VG108 Help Topics

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About VG Soni-Tech Industries

VG108 - Architecture

VG108 - Hardware

VG108 - Software

Operating - System

Error & Remedies


About VG Soni-Tech
About VG Soni-Tech Industries

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We have tried our best to supply all details regarding, hardware & software in this help file. We welcome your suggestion for upgrading software and hardware help with new ideas.

Promoter of this company had already designed and manufactured and supplied over 100's of  automation to Grauer & Weil (I) Ltd since from 1981 to 1993 for plating application. Some of them are listed here.

•	Bajaj Auto Ltd. Pune

•	Bajaj Auto Ltd. Aurangabad

•	Ballmer Lawrie & van-Leer(I) Ltd. Mumbai

•	Escorts, Surajpur

•	Hero Honda, Daruhera

•	IDL Chemical Ltd. Hyderabad.

•	Laxmi Machine works.

•	Mico Nagnathpura, Bangalore

•	TVs Suzuki, Hosur

•	Usha Martin Ltd. (Ranchi).

0	Today also VG Soni-Tech Industries has supplied automation to various companies, through M/S Penron & others. Few of them are listed here.

•	Ashok Leyland, Bangalore

•	Bajaj Auto Ltd. Pune

•	Ballmer Lawrie & van-Leer(I) Ltd. Mumbai(For Press Automation)

•	Dubai wire Ltd. Dubai(3 Installed)

•	Escorts Goetz Ltd. Bangalore

•	Glenmark (Nasik)

•	Hindustan lever Ltd. Silvassa)(For shrink wrapping)

•	Hindustan sanitary ware (Hyderabad)

•	Mega Rubber(Mumbai)(Phosphating)

•	Mega Rubber(Mumbai)(Rubber Moulding)

•	Ponds Ltd.(Pondicherry)(For shrink wrapping)

•	Ramdas Motors (Kakinada)

We thank you for the trust you have on us.


VG108 Architecture

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{Bmp c:\progra~1\VG108\rack.bmp}

Card (1) must be Power Supply.

Card (2) must be CPU card.

Card (3 or more then 3) can be Digital Input or Output Card.

Card (A to E or more) are Level Translator Card or Relay.

FRC Cable connected to Digital Input must connect to Level Translator card only.

FRC Cable connected to Digital Output must connect to relay card only.

Once unit is wired, Card position remains fixed.

VG108 basically is comprised of

•	8k Monitor Eprom, 256 Ram used for Monitor program, 24k Application EPROM or PEEPROM (Selectable version), 32k Ram Battery Backup Ram.1k Buffer used for error & plant stoppages logging.

•	16k Buffer for Load logging.

•	A Clock to maintain error & Load logging.

•	4K Private Flags. (Retentive).

•	256 Global Flag. . (Retentive).

•	3840 Private Counters. (Retentive).

•	240 Global Counters. (Retentive).

•	48 GlobalTimers Programmable having range of 0 to 9999, Selecteble unit of 1sec or 1 Minute. (Retentive).

•	8 Alarm Timers having range of 0 To 99 seconds.

•	8 Dwell Timers having range of 0 To 99 seconds.

•	256 Maximum Inputs. Each card is of 16 Inputs.

•	240 Maximum Outputs. Each card is of 16 Inputs

•	Instruments Like Ph, Rh, Temperature, Dosing.

•	One RS-232C serial Channel to Communicate with PC.

•	One RS485 Channel to communicate with instruments.

•	2 Line 32 Character Self Scan Liquid Crystal Display.

•	Necessary wire harnesses.

•	Powerful compiled software to program any machine type for zero maintenance time.


Hardware Description
VG108 Hardware

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All the cards and display described below are plug-in modules in a standard rack unit for ease of maintenance. Once a unit is wired properly one need not have to disturb this wiring to

Pull out any card .Serial communication cable is also brought out on C.P.U Mothercard for ease of CPU card maintenance. Following cards are available in SI - 108 systems. Some of them are essential and some of them are optional

•	One Power supply card.

•	One C.P.U Card.

•	Digital Input card.

