ELECTRICAL ENGINEERING TECHNOLOGY Introduction to RSLogix 5000 and the Compact Logix PLC

Transcription

1 KENNESAW STATE UNIVERSITY ECET 4530 ELECTRICAL ENGINEERING TECHNOLOGY Introduction to RSLogix 5000 and the Compact Logix PLC Introduction: In this exercise you will setup, configure, program and operate a motor control system that utilizes a Compact Logix 1769-L32E Programmable Logic Controller (PLC) to control a pair of 3 Induction Motors, one by means of a PowerFlex 40 Variable Frequency Drive (VFD) and the other by means of a 3 contactor. Preamble: To complete this entire experiment, access is required to one of the motor control lab benches in the Q-215 Electric Machines laboratory that contains all of the equipment following equipment: 1 Compact Logix L32E Programmable Logic Controller (PLC) with a 16-port IQ16 Digital Input Module and a 16-port OW16 Relay Output Module 1 PowerFlex 40 (PF40) Variable Frequency Drive (VFD) w/ Ethernet Module 1 Personal Computer (PC) with the following installed software packages: RSLogix5000, RSLinx Classic, BootP, & DriveExplorer. 2 Combination (NO/NC) Pushbuttons 1 Indicator Lamp (120V) 2 Three-phase (3Φ) Induction Machines 1 Three-phase (3Φ) Contactor with a 120VAC Field Coil 1 Three-phase (3Φ) 120/208V LabVolt Power Supply 1 Ethernet Switch If you only have access to a desktop computer that has the RSLogix software installed, you can complete the programming part of this experiment and save the results on a memory stick, after which you can complete the physical portions of the experiment when you are able to gain access to one of the motor control lab benches. Skip ahead to the section titled RSLogix 5000 Software on page seven (7) of this handout if you do not currently have access to the physical motor control system components. Physical Setup of the Motor Control System s Devices The required physical (wired) connections between the various control system components utilized during this experiment should already be complete. A detailed description of the required connections is provided in Appendix A of this handout for informational purposes in case you need to troubleshoot and/or make repairs to the system. DO NOT disassemble the control system components or modify any of the physical connections if the system is already setup as described in Appendix A. Additionally, the PF40 VFD should already be properly configured. A detailed description of the procedure required to properly configure the operating parameters of the VFD is provided in Appendix B of this handout in case you need to troubleshoot the system. Note that, even if the VFD is properly configured, you may find it beneficial to complete the configuration procedure provided in Appendix B

2 If the physical control system is already setup as described in Appendix A and the VFD is properly configured as described in Appendix B, then you are ready to complete this experiment. Unless instructed otherwise, perform all parts of the procedure, in order, without skipping any sections. Procedure: Desktop Computer Network Connection If the desktop computer is connected to the campus network, unplug the cable that connects the desktop computer s Ethernet port to the campus network. The computer must be disconnected from the campus network because the control system requires the use of the program BootP, which functions as a DHCP Server that can assign IP addresses to computers attached to the network. IT Policy does not allow individual users to operate DHCP Server software while connected to the campus network. Connect the desktop computer s Ethernet Port to the control system s Ethernet Switch. LabVolt Power Supply Switch on the main LabVolt power supply. Note TURN-OFF the supply immediately and notify the instructor if any unexpected operation occurs when the main supply is energized. CONFIGURATION OF THE NETWORK SETTINGS FOR THE CONTROL SYSTEM DEVICES Internet Protocol (IP) Addresses In order to communicate across the control system network, every device on the network must be assigned a logical IP address. Each address is composed of a set of four numbers that range from 0 to 255. Similar in nature to phone numbers; when one device needs to contact another device on the network, it passes the IP address of the remote device to its network interface, and the network hardware takes care of setting up the connection between the two devices. Most devices can be assigned either a static IP address which they maintain until that are assigned a new address or a dynamic IP address that they must renew after a preset amount of time (or whenever they reconnect to the network). Although the desktop computer will be assigned a static IP address, care should be taken when logging into the computer to be sure that the address is still set to the correct value. When connected to the campus network, the laboratory computers are configured to receive dynamic addresses. Thus, when changing between the campus and the control system networks, the computer s IP settings will need to be changed. The PLC and the VFD are configured such that, every time they are powered-down, they will discard their IP addresses. In-turn, whenever they are restarted, the PLC and the VFD will need to be reassigned IP Addresses. Thus, once they finish their boot-up processes, they will begin to broadcast (ARP) requests indicating that they are in need of an IP Address, and special (DHCP Server) software on the desktop computer will be configured to assign those addresses whenever it receives a requests. ARP Address Resolution Protocol DHCP Dynamic Host Control Protocol - 2 -

