Advanced PLC Topics for Micro800 Controllers with Motion Capabilities and CIP Messaging Functionality. For Classroom Use Only!

Transcription

1 Advanced PLC Topics for Micro800 Controllers with Motion Capabilities and CIP Messaging Functionality For Classroom Use Only!

2 Important User Information This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation ) is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation should only be used as a learning tool by qualified professionals. The variety of uses for the hardware, software and firmware (hereinafter Products ) described in this Documentation, mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards in addition to any applicable technical documents. In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter Rockwell Automation ) be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of, or reliance on, this Documentation. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in the Documentation. Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for: properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell Automation or third-party provided instructions, warnings, recommendations and documentation; ensuring that only properly trained personnel use, operate and maintain the Products at all times; staying informed of all Product updates and alerts and implementing all updates and fixes; and all other factors affecting the Products that are outside of the direct control of Rockwell Automation. Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use the following notes to make you aware of safety considerations: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. Identifies information that is critical for successful application and understanding of the product. Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: identify a hazard avoid a hazard recognize the consequence Labels may be located on or inside the drive to alert people that dangerous voltage may be present. Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

3 Advanced PLC Topics for Micro800 Controllers with Motion Capabilities and CIP Messaging Functionality Contents Before you begin... 5 About this lab... 5 Tools & prerequisites... 6 About the Connected Components Demo kit... 7 About the drives settings... 7 Exploring the CCAT building block features... 8 Load Demo program... 8 State Machine Operation- Manual mode State Machine Operation- Auto mode Lab 1: Load the starting project Load the starting project About the starting project Lab 2: Program your Abort Sequence Lab 3: Program your Clear Sequence Lab 4: Program your Reset Sequence Lab 5: Program your Run Sequence Lab 6: Program your Stop Sequence Lab 7: Assign checks for State Machine Lab 8: Validating your label machine sequence Appendix A PowerFlex 4 Drive configuration Kinetix 3 Servo Drive Configuration Appendix B RA_PF4_MBUS_STS User-defined Function Block... 87

4 RA_PF4_MBUS_CMD User-defined Function Block Appendix C RA_Motion_Move_Cmd User-defined Function Block RA_K3_MBUS_STS User-defined Function Block... 96

5 Before you begin The following should have already been verified with your demo kit by the lab instructors prior to the lab: 1. Micro850 controller firmware at v7.011 (updated via ControlFLASH if necessary). 2. PanelView Component terminal firmware at v1.80 (updated via USB drive if necessary). 3. PVc file Demo_Labeling_Machine.cha loaded on PanelView C600 terminal (copied via USB drive if necessary). 4. Demo kit power cycled off and back on. About this lab In this lab, you are to make a simple labelling application with a Servo and an AC motor for your customer machine. The picture above shows the parts you have in the machine and these parts correspond to what you have in the demo kit: The conveyor belt is driven by the PowerFlex 4M AC drive and motor, the labeling head is driven by the Kinetix 3 Servo drive and motor, and the label sensor is connected from the proximity sensor at the AC motor, to the PLC input terminal 4. The starting project consists of two building blocks from the Connected Components Accelerator Toolkit (CCAT). This gives you a head start in your program development. You willl program your labelling application with the PowerFlex 4 Speed and PTO Motion building blocks in this lab session. In this lab, you will Get to know how the template in the starting project gives you a head start Explore the Application Sequences in your starting project Try the different device functions through their face plates Create your labeling application program with the template Operate and troubleshoot your machine in Auto mode

6 Tools & prerequisites For this hands-on lab, we have provided you with the following materials that will allow you to complete the labs in this workbook. Software: Connected Components Workbench software Version Standard or Developer Edition Hardware: Connected Components demo kit DEMO-CCMICRO1 Required CCW Project Files: o Demo_Labeling_Machine_r7.zip (includes Demo_Labeling_Machine.cha) o Starting_Labeling_Machine_r7.zip Lab setup

7 About the Connected Components Demo kit The image locates items on the demo and verifies the lab setup: 1. Verify the demo power switch selector is according to your area socket AC output 2. Connect the cable and switch on the power 3. Micro850 controller 4. PanelView C600 terminal 5. Kinetix 3 servo drive 6. PowerFlex 4M variable frequency drive 7. Digital and analog input panel 8. Servo motor with homing sensor 9. PowerFlex AC motor with proximity sensor About the drives settings Both drives have been pre-configured to work with this lab. The settings for each drive are listed in Appendix A.

