CompactLogix Indexing Motion Accelerator Toolkit Quick Start Hardware Selection Plan System Layout Plan System Wiring Motion Logix Integration Motion FactoryTalk View Integration Motion System Application Guide
Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com) describes some important differences between solid state equipment and hard-wired electromechanical devices.
Where to Start Follow the path below to complete your CompactLogix Indexing Motion application.
Where to Start Notes: 4 Publication IASIMP-QS011B-EN-P — January 2009
Table of Contents Preface Introduction . . . . . . . . . . . . . . . . Required Software . . . . . . . . . . . . Conventions Used in This Manual Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 10 10 11 What You Need. . . . . . . . . . . . . . . . . . . . . . . Follow These Steps . . . . . . . . . . . . . . . . . . . .
Table of Contents Load and Open Logix Application File Configure Your Logix System . . . . . . . Using the DeviceNet Tag Generator . . Configure Axis Properties . . . . . . . . . . Configure Logix Communications . . . . Save and Download Your Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 53 55 59 61 62 Before You Begin . . . . .
Table of Contents Appendix B PhaseManager for S-88 Users Making Changes to the Program Template . . . . . . . . . . . . . 107 Making Changes to Operator Interface Screens . . . . . . . . . . 112 Appendix C Troubleshooting Publication IASIMP-QS011B-EN-P — January 2009 Troubleshooting the Manual Cycle . . . . . . . . . . . . . . . . . . . 115 Troubleshooting the Automatic Cycle . . . . . . . . . . . . . . . . .
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Preface Introduction This quick start provides examples of using a CompactLogix controller to connect to multiple devices (servo drives, motors, and HMI) over the Ethernet/IP network in a CompactLogix Indexing Motion application. These examples were designed to get devices installed and communicating with each other in the simplest way possible. The programming involved is not complex, and offers easy solutions to verify that devices are communicating properly.
Preface Required Software Conventions Used in This Manual To complete this quick start, the following software is required. Rockwell Automation Software Cat. No. Minimum Version RSLogix 5000 Mini Edition 9324-RLD200ENE 17 FactoryTalk View Studio for Machine Edition (Includes RSLinx Enterprise and RSLinx Classic) 9701-VWSTMENE 5.00 Ultraware Drive Configuration Software for the Ultra3000/5000 2098-UWCPRG 1.64 RSNetWorx for DeviceNet 9357-DNETL3 8.00.
Preface Additional Resources Resource Description http://www.ab.com Provides access to the Allen-Bradley website. http://rockwellautomation.com/knowledgebase Provides access to self-service support. http://www.rockwellautomation.com/components/connected Provides access to the Connected Components website.
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Chapter 1 CD Installation In this chapter, you install the Kinetix Accelerator Toolkit program CD to your personal computer. All of the necessary files are transferred to the personal computer for ease of use.
Chapter 1 CD Installation Install the Kinetix Accelerator Toolkit Program Follow these steps to download and install the Kinetix Accelerator Toolkit program from the CD. 1. Place the Kinetix Accelerator Toolkit CD, publication IASIMP-SP004, in your CD tray. 2. The installation program should run automatically. If not, browse to the CD and run the file Setup.exe. 3. Follow the on-screen instructions to complete the program installation.
CD Installation Chapter 1 The Kinetix Accelerator Toolkit program starts. Follow the steps in the remaining chapters of this manual to complete your system configuration.
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Chapter 2 Hardware Selection In this chapter, you make your motion application hardware selection. You can select from the basic motion control panels, or use Motion Analyzer software to size your servo drive and motor. The basic motion control panels can be modified with up to four axes, a different PanelView Plus terminal, and other optional equipment. Before You Begin • Determine your base motion system input voltage.
Chapter 2 Hardware Selection Follow These Steps Complete the following steps to select your motion system hardware.
Hardware Selection Chapter 2 Installing Motion Analyzer Software Motion Analyzer software is a comprehensive motion control tool with application analysis software used for sizing your application. You can download and install Motion Analyzer software from the Web, or install Motion Analyzer software from the Kinetix Accelerator Toolkit CD, publication IASIMP-SP004. Download Motion Analyzer Software From the Web Follow these steps to download and install Motion Analyzer software. 1.
Chapter 2 Hardware Selection Install Motion Analyzer Software from the Kinetix Accelerator Toolkit CD Follow these steps to install Motion Analyzer software from the CD. 1. From the Start menu, choose Programs>Rockwell Automation>Simplification>Kinetix Accelerator Toolkit. The Kinetix Accelerator Toolkit program starts. 2. From the toolkit menu, choose KAT Common Info>Required Program Software. 3. Open the 2 - Motion Analyzer folder.
Hardware Selection Chapter 2 4. Double-click MotionAnalyzer 4.x.exe. 5. Follow the on-screen instructions to complete the program installation. Open Motion Analyzer Software Follow these steps to run the Motion Analyzer software. 1. From the Start menu, choose Programs>Rockwell Automation>Motion Analyzer>Motion Analyzer. The starting selection window opens.
Chapter 2 Hardware Selection 2. Use the Product Family drop-down menu to select Ultra3000. (Kinetix 6000 is the default selection.) 3. Click Application Data. 4. Complete the system profile for your application. TIP For motor/drive performance specifications, refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001. For Motion Analyzer labs, refer to the Motion Analyzer Training Folder on the Kinetix Accelerator Toolkit CD, publication IASIMP-SP004.
Hardware Selection Chapter 2 Review Basic Panel Component Listings The tables in this section include servo drives and motors, CompactLogix controller, PanelView Plus terminal (HMI), and accessory components for 400/460V and 200/230V systems. Review the basic component listings and compare with your specific application needs. CompactLogix L31, 400/460V Base System # Used Components 1 Description Hoffman Rittal 1524 x 914 x 304 mm (60 x 36 x 12 in.