3 Although IP addressing theory will not be discussed any further at this point, the required procedural steps are provided for assigning the following set of IP Addresses to the control system devices that are able to communicate across a network: Computer PLC VFD Assigning an IP Address to the Desktop Computer 1. Check the IP configuration of the desktop computer by performing the following steps: a) Right-click on the Network icon on the taskbar in the bottom-right corner of the desktop. b) In the pop-up that appears, click Open Network and Sharing Center. c) In the Network and Sharing Center pop-up window, click Local Area Connection. This will allow you to view and/or modify the computer s network settings. Note that some of the values in your window may differ from those shown to the right. d) In the Local Area Connection Status pop-up window that appears, click the Details button. e) In the Network Connection Details window that appears, check the IPv4 Address of the computer. If the IPv4 address is then the computer is already properly configured. Close all of the network windows, skip step 2, and proceed to the next section: Assigning IP Addresses to the PLC & VFD. If the IP address is NOT correct, complete step Set the IP Address of the desktop computer to by performing the following steps: a) Close the Network Connect Details window. b) In the Local Area Connection Status pop-up window that should still be open, click the Properties button. c) In the Local Area Connection Status pop-up window, locate and double-click on Internet Protocol Version 4 (TCP/IPv4) in the list of items. d) In the Internet Protocol Version 4 (TCP/IPv4) Properties pop-up window that appears, click the radio button Use the following IP address. Enter into the IP Address field and then click on the Subnet Mask field. The subnet mask field will automatically populate with the value Click OK to save the changes or

4 INFORMATIONAL NOTE An IP Address has two parts, a Network Number and a Host Number. The Network Number identifies the network to which a device is directly connected and the Host Number identifies the specific device connected to the network. The Subnet Mask is used to determine which parts of the IP Address relate to the Network Number and the Host Number. Both the IP Address and the Subnet Mask are composed of a set of four numbers, expressed in the form A.B.C.D. Whenever a 255 exists in a specific position in the Subnet Mask, then that respective value in the IP Address relates to the Network Number. Whenever a 0 exists in a specific position in the Subnet Mask, then that respective value in the IP Address relates to the Host Number. Given the computer s IP address and its subnet mask , the first three values in the IP address are the Network Number and the last value is the Host Number. Thus, the computer is host 1 on network Note that the network number is expressed with a 0 s placed in the host number positions. e) Verify that the IP Address has been changed by clicking the Details button the Local Area Connection Status window and checking the IPv4 Address in the Network Connection Details window that appears. f) Once the IP address is properly set, close all of the network windows and continue on to the next section of the procedure. Assigning IP Addresses to the PLC and the VFD Whenever the PLC and the VFD are powered-up, they begin broadcasting requests for an IP Address on the Ethernet network. A DHCP Server is required to assign IP Addresses to these devices. The software BOOTP-DCHP Server on the desktop computer will be utilized to perform this task. Complete the following steps to start and configure the BOOTP software to assign the following addresses: PLC VFD Start the BOOTP software on the desktop computer by clicking Start and choosing: All Programs Rockwell Software BOOTP-DHCP Server BOOTP-DHCP Server. 4. The BOOTP program window has two main fields; Request History and Relation List. The Request History field displays the MAC Address of any network device that requests an IP Address. The Relation List field displays the devices to which BOOTP is configured to assign an IP Address if requested

5 5. Locate the Ethernet (MAC) Addresses of the PLC and the VFD that are present on your workbench. The MAC address of the PLC is written on the front of the PLC s LabVolt frame and the MAC address of the VFD is written on the VFD s terminal cover. MAC (Media Access Control) Addresses are hardware level addresses that are assigned by the manufacturers of the devices and are specific to the type of network that is being utilized, in this case an Ethernet network. Ethernet MAC addresses are composed of a set of six, two-digit hexadecimal numbers, expressed in the form AA:BB:CC:DD:EE:FF. 6. Whenever a device on the network broadcasts a request for an IP Address, the request will appear in the Request History field of the BOOTP window. Locate the MAC address of the PLC within the Request History field and double-click that entry. A New Entry window will appear. Note the example MAC address shown in the above figure may differ from that of your PLC. 7. Enter the IP Address, Hostname, and Description values shown below and click OK when done. Note that the MAC address displayed in the figure may differ from that of your PLC. 8. Once the new entry is complete, the entry will appear in the Relation List field of the BOOTP window. The Relation List shows all of the user-defined MAC IP address relations. The next time a device with a listed MAC address requests an IP address, BOOTP will assign the appropriate address to the device, after which that device will stop sending out any more address requests. 9. In the same manner, double-click on MAC address of the VFD within the Request History field of the BOOTP window, enter the following New Entry values and click OK. The information for the VFD should also appear in BOOTP s Relation List field. 10. When BOOTP assigns an address to a device, the assigned value will also appear in the Request History field of the BOOTP window next to the corresponding request. Note that you may need to scroll up or down in the Request History field to verify that an IP address has been assigned to a specific device. Yours will be xx - 5 -