•	Digital Output Card.

•	Level Translator Card.

•	Relay card.

•	C.P.U Mother Board.

•	Input & Output MotherCard.

•	Level Translator & Relay MotherCard.

•	Meters.

•	Terminal Card.[Part Number Si106TON00]

This is optional card, is meant for Digital Input/Output external connection. An Auxiliary 24V D.C should be supplied for working of opto isolated Input/Output. Two F.R.C connectors (20 pin Male) are also provided on for connecting to Digital Input/Output card.20 pin

0	Screw type connector (4 connectors of 5 Pin) is also provided for external connection.

•	RS485 Card. [Part Number VG108RSC85]

This card is connected to 9 pin female connector of CPU Mothercard. And its 3 pin outlet connectors are connected to all instruments.

•	2 line 32 character self scan display with its cable.

[Part Number Si106DSP00] Non Backlight

0	[Part Number Si106DSPBL] Having Backlight

Display is connected to CPU motherboard's 16 pin connector.

•	Wire harness (F.R.C) to connect Input to Level Translator OR Output to Relay.

[Part Number VG108FRC20]

This is essential for Digital Input/Output to LevelTranslator/Relay card OR to terminal card connection.

•	Wire harness (F.R.C) to connect bus system.

[Part Number Si106HEA14] for 14 pin

[Part Number Si106HEA16] for 16 pin

This is essential for Digital Input/Output motherboard to another digital Input/Output motherboard OR to terminal card connector.

This is also essential for CPU motherboard to Digital Input/Output motherboard connection.


Software Variables
Software

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Program is divided into 8 Wagon (1 To 8) Interpreter + General programming one can write each wagon programming in its corresponding Interpreter. Before Programming one has to fill up plant status.

Wagon programming is a rather interpreter, program will not go to next step unless it completes is current step, while general program will not wait to complete step, it will continue scanning all the step, and execute them all unconditionally ,while a program block will be executed conditionally.

General programming is further divided into 11 program blocks(0 To 10).Block(4) is further divided in to 8 Parallel Sequences each of can have 255 steps are provided with simple programming technique, to program for a almost zero maintenance time. With this technique of programming, a designer can continuously provide to user its current step of all sequence,

An error is also generated automatically; designers can also provide a text of cause & remedies to user.

This helps user not to waste time for debugging program with a Program debugger or a Hand-Held terminal.

A well planned software also allowed user to change program, timer or counter at flick of switch. For this purpose Sequence/Global Counter & Flags are used. Sequence Flags, Counters are useful for 8 Sequences its relative use, while Global Counters, Flags are shared by all sequences.

Block 0 as procedure block will no be scanned by program but can be called upon later in program. Block 1 also will no be scanned continuously, but it will be scanned only once at

time of power ON, thus it helps to initialize some counters, flags or even routines. Block 10 allows you to fix your display messages, still any message supplied directly in programmed will automatically be fixed in this block at time of compiling. Block 4 is used for 8 sequence program. For ease of a Zero maintenance programming this block is further divided in step completing, statement, step message, step alarm time and step Error text(Cause & remedy text).A detailed programming help is provided in General programming help.

VG108 also provide program line checking. As you entered one line, VG108 will debug it to find out program line error. An immediate error will be detected, & will be highlighted to you.

VG108 memory part consists of

1)	8k Monitor EPROM.

This contains libraries of useful programs. Such as

) 	Displaying messages or data for user.

) 	Displaying current step messages for designer.

) 	Automatic generation of error in case a particular step is not finished in programmed time.

) 	Rolling & Display & Resetting of Error/Remedy Text (Programmed by Designer) at time of error.

) 	Timer triggering with fixed data. By Counter or By Settable counter.

) 	Communication Protocol for PC.

) 	Communication Protocol for Instruments.

) 	24k Application EPROM, EPROM (Selectable version).

2) Volatile 256 Ram used for Monitor program.

3) Non Volatile 32k Ram Battery Backup Ram.

Ram contains Global/Sequence Counters & Flags & Buffers for data logging, & for Error logging & a buffer for tank data storage, some part of this memory also used for monitor program e.g. some buffer pointers, clock, timer flag, instruments data & others.