Chapter 2 Hardware Selection CompactLogix L31, 200/230V Base System # Used Components 1 Input power 1 Hoffman Rittal 1219 x 609 x 304 mm (48 x 24 x 12 in.) 2094-AL50S 230V, 50 A LIM module 140U-H-RVM12R Through-the-door disconnect Line Filter 2090-XXLF-X330B 3-phase, 30 A AC line filter Line Interface Module (LIM) 3 Ultra3000 Servo Drive Servo Drive 2098-DSD-010X-DN 1 kW output, indexing, DeviceNet communication option 3 Motors MP-Series Low Inertia MPL-A310P-MK22AA 0.
Hardware Selection Chapter 2 CompactLogix L23E, 200/230V Base System # Used Components 1 Description Hoffman Rittal 1219 x 609 x 304 mm (48 x 24 x 12 in) 2094-AL50S 230V, 50 A LIM module 140U-H-RVM12R Through-the-door disconnect Line Filter 2090-XXLF-X330B 3-phase, 30 A AC line filter Enclosure and panel (HxWxD, approx.) 1 1 Cat. No.
Chapter 2 Hardware Selection Verify Base System Performance Specifications This section provides system combination information for the Ultra3000 drives when matched with MP-Series low-inertia motors. Included are motor power, feedback, and brake cable catalog numbers, system performance specifications, and torque/speed curves. Refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001, for additional motor/drive performance specifications.
Hardware Selection Chapter 2 Ultra3000 Drives/MP-Series Low Inertia Motor Curves Publication IASIMP-QS011B-EN-P — January 2009 27
Chapter 2 Hardware Selection Select Add-In Components Follow these steps to add components to your base system. 1. From the toolkit menu, choose KAT Common Info>Add-In Application Packages. 2. Identify additional components listed in the Add-In Application Packages folder that you would like to add to your system. 3. If necessary, identify additional components not listed in the Add-In Application Packages folder. Contact your local Allen-Bradley representative for more information.
Chapter 3 Plan System Layout In this chapter, you layout the system components selected in Chapter 2. Use the CAD drawings supplied on the Kinetix Accelerator Toolkit CD, publication IASIMP-SP004, to add or remove components to and from the basic motion control panel system. For a copy of the CD, contact your local Rockwell Automation distributor or sales representative. Before You Begin • Complete the Kinetix Accelerator Toolkit CD installation. (Refer to Chapter 1.
Chapter 3 Plan System Layout Follow These Steps Complete the following steps to plan your system layout within the enclosure.
Plan System Layout Chapter 3 Load Basic System CAD Drawings The Kinetix Accelerator Toolkit CD provides CAD drawings, in DXF format, to assist in planning the layout of your system. The drawings are designed to optimize panel space and to minimize electrical noise. Follow these steps to locate the CAD files from the Kinetix Accelerator Toolkit CD. 1. Open the Kinetix Accelerator Toolkit program. From the Start menu, choose Programs>Rockwell Automation>Simplification>Kinetix Accelerator Toolkit. 2.
Chapter 3 Plan System Layout Verify Your Basic Panel Layout The basic motion control panel layout is shown below. Included is a three-axis Ultra3000 drive system with Line Interface Module (LIM), PanelView Plus 600 terminal, and CompactLogix controller with DeviceNet interface module. Verify that your system matches this diagram. If it does not match, follow the instructions in Modifying Your Motion Panel Layout on page 33.
Plan System Layout Chapter 3 Modifying Your Motion Panel Layout Follow the steps in this section if you do not use the basic motion control panel as is and want to modify your motion panel layout. 1. From the basic motion control panel CAD drawing, remove the equipment you do not need for your application. 2. Open the CAD drawings of optional equipment you would like to add to your system. From the Toolkit menu, choose KAT Common Info>Add-In Application Packages. 3.
Chapter 3 Plan System Layout Downloading Other Allen-Bradley CAD Drawings Follow these steps if you want to download other Allen-Bradley product CAD drawings. 1. Open your browser and go to http://ab.com/e-tools. The Configuration and Selection Tools webpage opens. 2. Enter the Catalog Number of the product. 3. Click Submit. The Configuration Results dialog opens. 4. Click DXF, AutoCad Drawing 2-D. 5. Download and save the file.
Chapter 4 Plan System Wiring In this chapter, you plan the cable layout for your system components placed in Chapter 3. Use the CAD drawings supplied with the Kinetix Accelerator Toolkit CD to assist in the routing of wires and cables for your system components. For a copy of the CD, contact your Rockwell Automation distributor or sales representative. Before You Begin • Complete the Kinetix Accelerator Toolkit CD installation. (Refer to Chapter 1.) • Complete your system hardware selection.
Chapter 4 Plan System Wiring • Ultra3000 Digital Servo Drive Installation Manual, publication 2098-IN003 • Line Interface Module Installation Instructions, publication 2094-IN005 • System Design for Control of Electrical Noise, publication GMC-RM001 • System Design for Control of Electrical Noise Video, publication GMC-SP004 • Documentation that came with your other Allen-Bradley products Refer to the Literature Library (http://literature.rockwellautomation.com) for access to publications.
Plan System Wiring Chapter 4 Load Basic System CAD Diagrams The Kinetix Accelerator Toolkit CD, publication IASIMP-SP004, provides CAD diagrams, in DWG format, to assist in planning your system wiring. The diagrams are designed to optimize panel space and to minimize electrical noise. Follow these steps to locate the CAD files for the Kinetix Accelerator Toolkit CD. 1. Open the Kinetix Accelerator Toolkit program.
Chapter 4 Plan System Wiring 5. Use your CAD program to open these and other wiring diagram CAD files. • CIMAT_Lxx_xxx_1_POWER_DISTRIBUTION.dwg • CIMAT_Lxx_xxx_2_CONTROL_POWER.dwg • CIMAT_Lxx_xxx_3_LIM_DISTRIBUTION.dwg • CIMAT_Lxx_xxx_4_DRIVE1_IO.dwg • CIMAT_Lxx_xxx_5_DRIVE2_IO.dwg • CIMAT_Lxx_xxx_6_DRIVE3_IO.dwg • CIMAT_Lxx_xxx_7_NETWORK_CONNECTIONS.dwg • CIMAT_Lxx_xxx_8_PLC_IO.dwg • CIMAT_Lxx_xxx_9_TERMINAL_DETAIL.dwg • CIMAT_Lxx_xxx_10_CONNECTOR_DETAIL_CN1.
