EDA Technology ED-PLC2010 CODESYS PLC

1. Introduction

The ED-PLC2010 is a high-performance Programmable Logic Controller (PLC) and Industrial PC (IPC) designed for automation and control applications. It supports the CODESYS development environment, enabling programming according to IEC 61131-3 standards.

1.1 Overview

The ED-PLC2010 offers flexible configuration options for RAM and eMMC storage:

• RAM: 1GB, 2GB, 4GB, 8GB
• eMMC: 8GB, 16GB, 32GB

It features a comprehensive set of communication interfaces including HDMI, USB, Ethernet, RS232, RS485, Wi-Fi, and 4G connectivity. Additional features include RTC (Real-Time Clock), Watch Dog timer, and EEPROM.

The system supports CODESYS Control runtime, with targets for EtherCAT/Modbus TCP, TargetVisu, WebVisu, Softmotion, CNC, and Robotics. It can act as an EtherCAT Master and Modbus TCP Master, and includes an OPC UA Server.

1.2 CODESYS

CODESYS is a leading development system for industrial automation, allowing users to create PLC and IPC applications. The ED-PLC2010 is compatible with CODESYS, supporting IEC 61131-3 programming languages such as LADDER (LDF), Function Block Diagram (FBD), Instruction List (IL), and Sequential Function Chart (SFC).

CODESYS supports development on both Windows and Linux platforms.

1.3 Communication Interfaces

The ED-PLC2010 is equipped with EtherCAT, RS485, and RS232 interfaces for industrial communication.

1.4 Connectivity Options

• Wi-Fi/BT: 1x 2.4GHz/5GHz Wi-Fi/BT module.
• 4G: 1x 4G/LTE module.

1.5 Hardware Interfaces

The ED-PLC2010 features a variety of ports for connectivity and expansion.

1.5.1 Front Panel Ports

• 1x ERR indicator
• 1x RUN indicator
• 1x PWR indicator
• 1x HDD/eMMC indicator
• 1x IO RUN indicator
• 1x IO SYS indicator
• 1x UDISK DETECT indicator
• 1x ECAT indicator
• 1x HDMI (Type A, HDMI 2.0, 4K @ 60Hz)
• 1x RJ45 Ethernet (10/100/1000M)
• 1x EtherCAT OUT RJ45
• 2x RS485 (6-Pin 3.5mm, IGND/A/B signals)

1.5.2 Side Panel Ports

• 1x Nano SIM slot for 4G connectivity
• 1x Micro SD slot

1.5.3 Rear Panel Ports

• 2x RS232 (6-Pin 3.5mm, GND/TX/RX signals)
• 4x USB ports (1x USB 2.0 Type A, 2x USB 3.0 Type A)
• 1x SMA connector for 4G antenna
• 1x SMA connector for Wi-Fi/BT antenna
• 1x FAC RST button (Factory Reset)
• 1x IPADDR RST button (IP Address Reset)
• 1x UDISK RM button (USB Drive Remove)
• 1x IMP button
• 1x STOP/START/PLC button
• 1x IO ERR indicator
• 1x IO indicator
• 1x UDISK BUSY indicator
• 1x UPDATE indicator

1.6 Reset Functions and Status Indicators

The ED-PLC2010 includes several reset buttons and status indicators:

• Reset Buttons: FAC RST (Factory Reset), IPADDR RST (IP Address Reset), UDISK RM (USB Drive Remove), IMP, STOP/START/PLC.
• Status Indicators: RUN, ERR, IO, IP, ETHERNET, ETHERCAT, 4G, UDISK BUSY, UPDATE, IO ERR.

1.7 LED Indicators

The device features various LEDs to indicate operational status:

• PWR: Power status.
• HDD/eMMC: Storage activity.
• RUN: PLC program running status.
• ERR: System error status.
• IO RUN: I/O module running status.
• IO ERR: I/O module error status.
• IO SYS: I/O system status.
• UPDATE: Firmware update status.
• UDISK DETECT: USB drive detection.
• UDISK BUSY: USB drive access status.
• ECAT: EtherCAT communication status.
• 4G: 4G network connection status.

1.8 Pin Definitions and Interfaces

Detailed pin assignments for various interfaces.

1.8.1 Micro SD and Nano SIM Slots

• Micro SD: For storage expansion.
• Nano SIM: For 4G/LTE connectivity.