6 11. Minimize (do NOT close) the BOOTP program window. By minimizing it instead of closing the program, BOOTP will continue running in the background. That way, if you have to power-down either the PLC or the VFD, BOOTP will automatically reassign them an IP address when they are powered-up again. Note that, by choosing File Save As in the BOOTP window, you can save a copy of the relation list in a.bpc (BootP Config) file, after which you can automatically restart BOOTP with the previously-entered relations by double-clicking on the saved bpc file. Confirming Ethernet Network Connectivity The PLC, the VFD, and the desktop computer should be networked together and able to communicate with each other. You can confirm this by utilizing Internet Explorer to access the webpage-based interfaces provided by both the PLC and the VFD. 12. To access the webpage-based interface of the PLC: Run Internet Explorer and enter the PLC s IP Address ( ) into the program s address bar; Internet Explorer will display the PLC s webpage-based interface. Take a moment to become familiar with the PLC s web interface before proceeding to Step To access the webpage-based interface of the VFD: Enter the VFD s IP Address ( ) into Internet Explorer s address bar; you will be taken to the homepage of the VFD s web interface. Take a moment or two to become familiar with the interface before proceeding to Step Close the Internet Explorer window. RSLINX CLASSIC RSLinx Classic is a program that provides the protocols necessary for Microsoft Windows applications such as RSLogix 5000 to communicate with Allen-Bradley networks and devices. Complete the following steps to start and configure the RSLinx software. 15. Run the RSLinx Classic software from the desktop. 16. In the main RSLinx window, choose Communications Configure Drivers. A new Configure Drivers window will open. 17. If any Configured Drivers are already present, Stop and Delete them. 18. In the Available Driver Types drop-down list, locate and choose EtherNet/IP Driver and click the Add New button. 19. Click OK to accept the default name AB_ETHIP-1 in the Add New RSLinx Classic Driver window that appears. 20. Choose the desktop computer s Ethernet adapter (IP Address ) from the list that appears in the Configure Driver: window and click OK

7 21. The Configure Drivers window should appear as shown to the right. Click Close to save and close the Configure Drivers window. 22. In the main RSLinx window, choose Communications RSWho. Your RSLinx window should look similar to the one shown to the right: 23. Click the next to the AB_ETHIP-1, Ethernet entry to expand that item. You should see both the PowerFlex 40 and the Compact Logix 1769-L32E devices similarly listed. 24. Fully expand all the 1769-L32E entry to investigate all of its attached components. The complete set of entries should appear as shown to the right. Note it may take a few seconds for each of the items to appear as you continue to expand down the list. Also note that the IP addresses shown above for the PLC and VFD differ from your values. 25. Minimize (do NOT close) the RSLinx window. You are now ready to begin programming the PLC. But, to do this, you must first create a project. RSLOGIX 5000 SOFTWARE RSLogix 5000 is the software that you will be utilizing to program the Compact Logix PLCs. Software Revision 20 is loaded on the laboratory computers. Note that the software revision must match the firmware revision that is loaded into the PLCs, which is currently version Log into the desktop computer (user:.\student pw: student) and execute the RSLogix 5000 software. If a shortcut is not available on the computer s desktop, the RSLogix software can be found by clicking on the Start button and choosing: All Programs Rockwell Software RSLogix 5000 Enterprise Series RSLogix Creating a New Project Specifying the Controller and its Modules 26. Run the RSLogix 5000 Software and open a New Project from the Quick Start window. A New Controller dialog box will appear

8 27. Locate and select the 1769-L32E controller in the Type field. 28. Configure the controller as shown to the right and click OK. Note if you prefer, you may replace the word Main in the controller s Name field with your last name. (I.e. Lastname_Controller ) 29. The 1769-L32E controller should now appear in the I/O Configuration folder in the Controller Organizer window. Right-click on the 1769-L32E Ethernet Port LocalENB and choose Properties. 30. In the Module Properties Report: Controller:1 window, configure the IP Address as shown below and click OK. 31. Now that the controller has been selected, its input and output modules must be defined. In the Controller Organizer window, locate CompactBus Local under I/O Configuration. You may need to click to expand the contents. 32. Right-click on CompactBus Local and select New Module 33. When the Select Module Type window appears, uncheck all of the boxes except for Digital and Allen-Bradley. Locate and select a 1769-IQ16 from the list of modules in the lower field and click Create. A New Module pop-up window will appear