Plan System Wiring Chapter 4 Route Cables for Your Motion Panel The base system enclosure diagrams for the three-axis motion control panel, including noise zones, is shown below. The enclosure CAD drawings are provided as examples of best-practices techniques used to minimize electrical noise, as covered in the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001.
Chapter 4 Plan System Wiring Lay Out DeviceNet and Ethernet Cables A sample DeviceNet and Ethernet cable diagram is shown below. The diagram provides designators that coordinate with the panel layout diagram, indicating where to route your DeviceNet and Ethernet cables.
Chapter 5 Motion Logix Integration In this chapter, you configure your servo drives, your DeviceNet network, and your RSLogix 5000 application file. Logix application files (.acd) are included in the Controller Program Files folder on the Kinetix Accelerator Toolkit CD. You can choose a: • 1-axis pre-configured CompactLogix L2x file. • 1-, 2-, 3-axis pre-configured CompactLogix L3x file.
Chapter 5 Motion Logix Integration Follow These Steps Complete the following steps to configure your CompactLogix Indexing Motion application.
Motion Logix Integration Chapter 5 Configure Your Servo Drives Follow these steps to configure your Servo Drives. IMPORTANT Before applying power to the Ultra3000 servo drive, you must set the node addresses for the DeviceNet network. If you have already applied power to the drive, you must cycle power after changing the network settings. 1. Use the rotary switches on the front of the Ultra3000 servo drive (labeled MSD and LSD) to set the desired DeviceNet node address.
Chapter 5 Motion Logix Integration 7. Double-click the drive symbol in the On-Line section to view its current settings. You may wish to click Reset EEPROM to Factory Settings if you are not sure what parameters have been previously changed in the drive. IMPORTANT Verify that you removed the ‘Enable’ input in the steps above. The drive may enable and run if the Enable signal is present. 8. Carefully use the pull-down menu to select the proper Motor Model from the list. 9.
Motion Logix Integration Chapter 5 14. For the Logic Command Mask, click the down arrow to view the pull-down list. 15. Check all the boxes all the way down to the bottom. Use the scroll bar on the right to reach them all. Checking these boxes gives access to all the commands to the drive over the DeviceNet network. This eliminates the need for additional I/O wiring, drive configuration, and PLC programming. 16. Change the Enable Behavior selection to Both.
Chapter 5 Motion Logix Integration 20. Exit Ultraware. IMPORTANT Repeat all steps in this section for additional Ultra3000 servo drives. Configure Your Logix DeviceNet Module Follow these steps to configure your Logix DeviceNet module. Commission an Out-of-Box DeviceNet Module IMPORTANT This section is for commissioning an out-of-box DeviceNet scanner module. You do not need to perform the steps in this section if your scanner is already configured. 1.
Motion Logix Integration Chapter 5 6. Click Browse to begin browsing to your DeviceNet module. 7. Select the appropriate RSLinx Classic driver and browse to your controller. 8. Under Backplane, expand the Local 1769 Bus Adapter and the 1769 Bus. 9. Expand the 1769-SDN scanner module. 10. Expand Port2 until you see the available DeviceNet nodes. 11. Highlight Node 63, the DeviceNet module. 12. Click OK (not shown) located at the top right of the window. 13. Click Yes for any additional prompts. 14.
Chapter 5 Motion Logix Integration 2. When the software opens, click the Online button to go online to your network. 3. Browse to your controller. 4. Under Backplane, expand the Local 1769 Bus Adapter and the 1769 Bus. 5. Under the 1769-SDN, highlight Port2. 6. Click OK to go online. 7. Click OK again to begin searching for all available network nodes. 8. Click Cancel after all available nodes have been identified. You don’t have to wait for it to search for nodes you don’t have in your system. 9.
Motion Logix Integration Chapter 5 12. Double-click the 1769-SDN scanner module to begin configuring the DeviceNet module. 13. Click the Module tab and select Download if prompted. This erases any settings in the scanner if it was ever previously used. 14. Set the 1769-SDN scanner module settings at the bottom of the dialog box as appropriate for your system. 15. Click Apply. 16. Click the Scanlist tab. 17. Automap all available devices into the scanner by using the >> button.
Chapter 5 Motion Logix Integration Additional Information for Single and Multi-Axis Systems The following information about DeviceNet is for reference only. No action is required. However, if you do map additional axes, be sure to close RSNetWorx for DeviceNet software before proceeding. Additional axes (drives) can be automapped as shown in step 17 into the DeviceNet module’s Scanlist. The Input tabs look similar, but contain more data.
Motion Logix Integration Chapter 5 The Output tabs also look similar, but contain more data. Single-Axis System Double-Axis System Notice that no custom data mapping is required of the data. Even though the words of data overlap and multiple drives share the same word boundary, this is handled by the Logix application code provided on the toolkit with no manual action required.
Chapter 5 Motion Logix Integration Select Your Logix Application File Choose the correct file for your system. Logix Platform Logix File Name Description CompactLogix L2x CIML2x_1axis_v00x.acd CompactLogix L2x file pre-configured for single-axis Ultra3000 drive system. CIML3x_1axis_v00x.acd CompactLogix L3x file pre-configured for single-axis Ultra3000 drive system. CIML3x_2axis_v00x.acd CompactLogix L3x file pre-configured for two-axis Ultra3000 drive system. CIML3x_3axis_v00x.
Motion Logix Integration Chapter 5 The RSLogix 5000 software launches and your application file opens. Configure Your Logix System Follow these steps to configure your Logix system to your needs. Select Your CompactLogix Controller 1. Choose Edit>Controller Properties. The Controller Properties window opens. 2. Select the General tab. 3. Verify that the controller Type matches your system. If not, perform the following steps. a.