1.8.2 Power Input

The device operates on a DC 24V (±20%) power supply.

1.8.3 RS485/RS232 Interfaces

The ED-PLC2010 provides two RS485 and two RS232 ports.

RS485: Uses 6-Pin 3.5mm connectors with signals IGND/A/B.

RS232: Uses 6-Pin 3.5mm connectors with signals GND/TX/RX.

Note: CM4 pinout mapping is provided for reference.

1.8.4 1000M Ethernet

Features one 10/100/1000M Ethernet port via RJ45 connector (Cat6 compatible).

1.8.5 EtherCAT

Includes one EtherCAT port via RJ45 connector.

1.8.6 HDMI

Features one HDMI Type A port supporting 4Kp60 resolution.

1.8.7 USB 2.0

Provides one USB 2.0 Type A port with 480Mbps speed.

1.8.8 USB 3.0

Provides two USB 3.0 Type A ports with 5Gbps speed.

1.8.9 SMA Connectors

Two SMA connectors are available for Wi-Fi/BT and 4G antennas.

1.8.10 I/O Modules

The ED-PLC2010 supports a wide range of I/O modules for Digital Input (DI), Digital Output (DO), Analog Input (AI), and Analog Output (AO) functions.

1.9 PLC Startup

The PLC typically starts within 30 seconds. The system status is indicated by the RUN and ERR indicators.

2. External Module Installation

Instructions for installing external modules.

2.1 4G/Wi-Fi Module Installation

1. Install the 4G/Wi-Fi module.

2.2 Micro SD Card Installation

1. Insert the Micro SD card into the designated slot.

2.3 Nano SIM Card Installation

Install the Nano SIM card for 4G connectivity.

1. Insert the Nano SIM card into the SIM slot.

3. Wiring and I/O Connections

Details on wiring the PLC and I/O modules.

3.1 PLC Wiring

Connect power and communication cables to the ED-PLC2010.

1. Connect the power supply.
2. Connect communication cables (e.g., Ethernet, RS232/RS485).

3.2 I/O Wiring

Connect I/O signals to the appropriate modules.

1. Wire I/O signals to the DIN/DOUT/AIN/AOUT terminals.
2. Ensure correct polarity and signal types are used for DIN/DOUT modules.

4. System Configuration

Configuration steps for the ED-PLC2010.

4.1 General Configuration

Refer to Section 1.8 for I/O and interface details. Ensure proper power supply connection (Section 1.8.2).

4.2 Operating System Installation

The ED-PLC2010 can run operating systems like Raspberry Pi OS.

4.2.1 Raspberry Pi OS (Desktop)

Install the Desktop version of Raspberry Pi OS for a graphical interface.

4.2.2 Raspberry Pi OS (Lite)

Install the Lite version for headless operation or minimal resource usage.

5. CODESYS Programming

This section details how to program the ED-PLC2010 using the CODESYS development environment.

5.1 CODESYS IDE Installation

The CODESYS IDE (version 3.5.19 or later) is required for programming. It runs on Windows PCs (Windows 10, Windows 11 64-bit).

1. Download CODESYS IDE from the official CODESYS store: http://store.codesys.cn/codesys/store/detail.html?productId=58
2. Run the installer and follow the on-screen prompts.
3. Click "Install" to begin the installation.
4. Click "Finish" upon completion.

5.2 PLC Configuration with CODESYS

Configure the ED-PLC2010 device within the CODESYS environment.

5.2.1 Ethernet Configuration

Connect the PC and the ED-PLC2010 via Ethernet. The PC IP is typically 192.168.0.99, and the PLC Ethernet IP is 192.168.0.100.

1. Connect the ED-PLC2010's Ethernet port to your PC.
2. Access the PLC's web interface at http://192.168.0.100:8100 to manage PLC settings.
3. Download the device description file (.xml) for the ED-PLC2010 from the EDA Technology website or provided resources.
4. Download the device description file for the ED-EIOBRG-EC module.

5.2.2 Adding Devices in CODESYS

Add the ED-PLC2010 and I/O modules to your CODESYS project.

1. In CODESYS, create a new project or open an existing one.
2. Add the ED-PLC2010 as a device, typically by selecting its controller type and specifying its IP address (192.168.0.100).
3. Add the ED-EIOBRG-EC device description file to CODESYS.
4. Add the ED-PLC2010 I/O modules to the project structure.