8 Exploring the CCAT building block features Every release 6 (and above) building block comes with a State Machine Building Block and Application Sequence template (e.g. Run, Stop, Abort sequence etc ). These sequences operate in state machine auto mode and are isolated from the state machine manual mode operation. When the state machine is in manual mode, you can operate each connected device separately through their face plate. The diagram below illustrates how the HMI, state machine, application sequences and building block interact. Load Demo program You are going to load the demo program into the Micro850 controller to experiment with what you would expect at the end of this session.

9 1. Ensure that the Micro850 is connected to your PC with a USB cable. 2. If it is not already open, run Connected Components Workbench by double clicking from the desktop. 3. Click from the task bar and browse to: C:\Lab Files\Micro800 Lab\Demo_Labeling_Machine _r7. a. Select Demo_Labeling_Machine_r7.ccwsln and click Open. 4. Connect to the controller. a. Scroll to the top of the Project Organizer window. b. Double click the Micro850 icon.

10 c. Click the Connect button in the top right hand corner of the configuration window. d. The Connection Browser screen will appear. e. You should see a USB driver with a + by it. (If not, ask for help.) f. Click the + to expand the USB driver. You should see a connected Micro850 controller. g. Select the controller and click OK. It should show Connected on the top right hand corner of the configuration window.

11 5. Build this project. a. Right click the Micro850 controller icon. b. Select Build. c. The output window should show that the build is successful.

12 6. Download your project a. Right click the Micro850 controller. b. Select Download. c. A Download window may appear to ask for permission to change to Remote Program mode if so, click Yes. d. The Download Confirmation window will appear. You will be prompted to overwrite the project in the controller. The two choices are Download and Download with Project Values. The second choice is a new feature in Release 7 of Connected Components Workbench. Now, when a project is uploaded from the controller, a snapshot of the values of all of the user variables is uploaded and saved. These values can be downloaded back into the controller along with the project by selecting Download with Project Values. If you clicked the Help button, you would find that the following conditions must be met in order for a Project Value to be downloaded to a variable: i. Variables with both a Project Value and an Initial Value will be initialized with their Initial Value. ii. Variables with an Attribute of "Read" or "Write" cannot be downloaded. Variables must have an Attribute of "Read/Write". iii. Variables with a Direction of "VarInput" cannot be downloaded. iv. Complex variables (structures, arrays) that contain members with Initial Values cannot be downloaded. e. In this lab, we will download using the assigned initial values. Therefore, just click Download. f. When download has completed, the Download window may appear again to request permission to change to Remote Run mode if so, click Yes.

13 7. On the PanelView C600 terminal, select File Manager from the Main menu: 8. Press the up/down arrows to find and highlight Demo_Labeling_Machine and press Run. 9. Press Start Drive Config and follow the on-screen directions.

14 10. When screen indicates Drive configuration complete! press Go to Demo to continue with lab.

15 State Machine Operation- Manual mode While the machine is in manual mode, you can control each connected device through its faceplate. There are two device building blocks installed in this demo. Next you will explore their features in machine manual mode. 1. Ensure that you are at the Machine Overview screen. If not, press X in the top right hand corner until you arrive at the Machine Overview screen. 2. Press Machine Functions to see the available functions installed for you. 3. There should be two devices already installed for you, namely PF4_01 and Axis_02 to control your AC and Servo motor respectively. Press Manual to set machine to manual mode. 4. Press the Device: PF4_01 to explore what you can do with the PowerFlex4 Speed building block.

16 PowerFlex 4 Speed building block screen 1. Confirm that any motor connected to the drive is in a safe state to operate manually. 2. If there is any fault, press Clear Fault 3. Set a speed reference by pressing the blue box, then entering a value from 1 to 60 Hz. 4. Set the drive direction forward by pressing the Fwd button. 5. Press Start, and verify the drive starts and ramps up to the speed reference specified. You can verify the actual speed reference in the Speed Ref Actual numeric display.

17 6. Verify that the Ready, Active, Fwd, and At Ref indicators are green once the drive is up to speed. 7. Press Stop, and verify the drive stops and ramps down to a speed reference of 0.00 Hz. The Active indicator will turn gray once the drive has completely stopped. 8. Test the Jog functionality by pressing and holding the Jog button. The drive will jog at the drive s preset jog speed of 10.0 Hz.

18 9. Press X to go back to Machine Functions screen. 10. Press the Device: Axis_02 to explore what you can do with the PTO Motion building block.

