timer 1 equals 0 

LD T 1 ;then load it with 1.5 s. 

15 

COM O 64 ;and toggle the output 64 

ECOB ;COB 0 ends here 

START UP 

COB 15 ;Next block 

0 

NOP 

ECOB 

(FBox: Blinker, Blink delay T) 

COB’s have 

different qualities: 

1: COB’s have a number. You can choose between 0 and 15. 

2: They can have a name. 

3: They have a SUPERVISION TIME. This time (in 10th’s of a ms), says 

how long the execution of the COB is allowed to take. If the supervision 

time elapses before the COB has finished execution (ECOB reached), the 

Exception bloc XOB 11 (will be explained right away) is executed. If there 

is no XOB11 programmed, the next COB is started. A supervision time of 

0 means that the supervision time is not activated. 

4: A comment can also be added. 

Example: FBD editor 

Example: IL-editor (Instruction list) 

2. 

1. 

3. 

4. 

3. 

2. 

1. 

4. 


Workshop PG5 


5.2 Program Blocks (PB 0 to 299) 

What’s a PB: 

You may also work with PB’s (Program Blocks). PB’s offer a good way to organize 

your program in a hierarchical manner. PB’s are only activated if they are 

called. They may be called from a COB or from another PB. 

There are two ways to call a PB: Conditional call or unconditional call. Conditional 

calls depend on the result of a logical operation. You can call the same PB several 

times in the program. If one PB calls another PB and so on, then you can do so 

up to seven levels. 

A PB call can 

be conditional 

or unconditional: 

COB 7 

Enable input is always 

high. Therefore the PB2 

will be called in every 

cycle => It's an unconditional 

call 

PB 

PB 

PB 

PB 

When the signal "move" 

becomes high the PB is 

called. This is a conditional 

call. 

Program blocks can not only be called from COB's, but also from PB’s, FB’s, or 

SB’s. 


Workshop PG5 


Technical 

stuff: 

Process image 

. 

Unlike the PLC's from SIEMENS or Rockwell, our PLC does not 

work with a so-called process image. If you work with a process image, 

then the PLC reads the state of all connected inputs and outputs at the 

beginning of the program cycle. Then during the cycle the PLC doesn't 

read and write to the inputs and outputs anymore, but to the image. At 

the end of the program cycle the PLC then writes all the results at once 

from the image to the outputs. Changes at the inputs which appear during 

the program cycle are not taken into consideration. If you want to write 

directly to an output during the program cycle you can still do so, but 

you have to configure the output consequently. 

SAIA PLC’s, always read and write directly from and to the inputs & 

outputs. This can be used if you want some program parts (and their 

Inputs & Outputs) to be treated more often then the rest of the program. 

You just have to put this part of the program into a PB and call the PB 

several times during the main cycle. Another nice solution would be to 

use an "Exception block" (XOB 14 or 15) 


Workshop PG5 


5.3 Function Blocks ( FB 0 to 999 ) 

What’s a FB: 

FB's ( Function blocks ) are nearly the same as PB's. Similar to PB's, FB's contain 

program parts which can be called from other blocks. This call can be conditional or 

unconditional. 

The unique difference is that FB's give you the possibility to call the block with parameters, 

as where with PB’s, you cannot. 

FB's with parameters can only be called from an IL program. 

The following example shows a FB which makes an output blink. 

The FB is called twice. First it makes the output 64 blink at a rate of 1.5 seconds 

and the second output 65 at a rate of 3 seconds. 

Call a FB: 

; Function block program 

FB 1 ; Function Block 1 

STL =2 ;If timer = L 

LDL =2 ; then load the time 

=3 

COM =1 

EFB 

; and toggle the output 

;The FB ends here 

; End function block 

; Main program 

;------------------- 

COB 0 ;Program start 

0 

;Call function block 

CFB 1 ;Call the FB 1 

O 64 

T 1 

15 

;Call function block 

CFB 1 ; Call the FB 1 

O 65 

T 2 

30 

ECOB 

;End main program 


Workshop PG5 


5.4 Structure View and Execution Path 

Once you have built your program, you can view the block structure of the program. Click on 

the Block structure view icon, located in the tool bar of the project manager. This will display 

the structure, and show you which COB is calling which PB, FB, or SB. The display below is 

for the FB example on the preceding page. It shows that FB1 is being called by COB 0 twice. 

Block structure 

view icon. 

Block structure 

view 

To display the execution path, you need to be online and the program running. Stop 

the program and place the curser in the center of the page and right click the mouse. 

This will display the pull down menu below. Click on Execution path, and it will 

display the path. This works with the above program because it consists of only 

FB’s. For a program with several segements, you would have to set break points to 

ensure you stop within a FB, PB, or SB. Setting break points is explained in 

chapter 7. 

The display shows that the FB 1 was called from 

the COB 0. (25) is the line number that we return 

to when the FB is finished. (10) is the line 

that we stopped on in the FB. 


Workshop PG5 


5.5 Exception Block (XOB) 

What’s a XOB: 

The exception blocks are treated automatically once a special event occurs. These 

events are defined by the firmware, and they cannot be modified by the user. It’s 

up to the user whether he want’s to program these events or not. 

START-UP PCD 

XOB 16 

The moment an event occurs, 

the PLC stops the task it is 

working on, and it starts to 

treat the XOB which corresponds 

to the event. 

When a XOB is 

called, the current 

program is 

stopped. 

Once the XOB is 

finished, the 

program continues: 

COB 2 

XOB 20 

Once the PLC has finished the 

XOB, it returns to the program 

point where the event appeared 

COB 5 

If an event appears but there is no program in the corresponding XOB, then the 

error LED on the PCD is lit and the PLC continues to run. 

Example: 

Turn on your PCD, take out the battery and the error LED will come up. If there 

was a XOB 2 ( see table on the next page ) in your program, then the LED won’t 

come up and the XOB 2 is executed instead. 


Workshop PG5 


All the XOB’s of 

the PCD family: 

XOB Description Priority Cold Start 

0 Power problem in the main rack (PCD6) or 

4 * 

WatchDog (PCD1/2) 

1 Power problem in the extension rack (PCD 6 ) 2 

2 Battery low 2 

4 Parity error on the I/O bus (PCD6) 1 

5 No response on a module I/O (PCD4/6) 1 

6 External error 1 

7 Over load of the system due to multiple events. 1 

8 Instruction not valid 4 * 

9 To many active tasks (Graftec) 1 

10 To many PB/FB levels 1 

11 Watch dog COB 3 

12 To many index registers used 1 

13 Error Flag 1 

14 Interruption cyclic 3 

15 Interruption cyclic 3 

16 Cold start 4 

17 S-Bus telegram 3 



20 Interrupt input INB1 3 

25 Interrupt input INB2 3 

30 No connection with RIO 1 

Use of XOB’s: 

- Helps to find errors in your program configuration 

- Errors in the addresses of the modules 

- More then seven program levels 

- More then 32 active transitions in a Graphtec structure 

- Never ending loop 

- Error in a mathematical operation 

- Errors in the communication 

- Maintenance of your PLC: 

- Surveillance of the batteries (needs to be changed every 3 to 4 years) 

- Surveillance of special events or very fast reactions on external signals: 

- Interrupt inputs 

- Interruption of the program every once and awhile 

- Interruption of the program when a telegram arrives 

- Cold start. Initial values 


Workshop PG5 


History Table: 

In the history table you may find all the hardware and software errors which have 

occurred. 

This table is updated even if the XOB’s are not programmed. You may find 

Time and date 

Programme line 

Error counter 

Text 

Very last error 

You have to consider the following points: 

- Every CPU has his own history 

- The line (BATT FAIL) only exists on the CPU 0 

- IF the error can be assigned to a program line then the line is indicated. If not, 

then it is displayed in hexidecimal. 

- - The XOB 0 is never listed. 


Workshop PG5 


5.6 Sequential Blocks (SB 0 to 31) 

Sequential blocks are a collection of so called STEPS and TRANSITIONS. 

In the step you execute a part of your program and in the transition you wait for a 

condition to appear in order to continue with a following step. 

Sequential blocks are created in a special editor. We call this editor GRAFTEC and 

the files have the extension *.sfc. The Graftec editor is explained in the next chapter. 

It is an excellent tool if you have to solve programming tasks, where your installation 

deals with a situation in a sequential manner. 

SB's can be called from any other block. 