9 34. Configure the module as shown to the left but do NOT click OK yet. 35. In the Module Definition section of the New Module window, click Change 36. When the Module Definition window opens, change the value of Electronic Keying to Disable Keying and click OK to close the Module Definition window. 37. The Electronic Keying option in the New Module window should now read Disable Keying. If this is correct, click OK. The 1769-IQ16 should now appear under CompactBus Local in the I/O Configuration folder. 38. Once again, right-click on CompactBus Local and select New Module 39. Select and configure a 1769-OW16 in the same manner that the 1769-IQ16 was configured. The 1769-OW16 is mounted in Slot 2 of the Compact Logix controller. Adding the PowerFlex 40 VFD 40. Once complete, the 1769-IQ16 and the 1769-OW16 should both be present under CompactBus Local in the I/O Configuration folder. 41. At this point, you must add the PowerFlex 40 Variable Speed Drive to the I/O Configuration. In the Controller Organizer window under the folder I/O Configuration, right-click on the 1769-L32E Ethernet Port LocalENB and select New Module 42. In the Select Module window, locate and select a PowerFlex 40-E drive. 43. Configure the module as shown to the right, remembering to Change the value of Electronic Keying to Disable Keying. Also, under the Connection tab, uncheck the box Use Unicast Connection over EtherNet/IP - 9 -

10 44. When the module is configured correctly, click OK. 45. The PowerFlex 40 should new appear in the I/O Configuration under Ethernet. The control system devices are now completely configured. Note if there were any more network-connected devices in the control system, such as an additional VFD or remote I/O modules, they would be configured similar to the PF40. You are ready to begin creating your ladder diagram (i.e. programming the PLC). Creating the Ladder Diagram (Program) 46. In the main RSLogix 5000 window, Choose View Toolbars. When the Toolbars window opens, be sure the first five options are selected and then click OK. 47. In the Controller Organizer window, expand the MainProgram folder by clicking next to the folder. 48. Double-click the MainRoutine icon to open the Routine Editor window. 49. The Routine Editor window should now display a blank ladder diagram as shown below: Note the column of e s that appear to the left of the rung. The e s signify that the rung is in edit mode to signify that one or more instructions on the rung have not yet been properly defined. Once all instructions have been properly defined, the e s will disappear. 50. Choose the Bit tab in the New Component toolbar. The Bit tab displays instructions that are associated with a single-bit in memory. 51. Left-click and hold the XIC instruction. 52. Using the mouse, drag and place this instruction in the left-most position on Rung 0. Note that as you drag the instruction into the Routine Editor window, small green circles will appear on the ladder diagram that show the available locations in which the instruction may be placed

11 53. Right-click on the? above the XIC instruction and choose New Tag. Tags: Tags contain information that identifies data stored in memory, allowing that data to be associated with a specific instruction in order to define its operation. For example a bit in memory that is used to define the state of the XIC (0 open, 1 closed) New Tag Data Fields: Name an alpha/numeric identifier (including underscores) assigned to data stored in memory. Names can be used to help clarify the ladder logic structure by relating data to a specific task, function, or the physical device linked to that data. Names must begin with an alphabetic character, cannot be greater than 40 characters in length, and are not case sensitive. Description text-based field that may be used to further identify the function of the data. Type defines how the tag operates. Base a tag that results in the allocation of memory (when initially created) and that provides a reference to that data stored in that memory location, allowing the data to be directly linked to the operation of an instruction. Alias a tag that allows the programmer to assign a name to an existing base tag, such as the base tags that are automatically created when a specific module or device is added to the controller s configuration. For Example RSLogix 5000 created a base tag for each input port when the IQ-16 module was added to the controller s. The programmer could create an Alias tag named Stop and assign it to one of these base tags. Alias For (only active for Type: Alias) the pre-defined base tag re-named by the Alias tag. Data Type defines the type of data stored at the specific memory location, such as: BOOL (Boolean): 0 or 1 INT (Integer): to Scope defines whether a tag is global or local. The controller allows an application to be broken down into multiple programs. A global tag is available to all of the programs, while a local tag is available only to a specific program, such as Main Program. External Access defines whether the tag will have Read/Write, Read Only, or no (None) access from external applications such as HMIs. Style defines how the tag is displayed. (Style does not affect the Data Type ) Binary: Base 2 Decimal: Base 10 Constant prevents executing logic (instructions) from writing values to the tag if checked