Chapter 5 Motion Logix Integration Changing the Slot Number of the DeviceNet Module (Optional) If you are using a pre-configured CompactLogix application file (CIMLxx_xaxis_v00x.acd), your Logix DeviceNet module is configured in slot 5. If this does not match your actual hardware configuration, follow the steps in this section to change the assigned slot number. 1. Scroll down to the bottom left of the RSLogix 5000 Explorer window and locate the I/O Configuration folder. 2.
Motion Logix Integration Chapter 5 In this example, GenericMachine_COND is renamed SorterMachine_COND. Using the DeviceNet Tag Generator IMPORTANT You do NOT need to perform the steps in this section if the Ultra3000 drives were automapped to the DeviceNet scanner module in order, starting at node address 01. Follow the steps in this section to enable communications to the axes of motion. Open the DeviceNet Tag Generator Follow these steps to open the DeviceNet Tag Generator. 1.
Chapter 5 Motion Logix Integration 3. For wizard Step 2, locate and double-click the DeviceNet scanner configured earlier in this chapter. 4. For wizard Step 3, locate and double-click the DeviceNet configuration file saved earlier in this chapter. 5. For wizard Step 4, locate and double-click the DeviceNet scanner node. 6. For wizard Step 5, click Generate Tags to finalize the process.
Motion Logix Integration Chapter 5 7. Click Yes to the prompt about inserting tags and logic. 8. There may be a warning that tags were created, but close the DeviceNet Tag Generator tool and return to your RSLogix 5000 project. 9. The program logic that was created can be found in the Tasks folder of the project. Do not make any changes to these programs or logic, as your DeviceNet nodes may quit responding.
Chapter 5 Motion Logix Integration 3. Scroll to the bottom of the tag editor and locate the tags created by the Tag Generator tool. The name of the tags will start with the name you gave the DeviceNet scanner, ‘Scanner’ in our case. TIP • The ‘Nxx’ indicates the DeviceNet node address assigned to each component. • The ‘I’ or ‘O’ indicates whether the data is an Input or an Output in reference to the DeviceNet scanner module. • Scanner Inputs are the status coming back from the DeviceNet components.
Motion Logix Integration Chapter 5 Configure Axis Properties Follow these steps to configure the axes of motion. Modify Axis Names The CompactLogix Indexing Motion application file (CIMLxx_xaxis_v00x.acd) contains program code for up to three axes, however, you may want to rename the axes from AXIS_0x to something more meaningful for your application. Providing useful names for these axes can aid in troubleshooting your machine.
Chapter 5 Motion Logix Integration 9. Repeat step 4…step 8 for each additional axis. The result might look like this. Set the Axis k Constant The CompactLogix Indexing Motion application file (CIMLxx_xaxis_v00x.acd) allows you to program all motion instructions in user units (inches or degrees, for example) instead of encoder counts. You will need to set the conversion factor (or k constant) from user units to encoder counts to allow the drive to be commanded properly.
Motion Logix Integration Chapter 5 5. Repeat step 3 and step 4 for each additional axis. TIP For a better understanding of the code provided in the sample file, as well as the benefits of PhaseManager, refer to Appendix A, CompactLogix Base Program Overview on page 95. Configure Logix Communications This procedure assumes that your communication method to the Logix controller is using the Ethernet protocol. It is also assumed that your Logix Ethernet module has already been configured.
Chapter 5 Motion Logix Integration The IP address shown is an example. Yours will be different. TIP If your Logix Ethernet module is already configured, the IP address is displayed on the module. 8. Click OK. 9. Click Close in the Configure Drivers window. 10. Choose Communication>RSWho. The RSWho window opens. 11. Expand the 1769 Ethernet Port and then expand the Backplane. 12. Verify that you can browse to your Logix controller. If not, repeat step 1…step 11, checking for any errors. 13.
Motion Logix Integration Chapter 5 3. Choose Communications>Who Active. The Who Active window opens. 4. Browse to your Logix controller and click Set Project Path. 5. Verify that the key switch on your controller module is in the REM (remote) position. 6. Click Download. The Download window opens. 7. To send the program to the Logix controller, click Download. 8. Verify that the three Logix DeviceNet module indicators are green. (Some may be flashing.) 9.
Chapter 5 Motion Logix Integration Notes: 64 Publication IASIMP-QS011B-EN-P — January 2009
Chapter 6 Motion FactoryTalk View Integration In this chapter, you configure your FactoryTalk View ME application file. FactoryTalk View ME application files (.apa) are included in the Kinetix Accelerator Toolkit. You can choose: • 1-, 2-, or 3-axis pre-configured FactoryTalk View ME application file for PanelView Plus 600 terminals. • 2-axis generic base application file for a variety of PanelView Plus terminals.
Chapter 6 Motion FactoryTalk View Integration Follow These Steps Complete the following steps to configure your FactoryTalk View ME Indexing Motion application.
Motion FactoryTalk View Integration Chapter 6 Select Your FactoryTalk View ME Application File PanelView Terminal PanelView Plus 600 FactoryTalk View ME File Name Description CIMME_1axis_U3k_PVP600_v00x.apa PanelView Plus 600 terminal pre-configured for single-axis Ultra3000 drive system. CIMME_2axis_U3k_PVP600_v00x.apa PanelView Plus 600 terminal pre-configured for two-axis Ultra3000 drive system. CIMME_3axis_U3k_PVP600_v00x.
Chapter 6 Motion FactoryTalk View Integration The Application Manager window opens. 5. Select Restore the FactoryTalk View Machine Edition application. 6. Click Next. Another Application Manager window opens. IMPORTANT Selecting Restore the FactoryTalk View Machine Edition application and FactoryTalk Local Directory will cause the local security settings on your personal computer to substitute for the security setting from the pre-configured application.
Motion FactoryTalk View Integration Chapter 6 Configure Local Communications The Local tab in Communications Setup reflects the view of the topology from the RSLinx Enterprise server on the development computer. In this example application, the development computer is communicating to the CompactLogix L32E controller via Ethernet network. Other CompactLogix controllers and communication networks can also be selected. Follow these steps to configure local communications. 1.
