Saia Burgess PCD4. U100 kit PCD4 controller upgrade tool

Saia Burgess PCD4. U100 kit PCD4 controller upgrade tool

Product foundation and core positioning

Product identity: PCD4.U100 kit is an old system upgrade tool launched by Saia Burgess. Its core purpose is to migrate traditional PCD4 controller systems to more advanced PCD2.M5xxx or PCD3.Mxxxx (NT-OS firmware version ≥ 1.10.16) platforms, achieving performance improvement, functional expansion, and long-term maintenance of old systems.

Core advantage: During the upgrade process, the original PCD4 I/O module functionality can be retained, while supporting the expansion of new PCD2/3 series I/O, communication, or storage modules without completely replacing the original hardware, reducing upgrade costs and risks.

Upgrade core requirements (hardware+software)

（1） Hardware requirements

Category specific requirements and key explanations

The firmware versions of target CPUs PCD2.M5xxx (with NT-OS) and PCD3.Mxxxx (with NT-OS) must be ≥ 1.10.16

The dedicated cables PCD2.K106 (compatible with PCD2.M5xxx) and PCD3.K116/PCD3.K106 (compatible with PCD3. Mxxxx) must be connected to the CPU module using specified cables

Compatible with I/O modules PCD4. W100, PCD4. W300, PCD4. W400, PCD4. W500, and PCD4. W600, which can be migrated and used normally. Some require program adaptation

Module PCD4. HXxx cannot be used after upgrading the entire series and needs to be replaced

Hardware versions B and above of the power module may damage the PCD4.U100 module

Replace the onboard serial port of the new CPU with a serial port. The original PCD4 serial port is not supported and needs to be replaced with a new serial port

（2） Software requirements

Software name and version require necessary operations

Saia PG5 ® 1.4.300 (Patch15 and above required) or 2.0.150 (SP1 and above required) versions lower than this are not compatible with upgrade features

FBox/FB activation requires running "Enable Fboxes PCD4. U100. exe" to activate and use the corresponding function block of PCD4 I/O

Project upgrade requires migration from old PG3/PG4. Before migration, the project needs to be backed up and CPU specific functions removed

Upgrade key configurations (addressing mode+serial port)

（1） Two addressing modes (core differentiation)

Addressing Mode Address Setting New I/O Expansion Capability Address Conflict Explanation Applicable Scenarios

Mode 1: PCD4 I/O starting address=0. Cannot add new PCD2/3 I/O modules. The I/O addresses of PCD4 and PCD2/3 conflict and cannot be used simultaneously. No need to expand new modules, only the original I/O functions are retained

Mode 2: Starting address of PCD4 I/O=256. Up to 8 new PCD2/3 I/O modules can be added. The overall address of PCD4+256 (including watchdog address) does not conflict and requires expansion of new modules to increase system I/O capacity

Mode switching method: Set through the addressing switch on the back of the PCD4 module, with a total of 4 gears corresponding to different CPUs and expansion scenarios:

Gear 0: Suitable for PCD2.M5xxx without expansion or PCD3.Mxxxx with expansion, address 0, no new I/O expansion;

Gear 1: Suitable for PCD3.M3xxx without expansion, address 0, no new I/O expansion;

Gear 2: Compatible with PCD3.Mxxxx with extensions or PCD2.M5xxx without extensions, address 256, supports 8 new I/Os;

Gear 3: Compatible with non expandable PCD3.Mxxxx, address 256, supports 4 new I/O.

Watchdog Address Change: In Mode 2, the watchdog address of PCD4 is changed to 511/767, and the new CPU watchdog address is 255, both of which are independent and conflict free.

（2） Serial communication configuration

The serial port of the original PCD4 CPU does not support migration and needs to be replaced with the onboard serial port of the new PCD2/3 CPU;

If a new PCD2/3. Fxxx communication module is added, the I/O address range will start from 256 and the new address needs to be adapted in the user program.

User program adaptation (Fupla+IL programming)

（1） Fupla programming adaptation

Automatic update: Install Saia PG5 that meets the requirements ®  After version, when opening the original project, the FBox corresponding to PCD4 I/O will automatically update without manual modification;

Required library version: Ensure that the "Analogue Module" version is ≥ SP2.6.150 and the "HVC Analogue" version is ≥ SP2.5.316 (PG5) ® 1.4) or ≥ SP2.6.150 (PG5) ® 2.0）；

Caution: PG5 cannot be used ® Device configurator 2.0 for media mapping.

（2） IL programming adaptation

Basic operation required: Add a 2-second startup delay

Reason: The new CPU runs faster and needs to reserve initialization time for the PCD4 I/O module;

Implementation method: Create a Wait_2s.src file, write the specified IL directive, and place it at the forefront of the link order;

Core code:

plaintext

$INIT 

ACC H LD T 0 T#2s 

LOOP: STH T 0 JR H LOOP ACC H 

$ENDINIT

Adaptation requirements for each module

|Model of PCD4 module | Adaptation operation | Key instructions|

|W100 | Add NOP instruction to read/write instructions | Compensate for the impact of CPU acceleration to ensure stable A/D conversion (requires 30 μ s wait)|

|W300 | No need to modify code | Fully compatible with new platforms, just migrate directly|

|W400 | No need to modify code | Fully compatible with new platforms, just migrate directly|

|W500 | Add initialization instruction in XOB16 | Call Control and config function blocks, specify base address and configure DB|

|W600 | Add initialization instruction to XOB16 | Consistent with W500 operation, each module needs to be configured separately|

Multi W500/W600 module adaptation: When multiple modules are used simultaneously, the Control command (restart module) needs to be executed sequentially in XOB16, followed by the config command (configure parameters) uniformly. The total initialization time should not exceed 3 seconds.

Complete upgrade process

Backup the original PCD4 project files and confirm that the original project can be used normally (upgrading is not recommended if there is no original project);

Disconnect the power supply, remove the old PCD4 CPU, and keep the power module;

Insert the PCD4.U100 module into the vacant slot of the original PCD4 CPU;

Connect the PCD4.U100 to the target PCD2/3 CPU using a dedicated cable;

Select the addressing mode through the switch on the back of the PCD4 module (depending on whether to expand new I/O);

Install Saia PG5 that meets the requirements ®  Version, activate PCD4 FBox/FB;

Migration and updating of user programs (Fupla automatic adaptation/IL manual addition of delays and instructions);

In PG5 ®  Select the target CPU model in the hardware/device configurator;

Download the program to the CPU, power it on for testing, and confirm that the original I/O and new expansion functions are functioning properly.

Differences and precautions in the old system

Exception handling changes:

XOB5: New CPU has no/IOQUIT signal, XOB5 is invalid and needs to be commented in the program;

XOB1: detects I/O bus power failure (response time of about 500ms), and PCD4. N210 also supports ± 15V voltage monitoring;

Operation taboos:

Do not use old versions of power modules (lower than version B) to avoid damaging the equipment;

Do not mix the I/O address 0 of PCD4 and PCD2/3 (in Mode 1);

When IL programming does not update FB, a 2-second startup delay must be added, otherwise the module cannot initialize properly.