6. GRAFTEC 


6.1 SEQUENTIAL BLOCKS (SB 0 ... 31) 1 

6.2 CYCLIC BLOCKS (COB 0 ... 15) 2 

6.3 OPEN A NEW GRAFTEC FILE 3 

6.4 ORGANIZATION OF THE SB’S 7 

6.5 GENERAL STRUCTURE OF AN SB 8 

6.6 BASIC RULE: ALTERNATE STEPS & TRANSITIONS 8 

6.7 TRANSITIONS 9 

6.8 STEPS 10 

6.9 TYPICAL SEQUENTIAL BLOCK STRUCTURES . 11 

6.10 EDIT A SEQUENCE 12 

6.11 WRITE YOUR FIRST SEQUENTIAL BLOCK 17 


6.13 HOW TO STRUCTURE GRAFTEC USING PAGES. 25 


This chapter covers Sequential Blocks. (also referred to as SB’s). SB’s are made up 

of 2 basic elements. Transitions and Steps. Programing SB’s is done using the Graftec 

editor. In this chapter, you will learn: 

♦ What a SB’s is. 

♦ How to call a SB’s. 

♦ How to organize several SB’s. 

♦ Some typical SB’s structures. 

♦ How to program SB’s. 

♦ How to structure the program into a pages format.

Workshop PG5 

Project management 

PG5-06-E.doc 


Workshop PG5 


6.1 Sequential Blocks (SB 0 ... 31) 

SB’s (Sequential Blocks) work different then the program blocks we learned about 

previously. SB’s are very efficient if you have an application where you have to do 

several things in a defined sequence. 

Example Elevator: “close the door” => “wait until the door is closed” => “move the 

elevator to the first floor” => “wait until the elevator has reached the first floor” => 

“open the door again” 

Because we don’t know how long your program will wait on a particular event ( 

milliseconds, minutes, days?) before it can continue with the next STEP, you can’t 

know the cycle time of an SB. Therefore it’s important to analyze your program and 

separate sequential problems in your application from parts which absolutely have to 

be in a cyclic block. 

Example: If you have an emergency switch on your application, then you want to be 

sure that this information is updated regularly. Therefore such information would 

never be put into a SB but into a COB. 

Typical Graftec Chart 

SB sequence 

starts here. 

The SB number. 

(each SB is assigned 

a number) 

SB sequence 

ends here. 

SB page 

number. 

PG5-06-E.doc © Saia-Burgess Controls Ltd. Page 6-1

Workshop PG5 


6.2 Cyclic Blocks (COB 0 ... 15) 

The fact that your SB is waiting on an event must under no circumstances block the 

rest of the program from being executed continuously. To prevent you from programming 

such a structure, a SB must be called from a COB. You can’t have a SB 

without a COB! 

The SB then will be called once a cycle and the state will be tested. If the SB is 

waiting on an event, then the program simply returns to the COB and continues to 

execute the COB. The next step of the SB will not be executed until the next cycle 

in which it is not in a waiting state. 

Cycle starts 

here 

Cyclic 

programs: 

Cycle time: 

Cycle 

ends here 

Until now our programs have been executed in an endless loop. They always started 

at the beginning of a COB and then one COB after the other was executed until the 

program reached the last COB. Once the program reaches the end, it automatically 

returns to the beginning of the first COB and starts the cycle all over again. 

The time it takes to execute all the COB’s from the beginning of the first COB to the 

end of the last COB, depends on the number and type of instructions and FBOX’s 

you use in your program. This time is called Cycle time. 

The cycle time is typically in the millisecond range. If you know the cycle time, then 

you know how long it takes for a PCD output to react on the change of the state of 

an input. 

Cyclic programs are built with program blocks like COB’s, PB’s, FB’s, SB’s or 

XOB’s. 


Workshop PG5 


6.3 Open a new GRAFTEC file 

Sequential Blocks are drawn in the Graftec editor. As already mentioned, a SB 

must always be called from a COB. Therefore we need to open two new files: 

• First we need to create a file containing a COB which calls the SB. This can be 

a FBD file for a graphical program (chapter 4) or the COB can be programmed 

in an Instruction list program (chapter 7) 

• Second we have to open a Graftec file. 

Open a new 

project: 

Start with a new project: 


Workshop PG5 


Open a FUPLA 

or a new IL file: 

Choose to open 

either a new Instruction 

List file 

or a Fupla file. 

Call the SB 

from a COB: 

Depending on the way you intend to write your program (Instruction list or FUPLA) 

you call the SB using a Call SB (CSB) instruction or a Call SB FBOX There is no 

difference between the two examples. Open the file you just created, and write the 

program as shown below. 



COB 1 ;Cyclic Block starts 

0 

CSB 0 ; calls the SB 0 

ECOB 

;Cyclic Block ends 

(FBOX: User definable, Call SB) 


Workshop PG5 


Open a new 

Graftec file: 

If you forget to add a COB, then the message window will tell you during 

the build process: 


Workshop PG5 



Workshop PG5 


6.4 Organization of the SB’s 

The SB List: 

When you create a graftec file, the graftec editor opens a Sequential Block 0 with an 

initial step for you. The SB 0 then is automatically entered into the SB list. To access 

this list, open the graftec file, and either click on the SB list icon, or click on 

File, then click on SB lists. This will display the list of SB’s in the opened file. You 

can have several SB’s in one file. (The maximum number of SB’s in a PCD is 32). 

Click on Edit and the SB number is displayed. (don’t confuse this number with the 

numbers of the individual elements. This number refers to the entire string of elements 

in the SB). Also there is a place to enter a name. We recommend that a 

name be entered for the SB. This will be helpful when navigating through your SB’s. 

If you don’t enter a name, the list will just display the number. 

Add SB’s to 

the list: 

As mentioned, you can have several SB’s in one file. To add additional SB’s to a 

file, open the SB list window, (displayed above) and click on Create. The Edit 

SB window will be displayed with the next available SB number. 

Enter a name for the SB and click on OK. This will add the SB to the list. You can 

then select the SB you want by highlighting it and clicking on Load. This will display 

the initial step for the selected SB. Now we can structure the sequence elements for 

the SB. 


Workshop PG5 


6.5 General structure of an SB 

Initial STEP 

Transition 

STEP 

Sequential blocks are built out of different elements which are called: 

Initial Step 

Step 

Transition 

SB’s start with an Initial STEP. When you call the SB for the very first time, then the 

SB will execute the program code inside the Initial Step. 

6.6 Basic rule: Alternate STEPS & Transitions 

Sequential blocks have a strict syntax. 

A sequential block always starts with an “Initial Step” 

Thereafter transitions and steps must alternate all the time. 

You must never have two Steps or two Transitions in a row. 

Right 

Wrong 

In contrast to other PLC's, SAIA PCD’s have implemented the SequentialBlockengine 

in the firmware which makes the sequential blocks extremely fast. 


Workshop PG5 


6.7 Transitions 

In a transition you put program parts which only have to run until a certain 

situation occurs. 

For example, you could read the characters from a serial port until a special 

character arrives, or you heat-up the dryers of a machine until they are 

warm enough to start the installation. 

The transition is always finished by an ETR command. The transition is repeated 

endlessly as long as the ETR is low. 

Example: The Flag 2 is toggled with each program cycle until the input 0 is 

high. 

FUPLA: 

IL: 

The " “End Transition" 

FBox is called here 

The STH instruction sets the ACCU to 

a high state, once the input I 0 goes 

high. The transition is considered finished 

as soon as the ACCU is high at 

the end of the transition. 

• You don't have to insert a program in every transition. A transition without a 

program is always true and will be skipped. 

• Transitions written in Instruction List: The ACCU is always high at the beginning 

of a transition or a step. 

• 2000 steps and transitions can be used to build up to 32 Sequential Blocks. 


Workshop PG5 


6.8 Steps 

Steps typically contain program parts which prepare the application for the next task. 

The task itself then often is inside a transition. 

You want to make your motor move from A to B. 

Typically you would first set the speed and direction 

of the movement. Second you would start the 

movement. Both tasks are non repetitive tasks which 

can be in a step since the step is only executed once. 

Once the movement is on its way, you'll have to 

monitor the movement and stop the motor as soon as 

it arrives at the destination B. This monitoring ( For 

example: read the end-switch ) has to be done over 

and over again until the motor arrives. This would 

ideally be done in a transition because transitions are 

executed cyclically. 

• A Step without a program goes directly to the next transition. 

• A Step is only treated once! A step is not cyclic! 


Workshop PG5 


6.9 Typical Sequential Block structures. 

Simple 

sequence 

Simple steps and transitions. There cannot be two steps or 

two transitions in a row. 