) 	16k Buffer for flightbar logging.

) 	A Clock to maintain error & Load logging.

) 	4K Sequence Flags. They are addressed by notation Sequence Flag (P).N where P varies from 1 To 8 & N varies from 0 To 255.e.g instruction “Puton SequenceFlag1.5” sets sequence1 flag 5.

) 	256 Global Flag. They are addressed by notation Global. (N) where N varies from 0 To 255. .e.g. instruction “Puton Global.120 puts on global flag 120.

) 	3840 Private Counters. They are addressed by notation Sequence(P).(N) where P varies from 1 To 8 & N varies From 0 To 239.e.g instruction Sequence1.120 = 45 loads

45 to sequence1 counter 120.

) 	240 Global Counters. They are addressed by notation Global. (N) where N varies From 0 To 239.e.g instruction Global.120 = 45 loads 45 to global counter 120.

) 	48 Global Timers Programmable having range of 0 to 9999,Selecteble unit of 1second or 1 Minute.

) 	8 Alarm Timers Programmable having range of 0 to 999.9 Second.

) 	8 Dwell Timers Programmable having range of 0 to 999.9 Second.


Power Supply

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[Part Number Si106PSULM]

This is one & Essential Card.

Power supply card has 230V AC +/- 10% Input & following supplies as output.

+5V D.C Regulated for C.P.U Card.

+5V D.C Regulated for Digital Input & Output Card.

+5V D.C for RS-232C Channel

+5V D.C for RS-485 Channel. [Optional].

+5V D.C for Display Backlight. [Optional].


Microprocessor Card

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[Part Number VG108CPULM]

This is Essential Card.

C.P.U card consist of EPROM, Ram, Timers and Rs232C serial communication and serial communication channel for instruments for suitable RS-485 Protocol. It has built in strong compiler for display routine, zero maintenance machine programming, Interpreter for Plating programming (Optional), communication protocol for meters on RS-485 and protocol for PC

on RS- 232C Channel. An Application program can be programmed through PC on Flash Programmable Memory, is supplied optionally and is built in monitor program. A Self Diagnostic Program, Application EPROM Checking program, and a status indicating built in program is strong advantage for zero time maintenance.


Digital Input Card.

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[Part Number Si106DIP16]

One card is essential.

Each card consists of 16 Inputs. Expandable up to 16 cards.

Different type of digital Input cards are available.+24V Input,+12V Input,6 m.a sink or source type.8 switches mini dip type single pole single way is provided on the card .

It is marked with 1 to 8 & it’s ON Position. To select this card as Zero number, marked 1 switch should be in on position & rest switches in off position(Input 0 To 15) Similarly To select this card as One number card, marked 2 switch should be in on position & rest switches in off position(Input 16 To 31). A rack to rack interface card decides it’s upper half position (Input 128 Input To 255).In front 16 green L.E.D's are provided for input status.


Digital Output Card.

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[Part Number Si106DOP16]

One card is essential.

Each card consists of 16 Outputs. Expandable up to 15 cards.

Different type of digital Output cards are available.+24V Output ,50 moa or 1 A  sink type.8 switches mini dip type single pole single way is provided on  the card .It is

marked with 1 to 8 & its ON Position. To select this card as Zero number card, marked 1 switch should be in on position & rest switches in off position (Output 0 To 15). Similarly To select this card as One number card, marked 2 switches should be

in on   position & rest switches in off position (Output 16 To 31). A rack to rack interface card decides its upper half position (Output 128 Output To 240).In front 16 red L.E.D’s are provided for output status.


Level Translator Card.

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[Part Number VG108LTC16]

This is optional card.

16 Input cards accept 230V A.C Input (8 M.A) & convert to suitable D.C for Digital Input Card. For ease of removing card 230V A.C connections are brought to euro connector. Also a Mothercard and a F.R.C is necessary to connect Level Translator card to Digital Input card. If this F.R.C is to be connected to Digital Input Card 0 then Inputs of Level Controller Card are considered as Inputs from 0 TO 15.If this F.R.C is connected

to Digital Input Card 1 then Inputs of Level Controller Card are considered as Inputs from 16 TO 31 & so on.