Chapter 6 Motion FactoryTalk View Integration The Communications Setup window opens. 9. Click the Design (Local) tab. 10. Select the CLX device shortcut. 11. Expand the RSLinx Enterprise tree to gain access to your CompactLogix controller. 12. Select your CompactLogix controller. 0, 1769-L32E is used in this example. The slot number is 0. Yours could be different. IMPORTANT RSLinx Enterprise will autobrowse to the controller if the controller is available on the network.
Motion FactoryTalk View Integration Chapter 6 Configure Target Communications The Target tab displays the offline configuration from the perspective of the device that is running the application and comprises the topology that is loaded into the PanelView Plus terminal. In this example application, the PanelView Plus terminal communicates to the same CompactLogix L32E controller via Ethernet. Follow these steps to configure target communications. 1.
Chapter 6 Motion FactoryTalk View Integration Adding Axes to the Project IMPORTANT If you have selected a pre-configured application with a specific axis count and it fits your application needs, skip this section and go to Modifying Axis Names beginning on page 77. The CIMME_U3k_PVPxxxx_v00x.apa file has two pre-configured axes for use. In this section you will add additional axes to your Ultra3000 drive system and the project file.
Motion FactoryTalk View Integration Chapter 6 2. Right-click Axis x Status and select Duplicate. The Save component name window opens. 3. Name the new parameter file. In this example, there are two existing pre-configured axes. We are duplicating and renaming the Axis 1 Status parameter file. The new name is Axis 3 Status. Yours could be different. 4. Click OK. 5. Double-click the Axis 3 Status parameter file created in step 3. The Axis x Status - CIMME_U3k_PVPxxxx_v00x/Parameters window opens.
Chapter 6 Motion FactoryTalk View Integration 6. Edit parameters 2 and 3. In this example: #2 = AXIS_02 becomes #2 = AXIS_03 #3 = SelectedAxis2 becomes #3 = SelectedAxis3 7. Choose File>Save. 8. Repeat step 2…step 7 as necessary for your axis count. 9. The pre-configured application files include HMI tags for up to four axes.
Motion FactoryTalk View Integration Chapter 6 3. Click the first empty row in the Tags editor window. Row 14 is used in this example. Yours could be different. 4. Enter ‘SelectedAxisx’ in the Name field. SelectedAxis5 is used in this example. Yours could be different. 5. Select String from the pull-down menu in the Tag Type field. 6. Select Memory in the Data Source Type field. 7. Enter ‘Axis x’ in the Initial Value field. Axis 5 is used in this example. Yours could be different.
Chapter 6 Motion FactoryTalk View Integration The Axis Selection display dialog box opens. 3. Right-click the last axis shown (Axis 2 for this example.) 4. Select Copy. 5. Right-click under Axis 2 (or the last axis shown) and select Paste. 6. Click the pasted axis (new Axis 2 in this example), drag and drop the axis in line beneath the others. 7. Right-click the new axis and select Properties. New Axis The Goto Display Button Properties window opens. 8. Click … to browse for the parameter file.
Motion FactoryTalk View Integration Chapter 6 11. Return to the Goto Display Button Properties window and select the Label tab. 12. Edit the text in the Caption field. In this example Axis 2 becomes Axis 3. 13. Click OK to close the Goto Display Button Properties window. 14. Verify that Axis Selection now includes your new axis (Axis 3 in this example.) 15. Repeat step 1…step 14 for each new axis and each of the AxisSelect displays identified in step 1.
Chapter 6 Motion FactoryTalk View Integration Edit Axis Shortcuts IMPORTANT Follow these steps to rename the axes in your FactoryTalk View ME program if you changed the names of the axes in your CompactLogix application file. In this example, AXIS_01 is renamed CONVEYOR and GenericMachine_COND is renamed SorterMachine_COND to match the changes in our Logix application in Chapter 5 Motion Logix Integration. 1. In FactoryTalk View ME software, expand the Explorer window to gain access to Parameters.
Motion FactoryTalk View Integration Chapter 6 3. Repeat step 2 for each SelectedAxisx HMI tag. Test the Project FactoryTalk View Studio lets you create and test individual displays or the entire project, so that you can navigate and test all the functionality before downloading your project to a terminal. IMPORTANT To test run the project, all communications must be configured first. Follow these steps to test your FactoryTalk View Studio project. 1. Choose Application>Test Application. 2.
Chapter 6 Motion FactoryTalk View Integration Download Fonts to the Terminal Because PanelView Plus terminals do not include the Arial Bold font when shipped but the FactoryTalk View ME applications require this font, it is necessary to download Arial Bold from your personal computer to the PanelView Plus terminal. Follow these steps to download fonts to the PanelView Plus terminal. 1. Apply power to the PanelView Plus terminal. 2.
Motion FactoryTalk View Integration Chapter 6 The Transfer Utility window returns. 9. Expand the Ethernet, Ethernet driver. 10. Select your PanelView Plus terminal. 11. Click Download. The font transfers to the terminal. Download the Project to a Terminal Follow these steps to download your FactoryTalk View Studio project. 1. Choose Application>Create Runtime Application. The Create Runtime Application window opens. 2. For Save as type:, select Runtime 5.0 Application (*.mer). 3.
Chapter 6 Motion FactoryTalk View Integration 5. Click the File Transfer Utility button on the tool bar. The Transfer Utility window opens. 6. Click … to browse for the runtime file. 7. Select CIMME_U3k_PVP1250_v001.mer. 8. Click Open.
Motion FactoryTalk View Integration Chapter 6 9. Browse for your PanelView Plus terminal. 10. Select Download. The file transfers to the PanelView Plus terminal. 11. Click OK. 12. Click Exit to close the Transfer Utility window. 13. Choose File>Close to close the application. Run the Project on a Terminal Follow these steps to run your project on the PanelView Plus terminal. 1. Apply power to the PanelView Plus terminal. 2.
Chapter 6 Motion FactoryTalk View Integration The Load Application window opens. 4. Scroll through the list of application files by using the up/down arrows and select the .mer file you intend to run. CIMME_U3k_PVP1257000_v001.mer is used in this example. 5. Click Load. The Replace Communications window opens. 6. Click Yes. If you click No, the communications settings from the project run previously will be used instead. The FactoryTalk View ME Station window returns. 7.