19 PTO Motion building block screen 1. Confirm that any motor connected to the drive is in a safe state to operate manually. 2. You are at the Command & Status screen for PTO motion. Press Servo Enable. This energizes the motor, and it attempts to hold its present position. 3. Set Deceleration to 100 mm/s Set Acceleration to 100 mm/s Set Jog Speed to 100 mm/s. 6. Press and hold Jog Forward. The motor rotates forward. 7. Release Jog Forward. The motor should stop.

20 8. Press and hold Jog Reverse. The motor rotates in the reverse direction. 9. Release Jog Reverse. The motor should stop. 10. Set Home mode to Press Start Homing. The motor begins to home and the Homed indicator turns green when axis is homed. 12. Press Advanced move to explore what it can do further. You will explore the different types of move commands supported by Micro800 motion.

21 13. Press Select Move once to change Move type to Velocity for Velocity control. 14. Set Direction to 1 for forward direction. 15. Press Move. Motor accelerates and cruises at 100mm/s. 16. Press Halt. Motor decelerates to a stop.

22 17. Press Move type once more to select Absolute to demonstrate absolute positioning. 18. Press Start Homing to home the motor. Motor will move to home position and reset current position to Enter 500 for Position.

23 20. Press Move. Motor will move to absolute position 500 and stop. 21. Press Move type once more to Relative to demonstrate relative positioning. 22. Enter 100 for Position. 23. Press Move. Motor will move for an additional 100mm to position 600mm. 24. Press Servo Disable. You have completed this demonstration. Return to the Machine Overview screen to test the program for the labeling application.

24 25. Press X twice to return to Machine Functions screen. State Machine Operation- Auto mode When the machine is in auto mode, it operates through a set of Application Sequences programmed to handle different tasks. In this demo program, the Application Sequences have already been coded for the labeling machine. You will explore how the labeling application works in this section. 1. Ensure that you are at the Machine Functions screen - if you are not, press X on the top right hand corner until you arrive at the Machine Functions screen. 2. Press State Diagram to look at the machine program flow. You should see that the current state is ABORTED and if you look at how the arrow flow, the next state is CLEARING. 3. Press Clear Faults. The state changes to CLEARING and then to STOPPED quickly. You may not see the CLEARING sequence turns green as it might be over before you can see it. When the state is at STOPPED, you have cleared the machine fault successfully.

25 4. Press Auto to set machine to Auto mode. Caution! Expect motion when you press Start. Ensure that the Servo and AC motor is safe to operate. 5. Press Start Machine. The state changes to RESETTING and the servo motor begin to move to home position. When Homed, the state changes to IDLE. 6. Press Start Machine again to run the program. The state changes to RUNNING.

26 About the program The program simulates a labelling machine application. The AC motor drives a conveyor belt and the servo motor drives a labeling head. When a product triggers the Label Sensor (simulated by triggering the sensor with the metal tape on the PowerFlex disc), servo motor index once to apply a label on the product and this cycle continue until someone stop the machine. 7. Press Stop Machine to stop. Both motors come to a stop and the state changes to STOPPED. You have completed this section of the lab. In the next section, you will load a starting project and learn how to program the labeling sequence for yourself.

27 Lab 1: Load the starting project In this section, you will load the starting project and understand more about the existing building blocks and application sequence template in the starting project. The purpose of the lab is to show how to complete the integration of these exisitng building blocks, along with the application sequence template, to create a functioning Labeling Machine. Load the starting project 1. Click the open icon. 2. From the Open window, browse to: C:\Lab Files\Micro800 Lab\Starting_Labeling_Machine_r7. 3. Select Starting_Labeling_Machine_r7.ccwsln and click Open. 4. Build your project and verify there are no errors. 5. Download the project to your controller.

28 About the starting project The starting project is loaded with the PowerFlex 4 Speed Control and Kinetix 3 PTO Motion CCAT Building Blocks, along with a State Machine for machine control. These building blocks provide helpful variables for controlling and monitoring the status of devices, as well as a structured flow of sequences during machine operation. The diagram below shows you the name of each program in your starting project.

29 The State Machine building block handles the Application Sequences according to the flow chart below: In this lab session, you will be programming each of these application sequences for the labeling machine and operate it through the demo kit. [1-5]

30 Lab 2: Program your Abort Sequence The program name of the Abort Sequence is App_Abort_Seq. In this sequence, we will stop all motion.

31 1. Double click App_Abort_Seq in Project Organizer.