Or function 

- maximum 32 tasks in a row. 

An OR Task always begins with several transitions in parallel. 

The transitions are then executed one after the other 

(from the right to the left) until one of the transitions are fulfilled. 

After that, only this branch is executed and the execution 

of the other transitions stop. An OR function always 

ends with several transitions ending up in one step. The 

maximum number of transitions in a row is 32.. If there are 

more then the XOB 9 is called (read chapter 5) 

Simultaneous 

Tasks (AND) 

Jump over a 

sequence 

Starts several sequences at once and resynchronizes in one 

final transition. 

- The common start is given by a transition, which 

launches several steps. 

- Ends with several steps which are connected to the 

same transition. 

- You can have up to 32 branches. If there are more 

then the XOB 9 is called (read chapter 5) 

The two transitions are executed until one or the other is 

fulfilled. If the transition on the right is fulfilled first, then 

the sequence on the left will be bypassed. 

Repeat a 

sequence 

This example is similar to the preceding example except 

that one of the transitions will be fulfilled every cycle. It will 

repeat the same step 5 times and then move on to the next 

step. 

C = 5 

C = C - 1 

( C = 0 ) ( C > 0 ) 


Workshop PG5 


6.10 Edit a Sequence 

Once you open a new sequential chart file, the initial step is displayed. The execution 

of a step always starts from here. In order to add new elements to the drawing 

you can either use the toolbar or the keyboard. 

Select 

mode 

IStep mode 

Add a 

Transition 

Add a 

page 

Zoom 

Toolbar: 

Mixed 

mode 

Add a 

Step 

Connect 

two 

points 

Edit a simple 

sequence: 

At the beginning of this chapter we created 

the file Pulse.sfc. Open this file and go to 

the SB list and load the SB “OpenMain- 

Gate”. Do the following exercises: 

1. Select the " Mixed Mode " 

2. Move the pointer under the the initial 

step and click the left mouse button. 

3. Move the pointer under the new transition 

and click the left mouse button 

again. 

4. Follow this format. 

1. 2. 

3. 

Draw a connection: 

Once the sequence is finished the program 

is finished also. If you want the program to 

restart, then add a loop. You cannot draw 

a connection between two steps or between 

two transitions. A loop always starts 

at a transition and goes to a step. 

1. Select the "Select Mode" 

2. Mark the transition you start from. 

3. Select the "Link Mode" 

4. Click on the step that you want to connect 

to the transition. 

3. 

1. 

4. 

2. 


Workshop PG5 


Draw an alternative 

(OR) 

task. 

1. Select “Transition mode” 

2. Click on a transition which is already 

followed by a step. 

3. An additional transition is drawn with 

each click. 

Close an alternative 

task 

In order to resynchronize your simultaneous 

task: 

1. Select "Select Mode" 

2. Mark the transition you want to close 

3. Select "Link Mode" 

4. Click on the Step you want to connect. 

1. 

3. 

4. 

2. 

Edit a simultaneous 

Task 

(AND) 

1. Select “STEP mode” 

2. Click on a step which is already followed 

by a transition. 

3. An additional step is drawn with each 

click. 

Close simultaneous 

task 

(AND). 

In order to close your OR task: 

1. Select "Select Mode" 

2. Mark the step you want to close 

3. Select "Link Mode" 

4. Click on the Transition you want to 

connect. 

1. 

3. 

4. 

2. 


Workshop PG5 


Add a comment 

1. Activate "Select Mode" 

2. Use the right mouse button to click on 

an element. Choose "Edit" "Element…" 

3. Insert your comment. 

3. 

Insert a sequence 

1. Select "Transition Mode" 

2. Click on a step which is already followed 

by a transition. The editor will 

insert a new transition and a new step. 

Delete a sequence 

3. Activate “Select Mode” 

4. Click on the first transition of your 

sequence. 

5. Click on the last step of the sequence 

you want to delete while holding the 

“Shift” key down. 

6. Press the “Del” key. 

Click + 

“SHIFT” 

“DEL 

” key 


Workshop PG5 


Copy/paste a 

sequence: 


2. Mark start of sequence. 

3. Click on the last step of the sequence 

while holding the “Shift” key down. 

4. Select the menu "Edit" " Copy" 


6. Click on the point where you want to 

insert the sequence. 

7. Select the menu "Edit" " Paste" 

1. 

2. 

3. 

Insert a sequence: 

Remark: 

Depending on the position of the element 

(transition or step) you select to insert, the 

sequence might be inserted underneath or 

beside the selected element. 

7. 

4. 

Insert sequence 

on a 

transition. 

Insert sequence 

on a 

step. 


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Workshop PG5 


6.11 Write your first Sequential Block 


Open the file pulse.sfc. Go to the SB list and load the SB called “Pulse” 

GOAL: 

We will make a program which makes a digital output (Three_ pulses O 33) blink 

three times each time we have a digital input (Start_3_pulses I 2) going to high. 

Diagram: 

Input START_3_pulses: 

Output Three_pulses: 

1s 

1s 

Time 

Draw the basic 

structure: 

We always start with the Initial step, where we initialize our elements. Once the 

initialization is done we can wait for the start signal. Draw the elements as shown 

and add the comment to the fields: 


Workshop PG5 


Once we start the sequence, we are going to turn the output “ Three_pulses” on for 

1 second. After a second we turn the output off for a second. We do so three times 

and then we restart the sequence: 

Choose the SEdit 

or FUPLA editor 

for your program 

code: 

Our sequence is finished now. We only have to fill in the program code in each step 

and transition. We can edit each Step and transition in Instruction list or FUPLA 

which ever you prefer. We will program our Initial step using the FUPLA editor. 

Double-click on the Initial step and choose the FUPLA editor: 


Workshop PG5 


Prepare the symbols: 

First we will establish a list with all the elements we are going to use in the 

SymbolEditor. Enter the elements as shown in the picture below. 

Edit the program 

code: 

Next load the counter (named: PulseCounter) with the constant 3 (named: Number_of_pulses). 

To do so we take the “Load counter” FBox from the “Graftec family”). 

Remember, do not take counters or timers from the other families. They are 

designed to run in a cyclic program only. 

How to program 

a Transition: 

A transition is repeated endlessly until the “End of Tansition” is active. In transition 

number 0 we will wait inside the transition until the “Start_3_pulses” input goes high. 

Open the Transition 0 and add this Fupla program: 


Workshop PG5 


Use Timers in a 

SB: 

Timers and Counters from the Standard Library 

aren’t made for the use in SB’s. They are designed 

for use in COB’s which are executed cyclically over 

and over again. If you want to use timers or counters 

inside a SB, use the ones from the “Graftec” family. 

They are especially designed for Sequential Blocks, 

because you can load them in one step and question 

the state later on in another step or transition. 

What we do in our program is: 

Turn the output on and load the timer in the step and 

then we go on to the transition where we wait and 

question the timer until the time elapsed and the timer 

has come to zero. 

Repeat the step 

and transition for 

the time were the 

pulse is off: 

The Step 2 and Transition 2 are the same as step1 and transition 1: 


Workshop PG5 


Decrement a 

counter: 

The counter is decremented each time the program 

passes by. The counter is only decremented if the 

binary input is high (read help on FBox) 

Remember: An empty input field is always set to 

high! (Chapter 4) 

The last two Transitions then are a piece of cake: 


Workshop PG5 



Workshop PG5 



BUILD: 

Once you have finished the drawing, you can compile the entire program by clicking 

on the BUILD button. (Make sure that the COB file and the Pulse.sfc file are the 

only linked files before you activate the build process. You may also want to delete 

the SB “OpenMainGate”). 



If you have entered the 

program correctly then the 

message window should now 

tell you: 

Build successful. Total errors: 

0 Total warnings: 0 

If there are any errors in the drawing, then the FUPLA will indicate the error in red 

letters. Double-clicking on the error message will take you to the error. 

Now download the program and go online. 

Online tools: 

The sequential block can be observed online. The red point always tells you which 

transition or step is active. 

RUN 

STOP 

STEP BY 

STEP 

Active 

Transition 

(red point) 

You can stop the 

PLC at any given 

moment and 

continue the 

execution in a step 

by step mode. 


Workshop PG5 



Workshop PG5 


6.13 How to structure GRAFTEC using pages. 

What are pages? 

In PG5 you can structure your big programs by creating a simple overall structure 

which then calls subpages. 

Symbol of a page. 

Create a page by using 

the "page-tool" 

Input Step off the page. 