Chapter 7 Motion System Application Guide In this chapter, you are guided through the pre-configured FactoryTalk View ME application that interfaces with the pre-configured Logix program that controls your base motion system. You will run your motion system in Manual mode and Auto mode, and use the built-in axis status and diagnostics. Before You Begin • Complete your system hardware selection. (Refer to Chapter 2.) • Complete your system layout. (Refer to Chapter 3.) • Complete your system wiring.
Chapter 7 Motion System Application Guide Follow These Steps Complete the following display overview steps to run the pre-configured application and gain an understanding the general motion system operation.
Motion System Application Guide Chapter 7 Startup Display With power applied to your CompactLogix Indexing Motion system, and the Logix controller and PanelView Plus terminal in Run mode, the Auto Control (startup) display automatically opens on your PanelView Plus terminal. IMPORTANT If the Auto Control display is not visible or errors are reported on either the CompactLogix controller or PanelView Plus terminal, refer to previous chapters to check system wiring and configuration settings.
Chapter 7 Motion System Application Guide Use the Manual Control Display Follow these steps to home and jog the selected axis using the Manual Control display. 1. Press Manual on the Application Navigation Bar. The Manual Control display opens. When pressed, Assume Manual Control toggles with Release Manual Control. Actual Position and Actual Velocity indicators are present to assist you in your initial axis setup. Application Navigation Bar 2.
Motion System Application Guide Chapter 7 Use the Auto Control Display The Auto Control display lets you start, stop, hold, and restart the motion system. The state machine section provides the status of the current motion system phase state. Press Auto on the Application Navigation Bar. The Auto Control display opens. Start Button Stop Button Application Navigation Bar Start and Run State Actions Follow these steps to start your motion system and proceed to Run state.
Chapter 7 Motion System Application Guide 2. Press Start. If System Status Then The (green) Stopped state moves to Resetting and then to Aborted The system failed to reset. Go to step 3. The (green) Stopped state moves to Resetting and then to Idle Your system is ready to start. Go to step 4. 3. Check for power to drives, verify that you have provided a Drive Enable input to each of the drives and try the Start command again.
Motion System Application Guide Chapter 7 Use the Trend Display The Trend display lets you view current, actual velocity, and actual position trends of your motion system axes over time. Follow these steps to view torque feedback, actual velocity, and actual position trends. 1. Press Trend on the Application Navigation Bar. The trend selector display opens. 2. Select your trend of choice. The trend display opens. The Command Actual Velocity trend (shown) operates similarly to the other trend displays.
Chapter 7 Motion System Application Guide Use the Axis Status Display The Axis Status display shows general motion, axis, and drive status, and faults. Follow these steps to view status and fault indicators and to select the axis. 1. Press Status on the Application Navigation Bar. The Axis Status display opens. 2. Select a system Status or Fault category from the axis (left) window. The green indicator confirms your status/faults selection. 3. Monitor the status or fault indicators (right side and below.
Motion System Application Guide Chapter 7 Use the Fault Log Display The Fault Log display lets you monitor and/or log motion group, module, axis, or drive fault events. Follow these steps to monitor and/or log fault events. 1. Press Fault on the Application Navigation Bar. The Fault Log display opens. 2. Select a system Fault category from the Fault window (left). The green indicator confirms your fault selection. 3. Monitor the Fault Indicators (right). In this example, Axis Fault indicators are shown.
Chapter 7 Motion System Application Guide Use the Security Display The security feature of FactoryTalk View ME lets you limit privileges to the individuals that use the FactoryTalk View ME application. Refer to FactoryTalk View Machine Edition User’s Guide, Volume 1, publication VIEWME-UM004, for more information. The security display adds login and logout functions to the application.
Appendix A CompactLogix Base Program Overview The pre-configured CompactLogix program is a Rockwell Automation solution that helps machine builders and end users streamline their motion control programming. This application template provides a basis for using motion control, understanding the principles of state programming, and creating a consistent program structure. The CompactLogix program template does the following: • Incorporates a simple state machine sequencing programming.
Appendix A TIP CompactLogix Base Program Overview If you are familiar with the full S-88 functionality of the Kinetix Accelerator Toolkit sample code, note that the CompactLogix Indexing Motion Accelerator Toolkit provides a reduced set of functionality. It does not use PhaseManager. Main Machine Control (P00_Control) All machine control is initiated from the P00_Control program within the T00_Main task.
CompactLogix Base Program Overview Appendix A Overall Program Flow The automatic cycle and the manual cycle are controlled by a state sequencer. The sequencer has an index register (for example, AutoCycle.StepIndex) that can only be at one value at a time, so the states of the machine are unique. The sequencer changes states based on the commands and conditions of the machine.
Appendix A CompactLogix Base Program Overview Automatic Machine Cycle Commands The diagram above shows the automatic cycle flow provided in the application template. As the commands are issued (Reset, Start, Stop, or Abort) by the user or the application logic, the action items shown inside the Action States are issued from the P00_Control routine to each of the Pxx_AXIS_xx programs. The actual axis commands (Fault Reset, Enable, Jog, Stop, etc.
CompactLogix Base Program Overview Appendix A Action Taken Should any of these command action states fail to complete, the application template issues an abort command which stops the running cycle and disables the servo drives.
Appendix A CompactLogix Base Program Overview Axis/Equipment Control The individual axis actions are controlled based on the machine state. Any of the states will issue commands that will initiate actions programmed within routines in the individual axis programs. In the rungs of code below, within the Auto-Running phase state logic, a sequence word is set to a value of 1 to initiate a run sequence in P01_AXIS_00…R06_AutoMotion routine. In this case, a Jog command is issued on AXIS_01.
CompactLogix Base Program Overview Appendix A Add Your Application Code Follow these steps to add application code to each of your Pxx_AXIS_xx programs. 1. In RSLogix 5000 software, expand the Explorer window to gain access to Tasks. Refer to Main Machine Control (P00_Control) on page 96 to see how that is done. 2. Modify rung 4 of the R04_Initialize routine to move your axes to their required starting positions.