32 2. Click anywhere on Rung 1, then toggle Ctrl+R to activate Manual-Input Enable. This prevents the variable selector window from popping up in a program when you insert a new instruction. Note: Alternatively you could enable this for the whole project by going to Tools > Option >IEC Languages > Function Block Diagram, under Editor Settings, set Automatically invoke Variable/Block to FALSE. In this lab, we shall toggle Ctrl+R in each program to enable the Manual-Input Enable.

33 3. Create a second branch parallel to the first branch. a. Drag a from the Toolbox. b. Drop it anywhere within the red boxed cell in your program A second branch is added. 4. Insert a from the Toolbox in the first branch. 5. Assign variable PF4_01_Cmd_Stop_Auto to the Set coil. a. Hover your mouse above the coil and a light blue box appears.

34 b. Click the light blue box, type in variable name PF4_01_Cmd_Stop_Auto and hit Enter. This command stops the AC motor. 6. Insert a from the Toolbox in the second branch. 7. Assign variable Axis_02_Cmd_Stop_Auto to the direct coil. a. Hover your mouse above the coil where the light blue box appears.

35 b. Click the light blue box, type in variable name Axis_02_Cmd_Stop_Auto and hit Enter. This command stops the Servo motor. 8. Insert two contacts in series in the third branch to the left of the MOV instruction. 9. Assign variables PF4_01_Sts_Active and Axis_02_Sts_InMotion to the first and second contacts respectively. These contacts verify that both motors have stopped.

36 Note Always end the Abort sequence with App_Cfg_Abort_Seq equal to 999. This allows the State Machine to move to the next application sequence 10. Build your project and verify there are no errors.

37 Lab 3: Program your Clear Sequence The program name of the Clear Sequence is App_Clear_Seq. In this sequence, we will trigger the clear fault variable in the building blocks.

38 1. Double click App_Clear_Seq in Project Organizer. 2. Click anywhere on Rung 1, then toggle Ctrl+R to activate Manual-Input Enable. 3. Right click to copy and paste Rung 1 to the empty space below it.

39 You now have 2 identical rungs. 4. Insert two to the area within the red boxed cell of rung 1.

40 You should have 4 branches altogether. 5. Insert a in the first branch and assign variable Axis_02_Cmd_Reset_Auto to it. This command resets the PTO motion building block.

41 6. Insert a in the second branch and assign variable Axis_02_Cmd_RsetDrv_Auto to it. This command resets the Servo drive. 7. Insert a in the third branch and assign variable PF4_01_Cmd_ClrFlt_Auto to it. This command resets the Powerflex 4 Speed building block and AC drive.

42 8. Insert two in the fourth branch and assign variables PF4_01_Sts_DriveFault and Axis_02_Sts_AxisErr to the first and second contacts respectively. These contacts verify that any faults have been cleared. 9. Assign 10 to i1 of the MOV instruction. When completed, your Rung 1 of App_Clear_Seq program should look like this.

43 10. In Rung 2, you can delete the rung comment copied from rung Assign 10 to i2 of = instruction. This rung is where we program for step Insert a in the first branch and assign variable Axis_02_Cmd_Enable_Auto to it. This command switches off the servo motor.

44 When completed, your program should look like this. Note Always end the Clear Sequence with App_Cfg_Clear_Seq equal to 999. This allows the State Machine to move to the next application sequence 13. Build your project and verify there are no errors.

45 Lab 4: Program your Reset Sequence The program name of the Reset Sequence is App_Reset_Seq. In this sequence, we will configure some motion parameters and move the servo to its initial position.

46 1. Open the App_Reset_Seq program. 2. Click anywhere on Rung 1, then toggle Ctrl+R to activate Manual-Input Enable. 3. Right click rung 1 to copy and paste to Rung 2 and 3. You now have 3 identical rungs.

47 4. Insert two to the area within the red boxed cell. You should have 4 branches altogether in rung Insert a in the first branch and assign variable Axis_02_Cfg_EnNegative_Auto to it.

48 6. Insert a in the second branch and assign variable Axis_02_Cfg_EnPositive_Auto to it. These commands enable the PTO motion axis to move in the positive and negative direction. 7. Insert a in the third branch and assign variable PF4_01_Cmd_Stop_Auto to it. This resets the stop command issued to the Powerflex 4 Speed building block in all previous Application Sequences.

49 8. Assign 10 to the input of MOV instruction on the fourth branch of Rung 1. This instruction brings the Reset Sequence to the next step (step 10). Your rung 1 should look like this. 9. In Rung 2, you can delete the comment copied from Rung Assign 10 to i2 of = instruction in Rung Insert a in the first branch and assign variable Axis_02_Sts_AxisEn to it.