A page always starts and 

ends with a step. 

Navigate from 

page to subpage 

Output step 

off the page 

It’s possible to 

create pages 

within other 

pages 

Roles while using 

pages 

- A page always starts and ends with a Step. 

- A page can have only one “Input Step” and only one “Output Step” 

- You can have pages within pages. (As many as you like) 

- You can neither move nor delete an “Input/Output Step” 


Workshop PG5 


Create a page 


2. Click on the first step of your sequence. 

3. Press the “Shift” key and click on 

the last Step of your sequence. 

4. Execute “Page” => “Create”. 

1. 

2. 

3. 

Go into a page: 


2. Click on the page. 

3. Execute “Page” "Calling Page" 

or "Subpage" 

1. 

Undo a page: 


2. Click on the page. 

3. Execute " Page" "Expand" 

2. 


7. Instruction list programming 

(IL) 


7.0 CREATE A NEW PROJECT AND A NEW INSTRUCTION LIST PROGRAM FILE 1 

7.1 THE INSTRUCTION LIST EDITOR "SEDIT" 3 

7.3 IL SYNTAX 5 

7.4 BASIC INSTRUCTIONS: 10 

7.5 WRITE YOUR FIRST IL PROGRAM 17 


7.7 DEBUG YOUR PROGRAM ONLINE 23 

7.8 SYNCHRONOUS VIEW 26 


The programming of SAIA PCD’s is based on a very powerful instruction set 

which is implemented in every PCD. 

Note: Unlike other products, the different SAIA PCD’s products all use the same 

instructions. Therefore you can port program files without problems from one 

PCD type to the other. 

The instruction list editor “S-Edit” will not only help you edit your programs, it 

also includes a whole range of powerful troubleshooting and online visualisation 

functions which will be a topic at the end of the chapter. 

You’ll learn the very basics of PG5 programming in this chapter. You’ll also learn 

how to debug your program once it runs on your PCD. 

Don’t start this chapter before reading chapter 3. “PCD Resources”.

Workshop PG5 

Instructionlist 

PG5-07-E 


Workshop PG5 


7.0 Create a new project and a new Instruction list program file 

Choose to open a 

new project: 

Open a new program 

file: 

To open a new program file in this project, click on the " New File" button or 

use the right mouse button. 

OR 

PG5-07-E © Saia-Burgess Controls Ltd. Page 7-1

Workshop PG5 


Open the editor: 

Double-click the new file and the “Instruction List” editor will open. 

Note: Instruction list files have the extension “filename.SRC” 


Workshop PG5 


7.1 The Instruction list editor "SEdit" 

The editor: 

The editor opens once you double-click a file with the extension *.src. With 

SEdit you can edit your source code. The programs are saved in a text format 

and can be viewed and edited by any text editor. 

File handling and 

text editing tools 

Search 

tools 

Bookmark 

Online 

tools 

Auto-format settings: 

Unlike a normal text editor, SEdit will analyse your code and format your inputs 

in a user friendly structure. We recommend to use this special function. 

( see settings in the picture below ). 


Workshop PG5 


General Syntax: 

When you write your program you have to respect a certain syntax which is 

described below. 

In order to edit your program you can enter the code like you would in any 

other windows based text-editor. The code arranges itself in four rows once 

you press the enter key, The colors can be changed. ( menu: "TOOLS" => 

"OPTIONS" => "COLORS" ) 


Workshop PG5 


7.3 IL Syntax 

Comments: 

IL programs are read by two kinds of entities: humans and compilers. The 

compiler requires the source code text to conform exactly to its syntax rules. 

For example a COB command demands two parameters. One behind the 

command COB itself and the second on the line below it. Humans are not so 

particular about how instructions are given, but they often need more explanation 

about what the function of the instructions are. Such explanation can be 

added to the source code. We call them comments and they are displayed in 

green. There are two ways to add a comment. 

; All the text from the semicolon to the end of the 

line is considered as comment and will be green. 

$skip $endskip All the text between the two instructions is 

skipped by the compiler and therefore is a comment. 

Comments can be added to every line. 

Structure: 

The code itself is structured in several rows. You can jump from row to row by 

using the TAB key. 

1. ROW: LABELS, General comments and TEXT 

2. ROW: Mnemo code. In this row you insert the actual instruction. 

3. ROW: The operands for the instruction. Also called media code. 

4. ROW: Comments to the specific program line. 


Workshop PG5 


Case sensitivity: 

Instructions and operands are not case sensitive. 

Symbols are not case sensitive unless they contain foreign characters, MotorOn 

is the same as MOTORON, but GRÜN is not the same as grün. 

Labels are symbol names given to locations in a program (program lines), 

which are used as destinations for jump instructions or to provide debug information. 

Characters allowed in labels are the same as those of symbols. 

Texts are case sensitive. ( Example: TEXT 20 

"UART:4800,8,N,1;MODE;MC2;DIAG:F0,R100;" ). 

Writing programs 

with symbols: 

Please make sure you have read the chapter "3. PCD Resources ". 

Why should we use symbols and name our input and outputs after all? 

Couldn’t we simply write our programs directly using the element address like 

shown? 

COB 0 

0 

ACC H 

STH I 0 

ANH I 4 

OUT O 33 

ECOB 

In fact you could write your programs like this if you like to. But: 

First symbols make your program easier to read. 

Second, imagine you have a program, which is 4000 lines long. The output O 

64 was used 30 times (for exp OUT 0 64, SET 0 64 etc.). During the start-up 

of your machine you break the output. For one reason or the other you don't 

have a spare card handy but lucky you, the output number O 67 off this card is 

available. You decide to use this one instead. 

You have changed the address of your output from O 64 to O 67. And you 

have to do so 30 times!!!! 

Had you declared O 64 by a symbol, you would only have to change the address 

one time in the symbol editor. 

That’s one of the reasons why its better to use symbols rather then fixed addresses 

in your program. 


Workshop PG5 


Writing programs 

with symbols: 

Take the symbol Timer1 for example. This timer is declared in the SymbolEditor: 

If you want to use the Timer 11 instead of Timer 12 then you can do so in 

one single step directly in the Symbol editor. 

Note that the Timer2 has no number at all! You don’t have to give an address 

to your elements if you don’t want to. The PG5 will auto allocate all 

symbols for you. 


Workshop PG5 


Technical stuff 

Addressing 

symbols & 

using arrays: 

By the way: 

If you work with symbols, you can add constants or other symbols to your 

symbol. Like this you can define a basis address and then refer to an element in 

perspective to this basis element. 

Example: 

An output card PCD2.A400 with 8 outputs is placed into the slot with the start 

address 80. We then want to set the third output (output 82): 

Definition: 

We can simply write: SET OutputMotor1+2 in our program. 

A more elegant way is to reserve an array of 8 outputs: 

In the program we then set the output 82 like this: 

SET OutputMotor1[2] 

Auto complete 

symbols: 

If you use long symbol names your program will become easier to read. On the 

other hand it will be annoying if you have to re-enter the long symbol name 

each time you use it in the program. Therefore you can simply enter the first 

letters of a symbol, and then lookup all the symbols which fit the first letters 

by using the keys “CTRL and SPACEBAR”: 

Example: 

CTRL + SPACE 

ENTER 


Workshop PG5 


Labels: 

You can make conditional and unconditional jumps in your programs. When 

you jump in your program, you have to tell the assembler where you want to 

jump to. Labels are symbol names given to locations in a program (program 

lines), which are used as destinations for jump instructions. 

Characters allowed in labels are the same as those of symbols. Labels can appear 

anywhere in the source file, but should be within a code block (COB, PB 

etc.), and must not be inside a multi-line instruction. 

The value assigned to a label is its offset within the code block where it is defined. 

All labels are local to the block in which they are defined, and the same 

label can be used many times in the same source module, providing it is always 

in a different block. Jumps to labels defined in another block are not allowed. 

Example: 

Range of symbols 

and labels: 

Symbols are always "local". Which means that the symbol name is only known 

to instructions, which are in the same file as the declaration (see chapter 3). If 

you have a symbol with the same name in another file, then the data of the two 

symbols won’t get mixed up. 

Labels are always local to the block. You can't jump from one file to the other 

or from one block to the other. Even if the two blocks are in the same file. 

All COB’s, XOB’s, PB’s, FB’s, SB’s, IST’s, ST’s, TR’s, TEXT’s, and 

DB’s, are globally known 


Workshop PG5 


7.4 Basic Instructions: 

Binary Instructions: 

Binary instructions work with inputs, outputs, flags, the state of timers/counters, 

and the ACCU. 