12 54. Define the New Tag fields as shown to the right and click OK. This XIC instruction will provide the logic for the controller s Stop button within the ladder diagram. The instruction will return false when the bit referenced by the tag Stop is 0, and it will return true when the bit is 1. Note an XIC, which resembles a NO contact, was chosen because it will be held true (closed) by the physical NC Stop Pushbutton that is wired to Input-0 of the IQ-16 until the button is pressed. You will link the Stop tag to Input-0 in a later step. 55. The Stop button should now appear in your ladder diagram. 56. Add a Branch to the right of the Stop button and place an XIC on each of the parallel paths. The XIC in the upper branch will provide the logic for the controller s Start button, while the XIC in the lower branch will eventually act as a hold-in contact after Start is released. 57. Define a New Tag for the XIC in the upper branch (similar to the Stop tag) but name it Start. Note the lower XIC s tag will be defined later 58. Place an OTE instruction to the right of the parallel branches. The OTE instruction will provide the function of the main contactor s field coil which, when energized, will actuate the contactor s main contacts, in-turn energizing Motor #1. In terms of the ladder logic, when the rung condition to the left of the OTE is true, the OTE sets a bit to 1 (energize the motor), and when the rung condition is false, the OTE resets the bit to a 0 (de-energize the motor). 59. Define a New Tag for the OTE and name it Motor_1 60. In a physical system, if a hold-in contact is to be placed in parallel with a NO Pushbutton (Start), then an auxiliarycontact from the main contactor would be utilized. Since the Motor_1 OTE in represents the main contactor s field coil, the hold-in XIC can be assigned the same Tag as the OTE such that the XIC s state will be determined by the operation of the Motor_1 OTE. (I.e. the XIC will close when the OTE is energized ) To copy the OTE s tag onto the XIC, left-click and hold the mouse pointer over the OTE s tag name Motor_1. Drag the tag name over to the hold-in XIC instruction until a green circle appears next to the XIC s?, and release the mouse button

13 61. The hold-in XIC should now have the same tag name as the Motor_1 OTE. Note you could also have assigned the XIC the tag name Motor_1 by double-clicking on the? (tag name) of the XIC to enabling a drop-down menu. Open the drop-down menu to view a list of all of the previously-defined base tags from which you can select the desired tag (Motor_1) by locating and double-clicking on Motor_1 in the list. Also note that there are several base tags displayed in the list that you did not create. These are the tags that were created automatically by the RSLogix 5000 software when you added the controller s modules and the VFD. 62. Add a new rung to your routine by dragging a Rung icon in the New Component toolbar into your ladder diagram just below rung 0. A green circle will appear between rung 0 and the End rung as shown to the right. Release the mouse. 63. Add an XIC instruction to the left side of the new rung and link it to the Motor_1 OTE. (I.e. assign it the tag Motor_1) 64. Select the Timer/Counter tab in the New Component toolbar. 65. Select a TON (Turn-On Delay) timer and place it to the right of the XIC on the new rung. 66. Right-click the? in the Timer field of the TON and define a New Tag for the timer as shown to the right. 67. Double-click the? in the Preset of the TON and enter the value The timer s Preset value is defined in msec, therefore the value relates to a time of 10 seconds. 68. Rung 1 should now appear as follows:

14 TON Operation: When the rung condition to the left of the TON becomes true, the timer will be enabled and its Enable (EN) bit will be set. The timer will then begin incrementing the value in its Accumulator (Accum) in real-time from the initial value stored in the Accum up its Preset value, at which time it stops counting and the Done (DN) bit is set. The timer will remain in this state until the rung condition becomes false, at which time both the EN bit and the DN bits will reset and the Accum will revert back to its initially defined value. Note that, while it is enabled, the TON s Accum can also be reset back to its initial value by utilizing the RES (reset) instruction that resides on the Timer/Counter tab in the New Component toolbar. 69. Add another rung to your diagram between rung 1 and the end rung. 70. Add an XIC instruction to the left side of the rung and double-click on the? above the XIC. 71. Click on the down-arrow that appears in the Tag field, locate and expand the group of Run_Timer tags within the list of tags that appear. 72. Choose the.en bit of the timer by double-clicking on that option. Then press Enter. 73. Add a One Shot (ONS) to the right of the XIC and define a New Tag to name it one1. Note the ONS instruction is located under the Bit tab of the components toolbar. ONS Operation: When the rung condition to the left of the ONS becomes true, the ONS is triggered, making the ONS true for that one scan of that rung. If, at that time, the entire rung condition becomes true, then any output instructions on that rung also become true for that scan of the rung. But, after the ONS is triggered, the ONS will return a false condition during any successive scans of the rung until the ONS is reset. In order to reset the ONS so it can be triggered again, the rung condition to the left of the ONS must become false for at least one scan of the rung. 74. Add an Output Latch (OTL) and an Output Unlatch (OTU) to the left side of the rung. 75. Double-click the? in the Tag field of the OTL instruction and locate PowerFlex_40:O in the drop-down menu that appears. 76. Expand the set of PowerFlex_40:O tags; locate and double-click the tag PowerFlex_40:O.Start The tag PowerFlex_40:O.Start assigned to the XIC actually refers to the tag O.Start that resides in the remote device called PowerFlex_40. To control or monitor this bit, the PLC must be able to communicate with the PF40 over the Ethernet network