Appendix A CompactLogix Base Program Overview 3. Replace rungs 2 and 3 of the R06_AutoMotion routine with code that signifies your axes are ready for the Running state of your automatic cycle. These rungs can also be replaced with an MOV instruction that simply increments each Servo_DATA.RunSEQ[0] register to a value of 100, which signifies that the axis is ready for the automatic cycle. This routine currently commands a jog instruction on each axis for the Running state of the automatic cycle. 4.
CompactLogix Base Program Overview Appendix A User-defined Data Types The pre-configured Logix program uses pre-configured user-defined data types (UDT). These are structures that organize data, status information, and commands for machine process and equipment. For example, this pre-configured UDT stores all the data for an axis, including speeds, accels, decels, direction, and sequencers. A tag structure is created for each axis based on this data type.
Appendix A CompactLogix Base Program Overview Add-On Instructions The real power and advantage of the CompactLogix Indexing Motion Accelerator Toolkit is the use of Add-On Instructions in RSLogix 5000 software to simplify the way that motion is commanded to the Ultra3000 Indexing servo drives. These Add-On Instructions look and program very similar to the integrated motion instructions for SERCOS motion systems, so the learning curve for using them is minimized.
CompactLogix Base Program Overview Appendix A PhaseManager PhaseManager integrates equipment phases into your controller logic. An equipment phase makes it easier to write, use, and manage the code for your machine or equipment. IMPORTANT PhaseManager is not required for using this toolkit. If your system is required to meet the ISA-88 Machinery Standard, you can easily alter the sample logic application files provided with this toolkit to use PhaseManager.
Appendix A CompactLogix Base Program Overview Notes: 106 Publication IASIMP-QS011B-EN-P — January 2009
Appendix B PhaseManager for S-88 Users The pre-configured CompactLogix program template is driven by a simple state machine, as shown in Appendix A. If your system must comply to ISA-88 (S-88), Rockwell Automation offers PhaseManager as an embedded state machine controller that runs in the firmware of the CompactLogix controller. The CompactLogix program template already includes the code necessary to convert your system from the state machine version to a version that is driven by PhaseManager.
Appendix B PhaseManager for S-88 Users 3. Select the Edits Tags tab and scroll down to the tags shown below. 4. Click on the box to the left of PZ_GenericMachine_Auto, then right-click and select Delete. 5. Similarly, click on the box to the left of PZ_GenericMachine_Manual, then right-click and select Delete. Replace the State Machine Program 1. In the Project Explorer, right-click on the P00_Control program and select Properties. 2. Change the name to P00_Control_SM. 3. Click OK.
PhaseManager for S-88 Users Appendix B 4. Drag the P00_Control_SM program to the Unscheduled Programs folder. 5. Drag the P00_Control_PM program to the T00_Main task folder. 6. Drag the PZ_GenericMachine_AUTO_PM Phase to the T00_Main task folder.
Appendix B PhaseManager for S-88 Users 7. Drag the PZ_GenericMachine_MANUAL_PM Phase to the T00_Main task folder. 8. In the Project Explorer, right-click on the P00_Control_PM program and select Properties. 9. Change the name to P00_Control and press OK. 10. Similarly, rename the PZ_GenericMachine_AUTO_PM phase to PZ_GenericMachine_AUTO. 11. Also rename the PZ_GenericMachine_MANUAL_PM phase to PZ_GenericMachine_MANUAL.
PhaseManager for S-88 Users Appendix B Reschedule Programs in T00_Main 1. Right-click on T00_Main and select Properties. 2. Click the Program/Phase Schedule tab. 3. In the Scheduled list, select an item that is out of order and use the Move selector buttons until the list looks like the one in the ‘After’ list in step 5 below. 4. Click OK. 5. Verify your program scheduling as shown below. Before After Your application logic now uses PhaseManager and the S-88 state model.
Appendix B PhaseManager for S-88 Users Making Changes to Operator Interface Screens Follow these steps to convert the FactoryTalk operator interface screen templates from a simple state machine to a version that uses PhaseManager and the S-88 state model. Replace the Auto Screen Display 1. Open FactoryTalk View Studio and the Machine Edition application file that you selected in Chapter 6. 2. In the application organizer, expand Displays. 3. Locate the S210_Control_AUTO display. 4.
PhaseManager for S-88 Users Appendix B 8. Right-click on it and select Rename. 9. Change the name of the display to S210_Control_AUTO. 10. Click OK. Your operator interface now displays the S-88 state model of PhaseManager on the Auto Control screen. You may now download your application logic to your CompactLogix controller and the operator interface screens to your HMI, following the steps in Chapter 5 and Chapter 6 respectively.
Appendix B PhaseManager for S-88 Users Notes: 114 Publication IASIMP-QS011B-EN-P — January 2009
Appendix C Troubleshooting This appendix provides troubleshooting information for the logic provided in the application template only. • Troubleshooting information for the manual cycle starts on this page. • Troubleshooting information for the automatic cycle starts on page 122.
Appendix C Troubleshooting 1. Expand the P00_Control program and open the R04_Commands_MANUAL routine. 2. Use the Navigation Banner in the HMI to open the Manual Control screen. 3. Select the axis that are you are attempting to control. Refer to Chapter 7 in this manual if you need assistance. 4. Press Assume Manual Control on the HMI screen. 5. Observe rung 1 of the R04_Commands_MANUAL routine and verify that the ManualControl tag is latched.
Troubleshooting Appendix C 6. Issue the command that you feel is failing to execute, such as the Jog Forward command on the HMI screen. Press and hold this button while you perform step 7…step 8 including resulting steps. 7. Observe rung 2 of the R04_Commands_MANUAL routine and carefully note what value is in the ManualCycle.StepIndex register. 8. Use the table below to determine where the cycle is stopping and what action to take next.