The ACCU is nothing more then an internal System flag, which memorizes the 

result of the last instruction. It can be either high or low. 

We have three different types of binary instructions: 

1. Type 2. Type 3. Type 

The first group of instructions 

alters the ACCU 

state 

In the second group of 

instructions, the execution 

of the instruction 

depends on the ACCU 

state. 

The third group of instructions 

depend on the 

ACCU state and alters the 

ACCU state. 

Input 

Output 

Or Flag 

Instructions: 

ACC 

STH 

STL 

Input 

Output 

Or Flag 

Instructions: 

DYN 

OUT 

SET 

RES 

COM 

Input 

Output 

Or Flag 

Instructions: 

ANH 

ANL 

ORH 

ORL 

XOR 

LU 

ACCU 

ACCU 

LU Input 

Output 

Or Flag 

LU 

ACCU 

LU= Logic Unit 

Example: 

STH I 14 

Sets the ACCU to high if 

Input 14 is high. 

Example: 

RES F 10 

Sets the flag 10 to 0 if the 

ACCU is high. 

Example: 

ANH I 23 

The ACCU is AND linked 

with the logical state of 

input 23, the ACCU is set 

to the result. 


Workshop PG5 


Word Instructions: 

Word Instructions work with registers, counters, timers, constants, texts, and 

db's. Although there are some instructions which depend on the state of the 

ACCU, the ACCU isn't that important here. ( see Instruction set booklet ). 

Not all the instructions allow you to use all the possible elements ( register 

counter ect) as parameters. Please refer to the booklet or the online help. 

A lot of the instructions not only write a result to the element ( register, counter 

ect), but they also note some general information about the result into four 

special flags called arithmetic flags. The flags are: 

1. Zero flag ( Example: Z flag is set if the copy instruction copies an empty 

register ) 

2. Error flag (Example: The Error (E) flag is set if the definition text of a 

SASI instruction is missing or invalid). SASI=SAIA Assigned Serial Interface. 

3. Negative flag ( Example: is set if the result of a calculation was negative ) 

4. Positive flag ( always inverse to the negative flag ) 

Example: 

ADD R 1 

R 33 

R 46 

The values of register R 1 and register R 33 are 

added. The result is in register R 46. 

The flags N,P , Z are set according to the value in 

register R 46 

ACCU 

Register 

Constant 

Timer 

Counter 

Register 

Constant 

Timer 

Counter 

? 

COPY 

ADD… 

.. 

Word 

Instructions: 

ALU 

32Bit 

? 

JR 

ACC… 

Register 

Constant 

Timer 

Counter 

E Z N P 

Error 

Arithmetic Flags 

Other Instructions (mainly the Control instruction family) are only executed, if 

the mentioned Arithmetic flag is set to high. 

Example: JR Z Label ;The Jump is only done, if the Zero flag is 

high. 

Most Word-Instructions are executed unconditionally. 

Zero 

Negative 

Positive 


Workshop PG5 


Jumps and calls: 

We make the difference between jumps and calls. When you want to go from 

one point in your block to another point within the same block, then you use a 

jump command. If you want to go from one block ( COB, PB, FB, or SB ) to 

another block, then you use a call the block. 

Another important difference is that if you call a block then the system will 

execute the called block and will then return to point where the block was 

called from. A jump doesn't return. 

WARNING: Jumps are potentially dangerous. This is because you can 

end up programming programs with endless loops. Therefore never ever 

jump backwards in a program. 

Jump instructions 

JR Jump relative 

JPD Jump direct 

JPI Jump indirect 

Block calls: 

CPB Call program block 

CPBI Call program block indirect 

CFB Call function block 

CSB Call Sequential block 

Unconditional 

jumps and calls: 

If you don't add a condition to your jump or call, then they will be done every 

time the program execution arrives to the jump instruction. 

COB 0 

0 

COB 0 

0 

PB 3 

JR 

Lablename 

CPB 3 

CPB 4 

PB 4 

Lablename: 

EPB 

EPB 

ECOB 

ECOB 


Workshop PG5 


Conditional 

jumps and calls: 

Jumps and calls can contain a condition code. A condition code is a flag which 

( depending on it's state ) executes a call or a jump. There are different condition 

codes.: 

1. You can activate a jump or a call depending on the state of the ACCU. 

Example: If you use the condition code H, then the instruction will be 

executed only if the ACCU is high ( equal 1 ). Condition code L executes 

the instruction if the ACCU is low. 

2. Another way to influence the behaviour of your program are the arithmetic 

flags Negative, Positive, Zero, and Error. All the arithmetic instructions 

and some of the communication instructions alter the state of the four flags. 

The booklet with the instruction set summary, lists all the instructions and indicates 

which of these instructions alter the ACCU or the arithmetic flags. 

Examples: 

We want to stop the acceleration of 

the motor once the speed is, equal to 

or higher than 200. Therefore we 

compare the speed with 200. If the 

value in the register called Motor 

speed is equal or higher than 200, 

then the Positive flag is set after the 

CoMPare instruction. 

The Jump Relative instruction checks 

the Positive flag and jumps over the 

program part which normally accelerates 

the motor. 

In this example we have a surveillance 

flag which is used somewhere else in 

the program. As soon as this flag is 

set ( flag content equals 1 ) we want to 

call the Program Block named Alarm. 

The STart High instruction sets the 

ACCU to 1 if the content of the surveillance 

flag is 1. The Call Program 

Block instruction on the next line 

checks the ACCU and calls the Program 

Block named Alarm as soon as 

the ACCU is High. 

MotorSpeed equ R 

MinimumSpeed equ 200 

COB 0 

0 

CMP 

MotorSpeed 

MinimumSpeed 

JR P NoAcceleration 

~ 

~ 

NoAcceleration: 

~ 

~ 

ECOB 

Surveillance equ F 

Alarm equ PB 

COB 0 

0 

STH Surveillance 

CPB H Alarm 

ECOB 

PB Alarm 

EPB 


Workshop PG5 


Index Register: 

Each and every COB has an internal register which is called an index register. 

The content of this register can be manipulated by five instructions: 

SEI 

SEt Index register 

INI 

INcrement Index register 

DEI 

DEcrement Index register 

STI 

STore Index register 

RSI 

ReStore Index register 

Most of the instructions can work with the content of this register and perform 

indirect commands with it. (these instructions are indicated in the booklet). If 

you add an X to the command name ( Example LD =>LDX ) you tell the PCD 

that you are using the index register in this program line. 

Example: 

COPY 

Normally an instruction like COPY would work like this: 

COPY R 10 

R 40 

The content of R 10 is COPIED into R 40 

COPYX 

COPYX works different: 

SEI K 2 

COPYX R 10 

R 40 

The Index register is set to 2 

R 10 is not copied into R 40, but the content of 

register R 12 is copied into R 42 ( add the content 

of the index register to R 10 and R 40). 

So now that you know the basics, we can start to write our first program. 


Workshop PG5 


$Instructions: 

$skip 

Until now we have only talked about instructions which are downloaded to the 

PCD. The PCD family has a set of instructions (called directives), which can 

change the way the build process is done. These directives aren’t downloaded 

to the PCD at all. Here’s a short list of the most common directives: 

One of these directives was already presented at the beginning of this chapter it 

was : $Skip => $endskip 

This directive tells the build process to skip the code between these symbols. 

The code is considered as a comment. 

$include 

When an include statement is encountered, the given file is read and processed 

as though it is part of the source file being assembled. 

Format: 

$INCLUDE ["][d:][path]filename[.ext]["] 

SEdit can open these files for you. If you have an $include directive in your 

code simply click on the statement using the right mouse button, and the specified 

file will be opened for you: 

$group 

All symbols defined between these directives are automatically prefixed with 

the group_name. This makes it easier to work with symbols which are inside 

groups. To reference a symbol in a group, either the group name can be used 

as a prefix to the symbol (separated by a full stop "."), or another $GROUP 

directive can be used to define the default group name. 

For example: 

STH FRED.SYMBOL1 ; SYMBOL1 in group FRED 

$GROUP FRED 

; select group FRED 

STH SYMBOL1 ; references FRED.SYMBOL1 

$ENDGROUP 

These are just a few of the available directives. Using these directives takes a 

lot of experience and explaining all these techniques would go way beyond the 

goal of this starter workshop. Please refer to the help for a complete list. 