15 77. Assign the tag PowerFlex_40:O.Stop to the OTU in the same manner that you configured the OTL. OTL Operation: When the rung condition to the left of the OTL becomes true, the OTL will set the bit associated with its assigned tag to a one (1). But, when the rung condition to the left of the OTL becomes false, the OTL does nothing. In other words, the OTL can set the bit but it cannot reset the bit. OTU Operation: When the rung condition to the left of the OTU becomes true, the OTU will reset the bit associated with its assigned tag to a zero (0). But, when the rung condition to the left of the OTU becomes false, the OTU does nothing. In other words, the OTU can reset the bit but it cannot set the bit. PF40 Operation: The PowerFlex_40 must initially be enabled before it can supply a set of variable frequency voltages to its attached Induction motor. But, instead of pressing the green Start button on the PF40 front panel, we previously configured the PF40 to receive its Start command via its Comm Port. This task can be accomplished by using an OTL to set the remote O.Start bit that is located in the PF40. When the OTL becomes true, the PLC will send a message to the PF40 via the Ethernet network using the IP Address that was previously specified when initially configuring the project. When the PF40 receives the message, it will set the O.Start bit. Note that the PF40 also contains an O.Stop bit that should be reset whenever the drive is enabled by setting the O.Start bit. The PF40 will accept the Stop command both via the Ethernet network and by means of the red Stop button on the PF40 front panel. Additionally, note that the drive can be disabled by setting the O.Stop bit and resetting the O.Start bit. Once the drive has been enabled, it will begin to output a set of voltages, the frequency of which is determined by the value stored in the PF40 memory location associated with the tag O.FreqCommand. Note that the value stored in the tag location O.FreqCommand must be an integer number ranging from This value relates to the output frequency of the drive, and is specified in tenths of Hertz. Thus, if the value 600 is stored in that location, the drive will output a set of voltages with a frequency of 60.0Hz. 78. Add another rung to your diagram between rung 2 and the end rung. 79. Add an XIC instruction to the left side of the rung and assign it the Run_Timer.EN tag. 80. Add a ONS to the right of the XIC and assign it the new tag one

16 81. Add a MOV instruction to the right of the ONS one2. The MOV instruction resides under the Move/Logical tab of the New Components toolbar. MOV Operation: When the rung condition to the left of the MOV becomes true, the MOV instruction copies the data located in or specified by the Source field into the location specified by the Destination field (such as a frequency value into the PF40 s O.FreqCommand register). Note that, when locations are defined in the Source or Destination fields, the values currently stored in those locations will be displayed by the MOV instruction the fields that contain??. 82. Double-click the? in the Source field of the MOV instruction and enter the value Double-click the? in the Destination field of the MOV instruction and locate PowerFlex_40:O.FreqCommand in the drop-down menu that appears. 84. Double-click PowerFlex_40:O.FreqCommand to assign it to the Destination field. Rung 3 should now appear as follows: Change to 600 In this case, when the Run_Timer.EN XIC becomes true, the ONS will trigger, causing the overall rung condition to become true for that scan of the rung, in-turn causing the MOV instruction will copy the value 600 into the destination location defined by the tag PowerFlex_40:O.FreqCommand. The MOV instruction will only be executed when the Run_Timer is initially enabled, because once it is triggered, the ONS will return a false condition as long as the Run_Timer.EN XIC remains true. In order to reset the ONS, the rung condition to the left of the ONS must become false, which will only occur when the Run_Timer disabled. 85. Add another rung, and configure it as shown below: When the Run_Timer s accumulate reaches 10000, its.dn bit will be set, causing the Run_Timer.DN XIC to become true, triggering the ONS, in-turn causing the MOV to copy a frequency of zero (0) into PowerFlex_40:O.FreqCommand, thus stopping its motor

17 86. Add another rung, and configure it as shown below: This will also cause a frequency of zero to be written to PowerFlex_40:O.FreqCommand when the Stop button is pressed. 87. Finally, add one last rung and configure it as shown below: Change to XIO (NC) This will disable the PF40 when the Stop button is pressed. Linking the Instructions to the Input & Output Ports 88. Right-click on the tag of the Stop XIC and choose Edit Stop Properties. 89. Change the Type to Alias. 90. In the Alias For field, click on the down-arrow and locate the Local:1:I option. 91. Expand Local:1:I, locate Local:1:I.Data and click the down-arrow next to INT. 92. Double-click on port The Alias For field of the Tag Properties Stop window should appear as shown to the right. If so, click OK. You have now linked the Stop XIC to the physical NC Stop pushbutton that is wired to PLC Input Port 0 (zero). 94. Alias the Start XIC to the physical NO Start pushbutton that is wired to PLC Input Port Alias the Motor_1 OTE to the field coil of the Main Contactor that is wired to PLC Output Port 0 (zero). Reminder the output module is connected to slot 2 of the local bus. (Local:2:O) 96. Rung 0 of you ladder diagram should now display as shown to the right:

18 Note that, after the Motor_1 OTE was aliased to Local:2:O.Data.0, the Motor_1 XIC updated automatically to new alias tag. This happens because, when Edit Tag is selected, it is the actual tag itself that is edited, not the specific instruction. Thus, when a base tag is changed to an alias tag, all of the instructions that have been assigned that tag will update. 97. Locate and click the icon at the top of the RSLogix 5000 main window to have the software check your ladder diagram for errors. If any errors are found, they will be reported in the field below your ladder diagram at the bottom of the RSLogix 5000 main window. 98. If any errors are reported, make the appropriate corrections until no more errors are reported. Going Online with the Controller Downloading Your Program into the PLC In order to download your program into the PLC, you must first set the path that the RSLogix software can use to locate your controller. The path is basically the location of the controller within your network. 99. Click the to the right of the Path field in the main window In the Who Active window that appears, expand the AB_ETHIP-1, Ethernet items until the 00, CompactLogix Processor is located. Note that the items in your list may differ from those shown in the list to the right: 101. Select the 00, CompactLogix Processor and click the Set Project Path button. The path should now appear in the Path field as follows: Note that, once the correct path has initially been defined, future attempts to set the path can be completed by clicking the down-arrow on the right side of the Path field and selecting the correct path from the list of recently set paths that are displayed Click the down-arrow just to the right of the Offline field in the upper-left portion of the main RSLogix window and select Download If a Connecting to Controller window appears stating that you must first update the firmware to be able to connect to the PLC, click on Update Firmware and answer positively to any other Update windows that may appear until the update is complete When the Connected to Go Online window appears stating that The open project has changes that aren t in the controller, choose Download

19 105. A Download window will appear that will allow you to copy your program into the PLC s memory. Read the warning and then click Download If a pop-up box appears asking if the controller should be switched back to Remote Run mode, click Yes The RSLogix 5000 software should now be online with the PLC such that the operational state of the PLC can be seen by viewing the ladder diagram. Components in the diagram that are active (true) are highlighted in green. Initially the Voltage Supply Rails and the NC Stop button should be active Verify that the PLC is functioning correctly (see the steps below): Press the Start button and verify that the motor operates in the expected manner. When the motor comes to a stop, press the Start button again to restart the motor. It should not restart. Press the Stop button to reset the one-shots in the program and then push the Start button again. The motor should begin its cycle again. While the motor is running, push the Stop button to verify that the motor will immediately begin decelerating, eventually coming to a stop. If any errors are detected, go back Offline and trouble-shoot your ladder diagram

20 APPENDIX A PHYSICAL CONFIGURATION OF THE CONTROL SYSTEM EQUIPMENT WARNING Make sure that the main LabVolt power supply is de-energized before making any physical changes to the configuration of the control system equipment. Programmable Logic Controller L32E CPU & Power Supply 109. Energize the PLC s DC power supply by connecting a power cord from the Edison Plug adapter on the front panel of the PLC s frame to an AC power-strip on the workbench Connect the PLC to the control system s Ethernet switch via the RJ-45 communications jack available on the front panel of the PLC. This will allow the PLC to communicate with any other devices that are connected to the control-system s Ethernet network such as the VFD and the desktop computer If not already in the proper position, turn the key-switch on the PLC s CPU to the REM position (vertical). This will allow the PLC to be switched between program and run modes remotely using the RSLogix software that is installed on the desktop computer. IQ16 Input Module 112. Connect the negative terminal of the PLC s 24VDC source to the Common terminal of the Input Module. Note that both of these terminals are available on the PLC s front panel. This provides the DC zero-volt reference for all of the PLC s inputs Connect a NC (Stop) Pushbutton between the positive terminal of the PLC s 24V DC source and Input Port 0 of the PLC. Since the PLC s inputs are triggered by +24VDC, the NC pushbutton will hold Input Port 0 high unless the NC pushbutton is pressed Connect a NO (Start) Pushbutton between the positive terminal of the 24V DC source and Input Port 1 of the PLC. Since a NO pushbutton is connected to Input Port 1, the port will remain low unless the NO pushbutton is pressed. OW16 Output Module 115. Connect the Common terminal for Ports 0-7 the Output Module to Terminal 1 of the constant 120/208V 3 supply. Since the output module is a relay-type module, whenever an output port (numbered 0-7) is activated, 120VAC (with respect to the AC supply s neutral terminal) will be present at that output port s terminal