5.3 I/O Configuration with CODESYS

Configure the I/O modules connected to the ED-PLC2010.

5.3.1 E-bus I/O Configuration

Configure E-bus I/O modules (e.g., ED-PLC2010 I/O modules) via CODESYS.

1. Add the ED-PLC2010 I/O device to the CODESYS project.
2. Configure the I/O mapping and parameters as needed.
3. Download the project to the PLC.

5.3.2 EtherCAT I/O Configuration

Configure EtherCAT I/O modules.

1. Add the EtherCAT Master to the CODESYS project.
2. Configure the EtherCAT network, typically using the 'eth1' interface.
3. Add EtherCAT slave devices (I/O modules) to the network.
4. Configure synchronization and cyclic data transfer.
5. Download the project to the PLC.

5.4 Digital Output (DO) Example

Example of controlling a digital output using CODESYS.

5.4.1 DO Module Configuration

Configure a DO module (e.g., 8 PNP outputs).

1. Map the output variable (e.g., %QX16.0) to the desired physical output.
2. Use a timer (TON) for blinking or timed output control.

PROGRAM PLC_PRG
VAR
    TON_TIME : TON; // Timer instance
    Light_Output : BOOL := FALSE; // Output state
END_VAR

// Timer logic
TON_TIME(IN := NOT TON_TIME.Q, PT := T#0.5S);

IF TON_TIME.Q THEN
    Light_Output := NOT Light_Output;
END_IF

// Assign output state to physical output
%QX16.0 := Light_Output;

// Reset timer when not needed (e.g., on PLC stop)
// TON_TIME(IN := FALSE);

This example toggles an output every 0.5 seconds.

5.5 PLC Control

Control the PLC's operation.

5.5.1 Start/Stop and Update

1. Start/Stop: Use the STOP/START button on the device or via the CODESYS interface to start or stop the PLC program.
2. Update: Use the UPDATE button or interface for firmware updates.

5.5.2 USB Update

Update the PLC application via USB.

1. Prepare the update file (e.g., Application.app, Application.crc).
2. Copy the update files to a USB drive.
3. Insert the USB drive into the PLC. The PLC will detect the update.
4. Monitor the UDISK DETECT and UDISK BUSY indicators.
5. The PLC will automatically reboot after a successful update.
6. Use the STOP/START, ERR, IMP, UPDATE, or UDISK RM buttons as needed for control and maintenance.

6. Troubleshooting and FAQs

Common issues and solutions for the ED-PLC2010.

6.1 IP Configuration

Ensure correct IP settings for network communication.

6.2 Ethernet

Verify Ethernet cable connections and IP addresses.

6.3 Wi-Fi

Check Wi-Fi module installation and network credentials.

6.4 4G

Ensure the 4G SIM card is properly inserted and has network coverage.

6.5 RTC

The Real-Time Clock maintains system time.

6.6 RS232/RS485

Verify serial port settings (baud rate, data bits, parity) and wiring.

6.6.1 Using picocom on Linux

picocom is a serial communication tool for Linux.

Install picocom:

sudo apt-get install picocom

6.6.2 RS232 Communication

The ED-PLC2010 has two RS232 ports, mapped to COM1 and COM3 (e.g., /dev/com1, /dev/com3).

To connect to COM1 at 115200 baud:

picocom -b 115200 /dev/com1

6.6.3 RS485 Communication

The ED-PLC2010 has two RS485 ports, mapped to COM2 and COM4 (e.g., /dev/com2, /dev/com4).

To connect to COM4 at 115200 baud:

picocom -b 115200 /dev/com4

6.7 CODESYS Connection Issues

Troubleshoot connection problems between CODESYS and the PLC.

6.7.1 Network Connection

Ensure the PC and PLC are on the same network (e.g., 192.168.0.x).

1. Connect the PC and PLC via Ethernet.
2. Access the PLC web interface at http://192.168.0.100:8100.
3. Verify the PLC's IP address and network settings.
4. Ensure no firewall is blocking communication.

6.7.2 Device Scanning and Communication

If the PLC is not found:

1. Check the PLC's IP address and ensure it is reachable from the PC.
2. Verify that the correct device description files (.xml) are installed in CODESYS.
3. Ensure the PLC is running and accessible.
4. Restart the CODESYS application and the PLC.