Workshop PG5 



Workshop PG5 


7.5 Write your first IL Program 


At the beginning of this chapter (7.0) we made a new file called : "Oilpump.src" 

We will write our first code into this file. 

GOAL: 

Lets start with a simple binary combination. 

We will turn on a pump ( Oilpump signal O 32 ) if the oil level becomes too 

high ( OilHigh signal input I 0 ) and if the machine is in conditional Run ( 

Cond_Run signal input I 1 ) or normal run ( NormalRun signal input I 2 ). But 

the pump must not run if there is an emergency stop ( Emergency signal input I 

7 ) 

This is what the program would look like in LADDER: 

Double-click on the file called: "Oilpump.src" and Sedit will open. 

Before we start to write our program, we have to make a list of the symbols we 

are planing to use. Enter the following symbols into the Symbol Editor: 


Workshop PG5 


Now we can start programming. For a good program you should always add 

some lines of comments explaining what this program does, by whom it was 

written and when the last modifications were done. 

After that you'll need to place your program inside a block. Since this is the 

only block in our project, the program must be inside a COB : 


Workshop PG5 


Now the programming 

begins: 

Input 

Input Input Output 

Input 

The ACCU is always set to high at the start of a block, therefore we don't have 

to set the ACCU first. 

A combination always starts with STH , STL, ACC L or 

ACC H: 

sth 

Cond_Run 

orh NormalRun 

out IntermediateFlag 

sth IntermediateFlag 

anl Emergency 

anh OilHigh 

out OilPump 

Set the ACCU to the state of the NormalRun signal ( = 

IF NormalRun ) 

If the ACCU was set by Cond_Run OR NormalRun 

Save the result in an intermediate flag and start a new 

combination: 

If the result of the Or function was high 

AND The Emergency signal is Low 

AND the OilHigh signal is active 

Then the ACCU is set and we just copy the ACCU state 

to the signal OilPump 

Why did we solve the OR combination ( the parallel contacts NormalRun 

Cond_Run ) first, before we tested the AND combinations ( Serial contacts 

Emergency, OilHigh, and (NormalRun or Cond_Run))? 

One important thing you have to remember is that an OR function 

has absolute priority over the AND ( ANd High or ANd Low ) 

function. 

If an OR function sets the ACCU, then the results of the following AND & OR 

functions don't matter anymore until you start a new combination with STH. or 

ACC H/L. 


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Workshop PG5 



BUILD: 

Once you have entered the program lines, you can compile the whole program 

by pressing the BUILD button. 



If you have entered the program 

correctly then the message 

window should now tell you: 

Make successful. Total errors: 0 

Total warnings: 0 

Create and find an 

error: 

Open the IL program once again and change the instruction: 

sth Cond_Run to stx Cond_Run 

and make the program a second time. This time the message window will signal 

an error: 

Assembling: oilpump.src 

Error 32: oilpump.src: Line 34: Invalid 

expression 

1 errors, 0 warnings 

Assembly complete. Errors: 1 Warnings: 

0 

If you double-click on the 

error message, then the editor 

will open and the faulty line 

itself will be highlighted with 

a red bar, so you can instantly 

locate the error inside your 

code. 

instruction stx back to sth and make the program a last time. 

Change the 


Workshop PG5 


CODE-VIEW: 

Now that the program was built successfully, we can see the code created by 

the assembler: 

The View Code button ( short cut F5 ) will display the final code inside the 

original program code: 

Original 

code 

(white) 

Resulting code 

after the Build 

(grey) 

Program line 

inside the PCD 

Hardware 

address of 

the symbol 

Cond_Run 


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7.7 Debug your program online 

Start/Stop your 

PCD: 

1. Download your program 

2. Go online. 

3. Start and stop your PCD. 

Look at the front of the PCD, 

and observe the RUN LED. 

It should turn on and off with the 

start and stop of the PCD. 


online: 

The state of each input 

and output is shown 

online. Turn on and off 

the inputs in order to 

see the changes. 

Using the right mouse 

button you can change the 

program online 

Example : Change a instruction 

from STH to 

STL or directly change 

the state of the media ( 

register content input, 

flag state ect) 


Workshop PG5 


Trace Mode: 

In Trace Mode the PCD is stopped and you just execute one line after the other. 

In order to stop your process at a given program line you just have to place the 

cursor on a line in your program and click on the : 

"GO TO CURSOR" button. The PCD will then stop at this program 

line and you can execute one line after the other by pressing the function-key 

"F11". 

If you have PB's or FB's in your program you can choose to “trace into” 

these blocks or “step over” these blocks. 

If you are inside a block, then you may leave the block with the 

"STEP OUT OF" button. 

COB 0 

0 

= PCD is in Run 

= PCD is in Stop 

(Trace mode) 

PB 7 

If you step over a block, 

then the PCD goes into 

RUN, executes all the 

elements inside the block 

and STOPs at the first 

instruction after the block 

call. 

PB 2 

CPB 7 

CPB 2 

EPB 

If you step out of a block, 

then the PCD goes into 

RUN, executes all the 

elements inside the active 

block and STOPs at the 

EPB 

first instruction after the 

block call. 

Like in the normal online mode, you can change the state of every program by 

selecting the active line and using the right mouse button and the commands: 

Edit Media/Status or Code 


Workshop PG5 


Break points: 

Often you would like your program to stop at a given event, say you want to 

stop the machine as soon as the EndSwitch is activated or as soon as the temperature 

stored in the Register 200 reaches the value 23. 

The “break point function window allows you to do just that. 

While your online with the PCD press the BreakPoint icon : 

In the window select the conditions you want to set. 

Example: Run the PCD until the register R 200 has the value 23. 

As soon as you press “ 

the PCD does go into conditional run. 

Conditional run means that the PDC isn’t running at full speed but it executes 

every instruction and after each program step the PCD checks whether the condition 

was met or not. The condition is saved in the list so you don’t have to reenter 

the same conditions over and over again. 

So in our example the PCD will continue to run in conditional run unti the 

register reaches the value 23. 

The “RUN” LED on the PCD blinks if it’s in conditional run. 

In the PG5 a conditional run is indicated by the RUN ICON 

which changes between red and green. 

Clear-Stop clears the conditional run and puts the PCD in stop. 

Clear-Run clears the conditional run and keeps the PCD running. 


Workshop PG5 


7.8 Synchronous view 

Synchronous view is a new feature in the PCD and you’ll need a new firmware 

for this function: 

Minimum FW: 

PCD1 

PCD2 

PCD4 

Synchronous view is an enhancement of the asynchronous view. Once you are 

online in SEdit simply click on the icon: 

The state of the ACCU, 

the MediaCode and the 

IndexRegister is shown 

for every line while the 

PCD continues to run. 

The screen freezes and you cant scroll anymore. The state of the systemflags 

and the content of the index register is shown in addition to the state of the 

element. A view which you can normaly only achieve in trace mode, is created 

here while the PCD continues to run! You can visualize the exact state of every 

element at any given line. 


EXERCISE 


GENERAL QUESTIONS 1 TO 7 1 

SOLUTIONS 1 TO 7: 3 

BINARY OPERATIONS & COUNTERS 7 


In order to solve these examples it’s helpful to print the file “Instructions.pdf” 

which is installed with your PG5. 

The file is designed for double-sided printing. 

Otherwise if you need help on one of the Instructions, then place the cursor on the 

instruction and press F1




General questions 1 to 7 

1. Which of the following instructions are executed only if the ACCU is 

high? 

SET RES COM INC STH 

2. How can you set / reset and flip the ACCU state? 

3. Load the state of the Error-Flag into the ACCU 

4. Write a program that corresponds to these two ladder diagrams 

Example 4.1: Example 4.2: 

I 1 * I 2 + I 3 = O32 

I 1 + I 3 * I 2 = O32 

5. What would the result in example 4.2 be, if the result of the first logic 

combination wouldn’t be saved in a flag: 

STH I 1 

ORH I 3 

ANH I 2 

OUT O 32 

Instead of => 

STH I 1 

ORH I 3 

OUT F 0 

STH F 0 

ANH I 2 

OUT O 32 

Draw the solution as electrical drawing. 



6. Which arithmetic flags are set after these instructions? 

LD R 10 

100 

LD R 11 

90 

CMP R 10 

R 11 

7. How would the example 2 work, if there would be an “ACC L” instruction 

at the beginning? 

ACC L 

LD R 10 

100 

LD R ..... and so on 



Solutions 1 to 7: 

Solution: 

1: 

SET RES COM INC 

How can you know? 