50 12. Insert a to the right of the reverse contact and assign variable Axis_02_Cmd_Enable_Auto to it. 13. Insert a in the second branch and assign variable Axis_02_Sts_AxisEn to it. 14. Assign 11 to the input of the MOV instruction. 15. In Rung 3, you can delete the comment copied from Rung 1.

51 16. Assign 11 to i2 of the instruction. 17. Insert a in the first branch and assign variable Axis_02_Cmd_Home_Auto to it. This command requests the servo motor to move to home position. 18. Insert a in the second branch and assign variable Axis_02_Sts_AxisHomed to it. This verifies that the servo motor is homed. Note Always ends the Reset Sequence with App_Cfg_Reset_Seq equal to 999. This allows the State Machine to move to the next application sequence.

52 When completed, your program should look like this. 19. Build your project and verify there are no errors.

53 Lab 5: Program your Run Sequence The program name of the Run Sequence is App_Run_Seq. In this sequence, we set the dynamic parameters and program a continuous labeling sequence.

54 1. Open the App_Run_Seq program. 2. Click anywhere on Rung 1, then toggle Ctrl+R to activate Manual-Input Enable. 3. Right click rung 1 to copy and paste to Rung 2, 3 and 4. You should have 4 identical rungs.

55 4. In rung 1, set the dynamic parameters for the conveyor belt, which is controlled by the AC motor. a. Insert a parallel to the first branch. Your branches should look like this. b. Insert a MOV instruction in the first branch by clicking on the existing MOV instruction, right click and Copy, click on the first branch, right click and Paste. c. Assign 1.0 to the input of the MOV instruction. d. Assign variable PF4_01_Cmd_SpeedRef_Auto to the output of the MOV instruction. This sets the speed reference for the PowerFlex 4 Speed building block to 1Hz. For more information about the UDFB used in the PowerFlex 4 Speed building block, you can refer to Appendix B.

56 e. Insert a in the second branch. f. Assign variable PF4_01_Cmd_SetFwd_Auto to it. This sets the PowerFlex 4 Speed building block in forward direction. When completed, your rung 1 should look like this. 5. In rung 2, set the dynamic parameters for the labeling head which is controlled by the Servo motor. a. Assign 10 to i2 of = instruction. This rung is step 10 of the Run Sequence.

57 b. Insert four more parallel to the right of the = instruction. Your program should look like this.

58 c. Insert a MOV instruction in the first branch. i. Drag and drop an Instruction Block from the Toolbox onto the first branch. ii. Double click this Instruction Block.

59 iii. A Block Selector window appears - type MOV in the search field. iv. MOV instruction appears click it and then click OK.

60 d. Assign 3 to the input of the MOV instruction. e. Assign variable Axis_02_Cfg_MoveMode_Auto to the output of the MOV instruction. This sets the PTO motion building block to Relative move mode. If you want to know what sets the PTO motion building block to the mode it is in, you can refer to Appendix C.

61 f. Insert a MOV instruction in the second branch. g. Assign 2.5 to the input of the MOV instruction. h. Assign variable Axis_02_Par_PositionData_Auto to the output of the MOV instruction. This sets the relative position reference for the PTO motion building block.

62 i. Insert a MOV instruction in the third branch. j. Assign to the input of the MOV instruction. k. Assign variable Axis_02_Par_AccData_Auto to the output of the MOV instruction. This sets the acceleration reference for the PTO motion building block.

63 l. Insert a MOV instruction in the fourth branch. m. Assign to the input of the MOV instruction. n. Assign variable Axis_02_Par_DecData_Auto to the output of the MOV instruction. This sets the deceleration reference for the PTO motion building block.

64 o. Insert a MOV instruction in the fifth branch. p. Assign 20.0 to the input of the MOV instruction. q. Assign variable Axis_02_Par_VelocityData_Auto to the output of the MOV instruction. This sets the speed reference for the PTO motion building block.

65 r. On the sixth branch, assign 11 to the input of the MOV instruction. This branch configures the dynamic parameters for the servo and brings the Run Sequence to step 11.

66 6. In rung 3, initiate the conveyor belt to move. a. Assign 11 to i2 of = instruction. This rung is step 11 of Run Sequence. b. Insert a in the first branch. c. Assign variable PF4_01_Cmd_Start_Auto to the Direct Coil in the first branch. This command starts the AC motor.