21 116. Connect Output Port 0 of the PLC to the left terminal of the contactor s Field Coil. Connect and the right terminal of the Field Coil to the Neutral (N) terminal of the constant 120/208V 3 supply. Whenever Output Port 0 is activated, the field coil will be supplied with 120VAC Connect Output Port 1 of the PLC to the left terminal of the Indicator Lamp. Connect the right terminal of the Indicator Lamp to the supply s Neutral (N) terminal. Whenever Output Port 1 is activated, the lamp will be supplied with 120VAC. Contactor Main Contacts 118. Connect terminals 1, 2, and 3 of the constant 120/208V 3 supply to terminals 1, 3, and 5 of the red contactor s NO contacts. Connect terminals 2, 4, and 6 of the contactor s NO contacts to terminals 1, 2, and 3 of the left-hand 3 Induction Motor s stator windings. Connect terminals 4, 5, and 6 of the left-hand 3 Induction Motor s stator windings together using two short (yellow) patch cables. When the contactor s field coil is energized, the NO contacts will close, in-turn energizing the left-hand induction motor by connecting terminals 1, 2, and 3 of the 120/208V supply to terminals 1, 2, and 3 of the motor s stator windings. PowerFlex 40 VFD 119. Connect the three blue leads attached to terminals L1, L2, and L3 of the PF40 VFD to terminals 1, 2, and 3 of the LabVolt constant 120/208V 3 Supply. This will provide the VFD with the supply voltage that is needs to operate Connect the three red leads attached to terminals T1, T2, and T3 of the PF40 VFD to stator terminals 1, 2, and 3 of the right-hand 3 Induction Motor. Connect terminals 4, 5, and 6 of the right-hand 3 Induction Motor s stator windings together using two short (yellow) patch cables. When the PF40 VFD is activated, the VFD will supply a variable-frequency AC voltage to terminals 1, 2, and 3 of the motor s stator windings Connect the VFD s RJ-45 Ethernet Port to the control system s Ethernet Switch. This will allow the VFD to communicate with any other devices that are connected to the control-system s Ethernet network such as the PLC and the desktop computer. Desktop Computer 122. Unplug the (blue) cable that connects the computer s Ethernet Port to the campus network. The computer must be disconnected from the campus network because the control system requires the use of the program BootP, which functions as a DHCP Server that can assign

22 IP addresses to computers attached to the network. IT Policy does not allow individual users to operate DHCP Server software while connected to the campus network Connect the computer s Ethernet Port to the control system s Ethernet Switch. LabVolt 3 Power Supply 124. Energize the main LabVolt power supply. Note TURN-OFF the main power supply immediately and notify the instructor if any unexpected operation occurs when the supply is energized,

23 APPENDIX B CONFIGURATION OF THE POWERFLEX 40 OPERATING PARAMETERS PowerFlex 40 VFD 125. The VFD is also configured such that, every time it is powered-up, it needs to be assigned an IP Address. Thus, once the VFD s CPU finishes its boot-up process, it will begin to send out broadcast requests for an IP Address on the Ethernet network. The VFD will also be provided with an IP Address once the desktop computer has been fully configured 126. Check (and correct if necessary) the setting of the 2 DIP-switches next to the Ethernet jack on the front of the PF-40. Correct Settings: Switch1 Off Switch 2 On Switch 1 is used to set the VFD for either single (off) or multiple drive operation (on). Switch 2 disables (off) or enables (on) the VFD s web browser interface Reset the VFD to its default configuration by changing the value stored in the VFD s Basic Program Group P041 to one (1) using the following procedure: a) Press the Esc button on the front panel of the PF40 two times. The left-most character ( d for Display Group) in the LED display should be flashing. b) Press the button once such that the left-most character changes to a P for Basic Program Group. This allows you to view and/or change the settings within this group. c) Press the Sel button once such that the right-most character of the display is flashing, and then use the or the button to change to program P041. Once P041 is displayed, press the button to choose this program. d) Use the or button to change the displayed value from a 0 to a 1 and press. This will reset the PF40 to default conditions. e) The PF40 s display should now be flashing F048. Fault code 48 occurs when the VFD s parameters were reset to their default values. f) Press the Stop button on the control panel of the PF40 to acknowledge/clear the fault. It is important that the VFD be reset back to its default configuration because the previous users may have changed its operating parameters, 128. In a similar manner, change the following parameter(s) of the VFD as stated below: P036 From 0 to 5 This allows the PF40 to receive the Start command (Start Source) from the Comm Port instead of the keypad. P038 From 0 to 5 This allows the PF40 to receive its drive Speed Reference (Speed Reference) (frequency) value from the Comm Port instead of the potentiometer on the front panel. P039 From 10 to 3 This decreases the length of time that it takes to PF40 to (Accel Time 1) increase its output frequency from an initial value to a commanded higher value from 10 sec down to 3 sec. P040 From 10 to 3 This decreases the length of time that it takes to PF40 to (Decel Time 1) decrease its output frequency from an initial value to a commanded lower value from 10 sec down to 3 sec Access the Display Group d012 and verify that it displays 55. This group displays the current settings of P036 and P038 as a 2-digit number