• Look up the instruction in the Instruction-List booklet. The instructions 

marked with a D, are only executed if the ACCU is high. 

• Enter the instruction in the S-Edit, place the cursor on the instruction 

and press “F1”=> A online help will tell you everything about 

the instruction. 

2: 

ACC H 

ACC L 

ACC C 

Sets the ACCU to high 

Set the ACCU to low 

Complements the ACCU state high 

becomes low, low becomes high 

3: 

ACC E 

4: 

4.1 

STH I 1 ; Copy the state of I 1 into the ACCU 

ANH I 2 ; AND link the ACCU with the state of 

;I 2 & then set the ACCU according to 

;the result. 

ORH I 3 ; Set the ACCU if I 3 is high. 

; (Or function) 

OUT O 32 ; Set output 32 to the ACCU state. 



4.2 

(I 1 + I 2 ) * I 3 = O 32 

{ 

F 0 

STH I 1 ; Copy the state of I 1 into the ACCU 

ORH I 2 ; OR link the ACCU with the state of I 2 

; & then set the ACCU according to the 

; result. 

OUT F 0 ; Set a flag to the ACCU state. 

STH F 0 ; AND link the result of the first logic 

ANH I 3 ; combination whit I 3 

OUT O 32 ; Set output 32 to the ACCU state. 

5: 



6: 

Result = CMP 100 

90 

100 > 90 

=> 

ZerroFlag = L 

PositiveFlag = H 

NegativeFlag = L 

ErrorFlag = Not changed 

How can you know? 

1. Solution: Enter the program into the Instructionlist editor, place the 

cursor on the instruction CMP and press the button F1 => A help on 

the instruction will come up. 

2. Solution: Built and download the program and trace online to the 

instruction CPM => you’ll see the state of all the Arithmetic flags: 

3. Solution: Have a look into the instruction booklet for more information 

about the instruction CMP. 

7: 

If you load a constant into a register, then the execution of the “load” instruction 

doesn’t depend on the ACCU state. Therefore the program 

would work the same. Have a look into the booklet for some help on the 

instruction “LD”. Note: An instruction LD T (load timer) or LD C (load 

counter) would depend on the ACC state but not a load register! 





Binary operations & counters 

Example: 

Parking lot 

Output 17 

(red light) is 

lit as soon as 

the parking 

lot is full 

(Lot_full) 

Input 0 

( NewCar ) 

Input 1 

( Car_leaving ) 

You have a parking lot with 8 parking slots. 

You have to sensors : One at the entrance gate which gives a pulse each time a 

car enters (Input 0 NewCar ) a second sensor at the exit tells you when a car is 

leaving (input 1 Car_leaving ). 

A signal ( output 17 Lot_full ) is lit as soon as 8 cars are in the parking lot. 

Cars can enter the lot even if the lot is already full !! 

Set the counter to 0 when you start up. 

Goal: 

This is a example you already know from the FUPLA examples. 

You learn to use counters in IL 

You learn to document the program. 

You learn how to reset values at start up. 





Solution: 

1. First create a new project and open a new IL ( Instructionlist ) file. 

2. Make a list of all the elements you think you are going to use ( inputs, outputs 

....) 

2. First you have to tell the PCD that you want this program to run in the COB 

0. Enter the COB 0 ECOB instruction as shown underneath. 

3. Add some comments. 

So. Now you already have a program. Although it wouldn't do anything yet, 

you could assemble and download it down to your PCD. 

4.Back to our parking lot program. 

The counter content always tells us how many empty places there are inside the 

parking lot. Once the counter comes to zero ( = 0 empty places ) we know that 

we have to turn on the red light. 

We presume that the parking lot is empty at the moment we turn on the PCD. 

So we load the counter with 8. 

When we want to do something at start up, we have to do so in XOB 16. Therefore 

add an XOB 16 in front of the existing COB and load the counter “NumberOFreeSlots” 

with 8. 



In the case of a counter, the LoaD instruction depends on the state of the 

ACCU. As we want this load to be an unconditional one, we have to be sure 

the ACCU is H. So set the ACCU to H first. 

XOB 16 

; Code executed at start up 

ACC H 

; Load the counter with 

LD NumberOfFreeSlots ; the value 8 ( unconditionally ) 

8 

EXOB 

; end of start-up program 

5. We then simply decrement the counter 100 each time a car enters the lot and 

increment the counter as soon as one leaves the lot. 

Each time we have a rising edge on the input 0 ( Sensor at the parking lot entrance 

) we want to decrement the counter “NumberOfFreeSlots”: 

STH NewCar_Signal 

DYN DynamiseNewCar 

DEC NumberOfFreeSlots 

The DYN instruction memorises the state of the Input 0 in a flag (Dynamise- 

NewCar)from one program cycle to the next. The ACCU is then set as soon as 

the DYN instruction sees that the Input 0 has gone from 0 to 1. 

The DECrement instruction is only executed, if the ACCU is set. Do the same 

thing for the parking lot 

Exit. 

STH Car_leaving_Signal 

DYN DynamiseCar_leaving 

INC NumberOfFreeSlots 



6. Turn on the light ( red_light Output 17 ) if the counter comes to zero ( no 

free parkingslots ). 

STH NumberOfFreeSlots 

OUT red_light 

STH sets the ACCU to high if the counter comes to zero. OUT gives the AC- 

CUstate to the Output 17. 

So that’s it. 

See how your program looks at the end. 




8. Additional tools 


8.1 DATA TRANSFER UTILITY 1 

8.2 CUSTOMIZE MENU 7 

8.3 WATCH WINDOW 9 

8.4 ONLINE CONFIGURATOR 13 

8.5 UPLOAD THE PCD CONTENT AND CREATE A PROJECT 17 

8.6 PROGRAM AN EPROM 22 

8.7 DOWNLOAD A NEW FIRMWARE VERSION 23 


PG5 has implemented some utilities which come in handy for situations like Battery-change; 

maintenance or documentation and others. This chapter explains the 

different tools.

Workshop PG5 

Additional tools 

PG5-08-E 


Workshop PG5 


8.1 Data transfer utility 

When you will 

use a DATA 

TRANSFER 

utility: 

The Data transfer tool can be used as a stand-alone tool. You can not only upload 

the program of a PCD but also the content of registers, flags, counters, 

ect. 

This comes in handy for different occasions: 

• If you change the battery and you make a backup for safety reasons. (In case 

of a power loss during the battery change and you loose information) 

• If you make data-logs with your PCD and you want to upload the data from 

time to time. 

• If you want to save the state of your installation at a given moment. 

Backup your 

PCD : 

In case you don’t have the original source file of your PCD or in case you want 

to backup all the PCD content (program as well as element content) use the 

upload all function: 

In case you have such a message 

: 

This might be because of: 

Your K111 cable is connected 

to a different COM port => 

Or the PCD is not running. 

(Change the port in Setup). 

Use “PGU 

direct connection” 


Workshop PG5 


Choose a name: 

Start the 

UPLOAD: 

Once you have started the “Upload All” and you have chosen a name for the 

uploaded file, press “Upload” to start the process: 

Depending on your program size, this can be a lengthy process. 


Workshop PG5 


Download the 

saved file: 

If you want to download a file you uploaded previously, then simply connect 

your PC to the PCD and start the download all function: 

NOTE: 

After the download your PCD won’t go into RUN. Even if you turn off the 

PCD and restart it again, it won’t. This is due to the cable PCD8.K111. As 

long as the cable is connected to the PCD, the PCD waits for a start signal from 

the programming tool. Disconnect the cable from the PCD to restart or start 

the PCD from the programming tool. 


Workshop PG5 


Upload some 

Data’s only: 

There are two ways to upload a selection of Data. 

• The Quick save. 

• The upload of a prepared file. 

Quick save: 

With Quick save you can easily upload a collection of elements. 

The Data is then loaded and saved in 

a text file called “filename.DT5” 

You can change the way the elements 

are saved in the file: 


Workshop PG5 


Upload elements 

using a script 

file: 

In case you want to download or upload one or several elements, you can prepare 

a list with all the element’s you want (see picture) and then start the Upload-button. 

Prepare the 

script: 

You can test the syntax of your list 

of elements to assure the uploader 

After the upload starts, a new file will be opened will recognize and all the all the elements elements: will be 

shown. 

This example list 

will upload three 

different registers 

and three flags 

Upload: 


Workshop PG5 



Use Data Transfer 

in command 

line mode 

There is much more to this last example then simple uploading of elements 

using this tool. Another plus of this list of elements lies in the 

fact that the Data-Transfer tool can be started in the command line mode 

too! You can write a batch file which uploads the data from time to 

time into a file and you can then display this data in an application such 

as EXCEL, or others you may prefer. 