67 d. Insert a in the second branch. e. Assign variable PF4_01_Sts_Active to the contact. This command verifies that the motor has started. f. Assign 12 to the input of the MOV instruction. This brings the Run Sequence to step 12 and your rung 3 should look like this. 7. In rung 4, the servo motor indexes once when the sensor senses a product. a. Assign 12 to i2 of = instruction. This rung is step 12 of Run Sequence and your rung 4 should look like this.

68 b. Insert a to the right of the = instruction. c. Assign variable _IO_EM_DI_04 to the contact. _IO_EM_DI_04 is the controller input terminal that connects to the sensor. d. Insert a to the right side of the rung. e. Assign variable Axis_02_Cmd_Move_Auto to the coil. This commands the servo motor to index whenever the sensor detects a product. f. Delete the MOV instruction and the second branch.

69 When completed, your 4 rungs program should look like this.

70 8. Build your project and verify there are no errors.

71 Lab 6: Program your Stop Sequence The program name of the Stop Sequence is App_Stop_Seq. In this sequence, we halt all motion. The program is very similar to Abort Sequence thus we can copy the program from App_Abort_Seq.

72 1. Copy program from App_Abort_Seq. a. Double click App_Abort_Seq. b. Select the first rung (only rung). c. Ensure that the rung is highlighted with green borders. d. Right click and select Copy. 2. Paste program to App_Stop_Seq. a. Double click App_Stop_Seq. b. Right click the first rung and select Paste.

73 The program is inserted in Rung Update the variables for App_Stop_Seq. a. Assign App_Cfg_Stop_Seq to the input of = instruction in Rung 1. b. Assign App_Cfg_Stop_Seq to the output of MOV instruction in the third branch of Rung 1. c. Assign Axis_02_Cmd_Halt_Auto to the Direct Coil in the second branch of Rung 1.

74 4. Edit the rung comment to Stop Sequence. 5. Delete Rung 2. When completed, your program should look like this. 6. Build your project and verify there are no errors.

75 Lab 7: Assign checks for State Machine The State Machine checks for conditions to make sure that the connected devices are operationally ready. If any of the devices is not ready, the application sequence will be set to Abort. For example, if there is a critical alarm in the connected device while the machine is running, the state machine will detect it and execute the App_Abort_Seq program to stop the machine. 1. Double click App_Main. 2. Insert two in series on Rung From the User Global Variables tab, assign PF4_01_Sts_DriveCommLoss to the first contact. 4. From the User Global Variables tab, assign Axis_02_Sts_DrvComm to the second contact. This rung detects communication loss for connected device. Your rung 10 should look like this. 5. Insert two in series on Rung Assign variable PF4_01_Sts_DriveFault to the first contact. 7. Assign variable Axis_02_Sts_AxisErr to the second contact. This rung detects faults generated by the building blocks. When completed, your rung 14 should look like this. 8. Build your project and verify there are no errors. 9. Download your project.

76 Lab 8: Validating your label machine sequence 1. Ensure that you are at the Machine Overview screen. If not, press X in the top right hand corner until you arrive at the Machine Overview screen. 2. When you are at the Machine Overview screen, it should be Aborted with First Scan indicating the reason that it last aborted. 3. Press Clear Faults. 4. Machine State should change to STOPPED - now you can press Start Machine. Caution! Expect motion when you press Start Machine. Ensure that the Servo and AC motor are safe to operate.

77 5. Machine State should change to IDLE - you can press Start Machine again to begin the labeling application. 6. Machine State should change to RUNNING and both motors should be operating according to what you have programmed.

78 7. Next let s assume that the label head has reached its limit and that the operator has to replace the film. Trigger DI1 on the demo kit to simulate this limit. 8. The Machine State changes to ABORTED. To know what caused the abort, we look at the device face plate. Press Machine Functions. 9. The Servo face plate has a red box over it. This indicates that there was an error event. Press the Device: Axis_02 button.

79 10. This brings you to the PTO motion face plate. You can see that there is an axis error, code E11. Press Fault Help for more details about the error. 11. This brings you to the Fault Help screen of the PTO motion face plate for more information about the fault.

80 12. Press X in the top right hand corner three times to return to the Machine Overview screen. 13. Press Clear Fault to reset the error. 14. Once the error has cleared, you can press Start Machine to home your servo motor. 15. Once your servo motor is homed, you can press Start Machine again to run the labeling application. 16. To stop the machine, press Stop Machine. Congratulations! You have completed this lab.