A 20 V A.C is required as auxiliary power as these inputs are opto coupled.


Relay Card.

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[Part Number VG108RLC16]

This is optional card.

16 Output card has relay N.O contact as output. Contacts are rated for 230V A.C 2Amp resistive Load. Relays are driven by Digital Output Card .For ease of removing card 230V A.C

connections are brought to euro connector. Also a Mothercard and a F.R.C is necessary to connect Relay card to Output card. If this F.R.C is to be connected to Digital Output Card 0 then Outputs of Relay Card are considered as Output from 0 TO 15.

If this F.R.C is to be connected to Digital Output Card 1 then Outputs of Relay Card are considered as Output from 16 TO 31 & so on. Rely contacts are protected with snubber circuit for inductive loads

A 20 V A.C is required as auxiliary power as this outputs are opt coupled.


MotherBoard For CPU & PowerSupply Card.

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[Part Number Si106CMB00]

This is one & essential card.

This card has 2 Euro female connectors for support of power supply & C.P.U card to be plugged in. There are four different type of connectors mounted, One for 230 V A.C (3 Pin screw type), One for display (16 Pin), One for RS232C (9 Pin Dsub male) and One for RS485 (9 Pin female).Also one 16 & one 14 pin Header connection is provided for C.P.U bus to IO Mothercard bus. Interface for display is also mounted on this card.


MotherBoard For Digital Input/Output Card.

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[Part Number Si106IOM00]

One Card is Essential for 2 IO’s card.

This card has 2 Euro female connectors for support of Digital Input/Output card to be plugged in. Also one 14 pin & one 16 pin Header connection is provided for IO Mothercard bus to IO

Mothercard /C.P.U Mothercard. Two F.R.C connectors (20 pin Male) are also provided on for connecting to Relay/Level Translator card or to Input/Output to terminal card connector.


MotherBoard For Level Translator, Relay Card.

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[Part Number VG108LRM00]

One is Essential for 2 Level/Relay’s card.

This card has 4 Euro female connectors for support of Level Translator/Relay MotherCard card to be plugged in. Two F.R.C connectors (20 pin Male) are also provided on for connecting to

Digital Input/Output card.20 pin screw type connector (4 connectors of 5 Pin) is also provided for external connection. 2 pin screw type connector is also provided for 20V A.C input for auxiliary power supply connection.


Instruments.

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•	Temperature Controller Meter. [Optional].

•	Rectifier Controller Meter. [Optional].

•	PH Controller Meter. [Optional].

•	RH Controller Meter. [Optional].


Operating System.

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Operating system of VG108 uses first four Inputs (0 To 3) 0f card 0 & Outputs (0 & 7) of card 0 for its internal function & Display Line 0 & 15.

There are two types of errors can be created. One Main Error (Causing trouble in automation) & Second Auxiliary Error (Does not affect Machine Movement, Like meters, buffer Full).

Display Line 0 Shows whether Emergency is on, auto mode, manual mode or error. First priority is given to emergency, next to error, next to manual or auto mode. If any one of these changes the status of display, Line 0(Out of 0 To 15 Line of Display) will be Shown by system automatically. Display Line 15 is used for Auxiliary Error.

If Main error is turned then Output 0 of OuputCard0 is blinked at every 1 seconds, If auxiliary error is turned on then Output 7 of OuputCard0 is blinked at every 1 seconds.

If Input 0 is on it assumes that emergency is on else it assumes emergency is off.

If Input 1 is pushed to on & off then Display Line is advanced & next display line message is shown.

If Input 2 is on it assumes that Plant is in auto mode else it assumes Plant is in manual mode.

Input 3 is used at time of main error is on, pushed to on & off at time of error will advance Error Text to next line in same display line 0.i.e Error Text is rolled on Display Line 0.