Appendix C Troubleshooting 3. If not, make sure that your controller is in Run Mode, and that the HMI is communicating properly with the controller. Correct Manual Cycle Problem: ManualCycle.StepIndex Stops at 10 If the ManualCycle.StepIndex stops at 10, the Axis_nn_CMD.Reset command is failing to clear the faults on the servo drive and the resetting state is not completing. Perform the following steps to correct this condition. 1.
Troubleshooting Appendix C 4. Move to rung 3 of this routine and note the value of the ERROR word shown on the AOI_MAFR instruction. 5. Click on the AOI_MAFR instruction and press the F1 key for assistance with the error code. 6. Follow the instructions shown for the associated ERROR CODE and execute the manual command from the HMI again. Correct Manual Cycle Problem: ManualCycle.StepIndex Stops at 20 If the ManualCycle.StepIndex stops at 20, the Axis_ nn_CMD.
Appendix C Troubleshooting 3. Open the R03_EnableDisable_FaultReset routine for this axis. 4. Move to rung 1 of this routine and note the value of the ERROR word shown on the AOI_MSO instruction. 5. Click on the AOI_MSO instruction and press the F1 key for assistance with the error code. You may need to scroll down to find your error code. 6. Follow the instructions shown for the associated ERROR CODE and execute the manual command from the HMI again.
Troubleshooting Appendix C Correct Manual Cycle Problem: ManualCycle.StepIndex Stops at 200 If the ManualCycle.StepIndex stops at 200, the Jog or Define Home command is failing to execute. 1. Open the R05_Manual routine for the failed axis. 2. Move to rung 2 of this routine and note the value of the ERROR word shown on the AOI_MAJ instruction. 3. Click on the AOI_MAJ instruction and press the F1 key for assistance with the error code. You may need to scroll down to find your error code.
Appendix C Troubleshooting 4. Follow the instructions shown for the associated ERROR CODE and execute the manual command from the HMI again. Troubleshooting the Automatic Cycle Follow these steps for assistance with problems experienced during use of the automatic cycle of the CompactLogix program template. Determine Where the Program Fails The first step in troubleshooting the code within application template is to determine where the program fails or stops.
Troubleshooting Appendix C 3. Verify that the Release Manual Control message is not being displayed. If it is, press the indicator to release manual control. 4. Next, press and release the green button on the HMI to issue the reset command to the machine. 5. Wait for the command to execute during the Resetting state. 6. If the Machine Control graphic indicates the Aborted state, go to Problems in the Aborted/ Resetting State below.
Appendix C Troubleshooting 4. If this is not the problem, move to rung 9 of the R03_Commands_AUTO routine and carefully note what value is in the AutoCycle.StepIndex register as you press the green reset button again on the HMI. 5. Use the table below to determine where the cycle is stopping and what action to take next. If AutoCycle.StepIndex = The current state is: Take this action: 0 Stopped Go to Correct Aborted/Resetting State Problem: Reset Command Is Not Commanding Any Action.
Troubleshooting Appendix C Correct Aborted/Resetting State Problem: AutoCycle.StepIndex Stops at 10 If the AutoCycle.StepIndex stops at 10, the Axis_nn_CMD.Reset command is failing to clear the faults on the servo drive and the resetting state is not completing. Perform the following steps to correct this condition. 1. Observe the logic that begins at rung 10 of the R03_Commands_AUTO routine. 2. Scroll down through the subsequent rungs and identify which drive is not setting the Axis_ nn_Status.
Appendix C Troubleshooting 5. Click on the AOI_MAFR instruction and press the F1 key for assistance with the error code. 6. Follow the instructions shown for the associated ERROR CODE and execute the reset command from the HMI again. Correct Aborted/Resetting State Problem: AutoCycle.StepIndex Stops at 20 If the AutoCycle.StepIndex stops at 20, the axes are not completing their initialization procedure which includes enabling each drive and commanding the axis to a starting position.
Troubleshooting Appendix C 4. Move to rung 11 and verify that all Axis_nn_Status.Enabled status bits are active (set). For any drive that is not enabled, perform these substeps. a. Expand the associated Pnn_AXIS_nn program. b. Open the R03_EnableDisable_FaultReset routine for this axis. c. Move to rung 1 of this routine and note the value of the ERROR word shown on the AOI_MSO instruction. d. Click on the AOI_MSO instruction and press the F1 key for assistance with the error code.
Appendix C Troubleshooting 5. Move to rung 11 of the R02_MachineMonitor routine in the P00_Control program and verify that all Axis_ nn_Status.Initialized status bits are active (set). For any drive that is not initialized, follow these substeps. a. Expand the associated Pnn_AXIS_nn program. b. Open the R04_Initialize routine for this axis. c. Move to rung 4 of this routine and note the value of the ERROR word shown on the AOI_MAM instruction. d.
Troubleshooting Appendix C Problems in the Idle or Running State • If the state machine makes it to the Idle state, it will most likely go to the Running state as well. Press the green button on the HMI one more time to move to the Running state. • If the state machine graphic shows that it has moved to the Running state but the machine is not behaving as expected, the problem probably is located in one or more of the axis programs. Perform the following steps to correct this condition. 1.
Appendix C Troubleshooting Correct Idle/Running State Problem: AutoCycle.StepIndex Stops at 110 If the AutoCycle.StepIndex stops at 110, one or more of the axes failed to complete the automatic cycle running procedure. Perform the following steps to correct this condition. 1. For each of the axes, expand each of the Pnn_AXIS_nn program and open the R06_AutoMotion one by one. 2. Move to rung 2 of this routine and note the value of the Servo_DATA.RunSEQ[0] register. 3.
Troubleshooting Appendix C command associated with this status bit to execute. Your application code may differ. Correct Idle/Running State Problem: AutoCycle.StepIndex Stops at 200 If the AutoCycle.StepIndex stops at 200, the problem is not in the sample code provided in the application template. Perform the following steps to correct this condition. 1. Review the application code that you added for your specific machine in Appendix A of this document. 2.
Appendix C Troubleshooting Notes: 132 Publication IASIMP-QS011B-EN-P — January 2009
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