81 Appendix A PowerFlex 4 Drive configuration The configuration listed here are the non-default value settings. # Name Value Units Internal Default Min Max Value 2 Commanded 1.0 Hz Freq 5 DCBusVoltage 354 V Drive Status Fault 1 Code Fault 2 Code Fault 3 Code Control Source 13 Contrl In Status Comm Status Control SW Ver 17 Drive Type Elapsed Run 1 x10h Time 19 Testpoint Data Analog In 0.1 % mA 22 Drive Temp 29 C Start Source Comm 5 Keypad 0 5 Port 108 Speed Comm 5 Drive Pot 0 5 Reference Port 109 Accel Time Sec Decel Time Sec Comm Data 19.2K Rate 305 Comm Loss Time 35.0 Sec

82 Kinetix 3 Servo Drive Configuration The following drive functions are not used thus configuration details are not included in the document Index Homing Analog output control Preset speed Tuning parameter. (For optimal result, users need to auto tune their servo motor). Description Value Drive Name Drive AC Line Loss Check Enable Auto Motor Iden Enabled Motor Model TL-A110P-RXX2 Command Polarity Normal Displayed Units Metric Operation Modes (Main/Override) Follower/None Initial Current Bias 0 % rated motor current Velocity Limits Velocity Limit Mode Disabled Manual Velocity limit 5000 RPM Acceleration Limits Acceleration Limits Active Acceleration Revs/s^2 Acceleration Time to Max Speed 200 ms Deceleration Revs/s^2 Deceleration Time to Max Speed 200 ms S-Curve Time 0 ms Communications Drive Address 1 Baud rate bps Frame Format 8 Data, No Parity, 1 Stop bit Protocol ASCII Communication Method RS232 MODBUS Run Function Control Disable MODBUS Input Function Control Disable Current Limits Positive Internal 300 % rated motor current Negative Internal 300 % rated motor current Positive External 100 % rated motor current Negative External 100 % rated motor current

83 Position Limits Enable Software Limits Positive Software Limit Negative Software Limit Positive Decel Distance Negative Decel Distance Speed Functions Speed Window Up to Speed Zero Clamp Position Functions In Position Size Near Position Size Motor Encoder Units Position Label Position Scale Velocity Label Velocity Scale Acceleration Label Acceleration Scale Stopping Functions Over Travel Stop Method Maximum Stopping Current Fault and Disable Braking Disable Delay Braking Application Speed Auxiliary Function Selection 1 Velocity Observer Emergency Stop Input off Counts Counts 0 Counts 0 Counts 10 RPM 20 RPM 0 RPM 10 Counts 20 Counts Counts 1 Counts per User Units RPM 1 RPM per User Units Revs/s/s 1 Revs/s^2 per User Units Current Control 300 % rated motor current Brake and hold 0 ms 100 RPM Disable Disable Mode Configuration Analog Velocity Scale Current Scale Velocity Command Offset Current Command Offset RPM/Volt 33.3 % motor rated cont. current/volt 13.2 mv 34.2 mv Follower Command Type Controller Output Type 1st Gear Ratio Change Step/Direction. Positive Logic Open Collector Input Always Enable

84 1st Gear Ratio 2nd Gear Ratio Digital Filter Cut-off Frequency Line Driver Input Open Collector Input High frequency Line Driver 1:128 Master Counts:Follower Counts 1:4 Master Counts:Follower Counts MHz MHz Input MHz Motor Auto Motor Iden Enabled Motor Model TL-A110P-RXX2 Inertia Ratio 0.00 Load / Motor General Motor Flag Standard Motor Type Rotary Torque Constant N-m/A Inertia Kg-cm^2 Poles/Revolution 8 Integral Limits No Electrical Rated Voltage 230 Volts Resistance Ohms Inductance mh Ratings Maximum Speed 5000 RPM Intermittent Current 1.49 Amps Continuous Current 0.55 Amps Feedback Encoder SA35 Commutation Sinusoidal Sinusoidal Startup Serial Hall Input Offset 0 degrees Lines/Revolution Thermal Integral Thermostat No Software Protection Yes Rth(w-e) C/W Cth(w-e) 1.00 W-s/C Rth(w-a) 2.10 C/W Cth(w-a) W-s/C Autotuning