Input 3 is also used at time of Plant is put to auto mode. If it is off then plant restart from its last left position. Like Power Fail or Error occurred Or plant was switched to manual mode while it was in auto mode. If it is on then Plant Start from its Basic position. In Auto-Restart All buffers &

logged process data will be reset. If Input 3 is on at time of main power is switched on, (& Input 0 is also ON) then also system is reset.

Following are modes available for smooth operation of plant.

Self Test Mode.

Emergency Mode.

Manual Mode.

Auto Mode.

Error & Remedies.

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Main Error (Output 0 of card 0 is blinking) is generated by system software allows programmer to put Err Text on display. It is basically responsibility of programmer to provide all remedies of particular error to the users. One has to just read this Err text on Display Line 0.Display can only show one line of Err text at a time. To see the next line one has to push Input 3 of card 0 on to off .When end of Err Text comes display line 0 automatically shows first line of Err Text. After Reading this Err Text one has to take necessary action.

To clear Main Error, one has to just push Emergency (Input 0 of card 0) on or switch to manual mode.

Auxiliary Error (Output 7 of card 0 is blinking) is generated by system software allows programmer to put Err Message on display. It is basically responsibility of programmer to provide single line Message on any one of Display Line 0 To 15.

To clear Auxiliary Error, one has to just push Emergency (Input 0 of card 0) on or switch to manual mode or just pushes Start Input (Input 3 of Card 0).


Self Test.

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While switching on main power supply of VG108 if Start Input (3 of Card 0) & Emergency Input (0 of card 0) both are on then Self Test mode is established. This also reset machine.

Display Line 1 will Show you following Message

TEST: CARD 0 INPUTS 0 IS ON

& Output 0(card 0) will blink on to off. To test other Input click Start Input 3(card 0).This will increment Input number on display. After every 16 Input card number is also incremented also corresponding Output number of corresponding card will blink.

Example:

To check card 1 Input 9.

Click Start Input 3(card 0) or keep it pressed until display line 1 show

TEST: CARD 1 INPUT 9 IS Off (OR) On

Supply 230v AC to LEVEL TRANSLATOR CARD 1 INPUT 9

Display line 1 should show following message

TEST: CARD 1 INPUT 9 IS On

Now remove supply from LEVEL TRANSLATOR CARD 1 INPUT 9

Display line 1 should show following message

TEST: CARD 1 INPUT 9 IS Off

If in above cases none of test is true then one has to replace its Digital Input Card 1 and/or and its Level Translator card.

Example:

To check card 0 Output 3.

Click Start Input 3(card 0) or keep it pressed until display line 1 show

TEST: CARD 0 INPUTS 3 IS Off (OR) On

Unconditionally Output 3 of card 0 should be blinking, if it is not then replace Digital Output Card 0 otherwise replace its Relay Card if contacts of relay 3 of card 0 is not turning on & off.

To exit this mode just release Emergency mode (Input 0 of card 0 is off).


Emergency.

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Emergency can be put any time by just pressing Emergency Input (0 of card 0 ON).It is decided by programmer that which output(S) should be switched off during this mode. Display Line 0 is shown with a message EMERGENCY ON INPUT 0 ON.

This also clears Main & Auxiliary Error. If plating plant is used then it also clears all manual function of all wagons.

To exit this mode release Emergency Input (0 of card 0 is OFF).


Manual Mode.

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If Input 2 of card 0 is off then plant is in manual mode. Display Line 0 is shown with a message (provided there is no emergency) MANUAL MODE INPUT 2 OFF.

If switched to manual from auto mode then it also clears Main & Auxiliary Error. All manual functions are carried out in this mode.


Auto Mode.

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If Input 2 of card 0 is on then plant is in auto mode. Display Line 0 is shown with a message (provided there is no emergency) AUTO MODE INPUT 2 ON.

While switching to auto from manual mode if Start Input (3 of card0) is on then plant is started from its basic position else from its last position. (Like a power fail occurred, An error occurred)

It is user’s responsibility to see that whether he wants to start from basic or last position. A proper care must be taken for any type of auto. If he wants to start from basic then he should carry out all his basic procedure as recommended by manufacturer.


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