Read the online help for more information on the possible commands 


Workshop PG5 


8.2 Customize Menu 

You can add links to you favourite programs via the tools menu. Example: 

} 

These three applications were added to the 

“Tools” menu with the help of the “Customize 

Menu...” function. 

How to add an application to the “Tools” menu: 

Create a new 

menu item. 

Delete a 

menu item. 

Arrange the 

menu items 


Workshop PG5 



Workshop PG5 


8.3 Watch Window 

The watch window is a great tool for debugging an installation. You can list 

your most important signals in the window and display and alter these signals 

online. 

To open a new program file in this project, click on the " New File" button or 

use the right mouse button. 

OR 

Open the 

WatchWindow: 

Double-click the new file and the “WatchWindow” will open. 

Note: WatchWindow files have the extension “filename.5WW” 


Workshop PG5 


Add elements to 

the WatchWindow: 

Now drag-n-drop symbols from the program or symbol editor to the Watch- 

Window. You can also enter elements directly to the watchwindow. Press the 

“Insert” key while the window is active and enter the address of the element 

you would like to see online. Example: R 200 

View elements 

online: 

As soon as your online you’ll see the content of each element. Go online: 

Change date online: 

You can not only view elements but also write to the symbols. Right-click on 

any element and alter the content. Example: Change the content of Register 

200 from 300 to 4444: 


Workshop PG5 


If you don’t like the format which is used to display the elements then use the 

right-click menu to change it. 

Example: Change the display of the Register from Decimal to Hex. 

Not only display output 32 but all the outputs of the card from O 

32 to O 39. 


Workshop PG5 



Workshop PG5 


8.4 Online configurator 

The “Online configurator” let’s you set the most important parameters while 

your online with the PCD. 

You’ll need this 

tool if: 

• If you want to update the firmware. 

• Your PCD came to a halt and you want to read the history in order to see 

the cause of the halt 

• You want to set the clock in the PCD. 

• You want to set a password 

• Set the serial ports 

Calling the main 

window: 

Provided the PCD is properly connected to the PC via a PCD8.K111 cable, 

and the PCD is switched on, double click on the 'Online Configurator' in the 

program manager, under “Tools”: 


Workshop PG5 


NOTE: 

In case you have this message : 

Make certain that: 

1. Your K111 cable is connected to the right COM port => change the 

port in the SETUP.=> 

1. The PCD is running 

Clarification of 

each field in the 

Online-Configurator: 

• PCD type: Identification of the CPU (Hardware) 

• Version: Current firmware version of the connected PCD. 

• Program name: Current project in the PCD program memory 

• Date: Current date of the PCD hardware clock (if there 

is no hardware clock then the date will be 1/1/92 

• Time: Current time by the hardware clock 

• Day: Current day of week: 1 = Monday, ... 7 =Sunday 

• Week: Current week number of current year 

• Status: RUN, STOP, HALT or Conditional Run 

• CPU: for PCD2 always 0, 

for PCD4 0 or 1 

for PCD6 0 - 6 

• Protocol: PGU direct or S-BUS 

• Baud: Transmission speed: 

for PGU direct: always 9600 Baud 

for S-BUS: 110 – 38,400 Baud 

• Station: Station number: 

for PGU direct: not relevant 

for S-BUS: 0 - 254 


Workshop PG5 


Clarification of 

each button in 

the Online-Configurator: 

'Memory...' function 

This is basically the same function as the Memory setting in the Hardware- 

Configurator, but online. 

'S-BUS...' function 

Same as the “Memory” function. 

'Clock...' function 

Most of the PCD’s have a built in RTC (real time clock). 

The "PC Clock" on the left contains the current date and time in the IBM PC, 

The "SAIA PCD Clock" on the right shows the date, time, day of week and 

week of year of the connected PCD. 

Clicking on the "Copy to PCD >>>" button copies the date and time from the 

IBM PC to the PCD. 

The values in the "SAIA PCD Clock" window can also be entered individually. 

The entered values are checked for validity. 


Workshop PG5 


'History' function 

The History function is a great help after a system error. It may happen that 

you program a situation, which makes it impossible for the PCD to react on it. 

Example: You have signal on the interrupt input but no exception block, 

which handles the signal. 

The fact that there is an entry in the history doesn’t necessarily mean that there 

is a problem. Read the help for more information. 

After clicking on "History" in the main window, the following dialog box appears: 

Very last 

error 

The 4 most 

common 

messages 

The history table is displayed for the chosen CPU in the connected PCD. 

With one click on the "Clear history" button, this memory can be deleted. 

'Password' function 

This is basically the same function as the “Password” setting in the Hardware- 

Configurator, but online. 


Workshop PG5 


8.5 Upload the PCD content and create a project 

One day you might be confronted by a situation where you must debug a machine 

where the source code has been lost. In such situations you need to upload 

the program from the PLC and recreate the project. 

Please note that you can upload programs which where written in FUPLA but 

you’ll only get the “Instruction List” code which was created by the FUPLA 

and not the drawings. 

The four steps 

for uploading a 

project: 

So. how can you upload the code then? 

1: You have to upload the code from the PLC. The PG5 will create a file with 

the extension *.upl 

2: You can then disassemble the code and choose to either make a project or 

3: Then analyze the new project and handle the system information. 

4: At last you can make your changes to the program and rebuild the project 

again. 

STEP 1: Open a 

new Project and 

upload the code 

First open a new project. 


Workshop PG5 


Then go to the menu “Tools” => “Upload Program” and start the uploader. By 

default the uploaded file will be put into the project folder. 

You can define the way 

you connect yourself to 

the PLC here. Default 

is PGU Mode. 

Once the upload is finished close the window by pressing “CLOSE”. 


Workshop PG5 


STEP 2: Disassemble 

your 

code and create 

the project. 

The disassembler 

will by default list 

the latest file you 

have uploaded. 

Tell the PG5 to 

create a new CPU 

in the current project. 

Specify how you want your program 

to be saved; 

All Blocks in one file 

One file for each block type 

Or a file per block (can be 

many) 

The result will be a new CPU in your project with all the source files (*.src) 

you need to recreate the project. 

STEP 3: Analyze 

the new project 

and handle the 

system information. 


Workshop PG5 


PG5 does add some instructions into the program code in order to configure 

the PCD. 

If you upload your code and you make a project, then these instructions will 

be uploaded too. Therefore if you build your program again, then the PG5 

tries to add these instructions again and this will create an error like: 

The instruction concerned are: 

DEFVM 

DEFTB 

DEFTC 

Another error you can get is : 

Error 369: Absolute address in auto allocation segment: F 7500 

You can tell the Software settings not to add 

the DEF-Instructions and not to use auto allocation. 

With this setting activated the project will 

build without errors. 


Workshop PG5 


Change the 

source code in 

order to use the 

software configurations: 

If you want to use the Software settings tool, then you have to erase the DEF- 

Instructions in the XOB 16. 

You can simply mark them out: 

Another thing you might change are the “Auto allocation” ranges of the 

FLAGS, REGISTERS, TIMERS, and COUNTERS. 


Workshop PG5 


8.6 Program an EPROM 

If your client has no PG5 installed then you can send him an EPROM containing 

the user program instead. PG5 can create the most common EPROM formats 

for your EPROM burner. 

In order to create an EPROM you must build your program first. 

Choose the “Output File Format:” and press “Create Files” 

The HEX files are then created and you can use the files in your EPROM 

burner software. 


The EPROM not only contains the user program but also the hardware configuration. 

So if you plug in a EPROM into the PCD system then at start-up the 

system is configured and only then the PCD starts to run. Make sure that you 

change the jumper on the PCD from R (RAM) to E (EPROM) if you use an 

EPROM. The jumper location is explained in the hardware manual of every 

PCD. 


Workshop PG5 


8.7 Download a new Firmware version 

With the new generation of SAIA PCD’s (starts with PCD2.M170) the firmware 

can be changed by the PG5. There is no need to burn the firmware anymore. 

In order to change the firmware just open the “Online Configurator” and go 

online. 

Once the “Online Configurator” is running, start the “Firmware Updater” from 

the menu : 

“Tools “ => “ Update Firmware” 

Firmware loader: 

Add the new FW 

you want to download 

here. 

“Start” downloads 

the Firmware to 

the PCD.

Introduction.

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