85 Autotuning Speed 700 RPM Off-Line Tuning Mode Inertia Moment Estimation and Resonant Frequency Detection On-Line Vibration Suppression Mode Disable On-Line Vibration Suppression Gain Low Velocity Regulator Configuration Velocity Command Filter on Follower Disable Gain Switching Gain Change Enable Disable Mode of Gain Switching 1st Gain Fix Delay Time of Gain Switching 0.2ms Level of Gain Switching 0 Hysteresis of Gain Switching 0 Position Gain Switching Time 0.2ms 2nd Regulator Gains P 60 Integrator Gain 26 Low Pass Filter Bandwidth (VReg) 1000 Hz Kp 20 Hz Low Pass Filter Bandwidth (IReg) 300 Hz 3rd Regulator Gains P 60 Integrator Gain 26 Low Pass Filter Bandwidth (VReg) 1000 Hz Kp 20 Hz Low Pass Filter Bandwidth (IReg) 300 Hz 4th Regulator Gains P 60 Integrator Gain 26 Low Pass Filter Bandwidth (VReg) 1000 Hz Kp 20 Hz Low Pass Filter Bandwidth (IReg) 300 Hz Encoder Encoder Output Forward Direction Output Ratio Encoder Backup Battery Incremental Feedback Loss A Leads B 1:128 Output Counts:Motor Counts Not Installed Monitored Digital Inputs Input 1 Input 2 Drive Enable Fault Reset

86 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 Input 9 Input 10 Moving Enable Integrator Inhibit Unassigned Unassigned Unassigned Unassigned Unassigned Unassigned Digital Outputs Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Brake Inactive Delay Brake Active Delay Ready Up to Speed Brake Unassigned Unassigned Unassigned 0 ms 500 ms Faults: AC Line Loss Fault Delay Following Error Limit Channel A Channel B Channel C Channel D 20 ms Counts Velocity Feedback Current Command Bus Voltage U Phase Current

87 Appendix B This appendix shows the UDFBs used to control and monitor the PowerFlex 4 drive RA_PF4_MBUS_STS User-defined Function Block Copied from CC-QS026 page 67-69

88

89

90 RA_PF4_MBUS_CMD User-defined Function Block Copied from CC-QS026 page 70-72

91

92

93 Appendix C This appendix shows the UDFBs used to control and monitor the Kinetix 3 Servo drive RA_Motion_Move_Cmd User-defined Function Block [5-1-1]

94 RA_Motion_Move_Cmd Inputs Variable Data type Description Range FBEN BOOL Set this bit TRUE to enable the function block. 0,1 AxisIn Axis_Ref Assign this to the motion axis created via the configurator MoveMode INT 0: Maintenance mode (Jogging is permited) 1: Velocity control (Motion is in velocity move mode) 2: Absolute control (Motion is in absolute position move mode) 3: Relative control (Motion is in relative position move 0..3 mode) PositionData Real Only valid in Mode 2 and 3 2: Absolute position 3: Relative position E E+38 VelocityData Real This value set the speed of the motor E E+38 AccData Real This value set the acceleration of the motor E E+38 DecData Real This value set the deceleration of the motor E E+38 JerkData Real This value set the jerk of the motor E E+38 DirData SINT Only valid in velocity control mode. This value set the rotating direction of the motor Execute BOOL Set this bit TRUE to execute motion 0,1 Halt BOOL Set this bit TRUE to stop motion 0,1 Jog_Positive BOOL Set this bit TRUE to execute jog in the positive direction. 0,1 Set this bit FALSE stops jog Jog_Negative BOOL Set this bit TRUE to execute jog in the negative direction. Set this bit FALSE stops jog 0,1 RA_Motion_Move_Cmd Outputs Variable Data type Description Range FBENO BOOL This variable reflects the state of FBEN. 0,1 AxisState USINT This value returns the status of the axis with respect to the motion currently in progress. CurrentMoveMode INT This value returns the current move mode 0..3 MoveDone BOOL When move mode is 0,1 0 or 1: This bit is TRUE when the motor has reached the set velocity 2 or 3: This bit is TRUE when the motion is complete MoveBusy BOOL This bit is TRUE when the motion axis is busy 0,1 MoveActive BOOL This bit is TRUE when the function block is in control of 0,1 the axis MoveAborted BOOL This bit is TRUE when the command was aborted by 0,1 another command Error BOOL This bit is TRUE when an error was detected 0,1 ErrorID UINT This value returns the motion error code ErrorMsg String This value returns which command causes the error

95 RA_Motion_Move_Cmd Function Block Flowchart

96 RA_K3_MBUS_STS User-defined Function Block Refer to CC-QS025B-EN-P page 71-73

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100 Allen-Bradley, Connected Components Workbench, FactoryTalk, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, PowerFlex, PanelView, Rockwell Software, are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication CE-DM262C-EN-P October 2014 Supersedes Publication Copyright 2014 Rockwell Automation, Inc. All rights reserved.