Rockwell Automation 193 User Manual

Quick Start

Drives and Motion Accelerator Toolkit

Important User Information

IMPORTANT

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: 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.

ATTENTION: 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, and recognize the consequence.

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, CompactLogix, ControlFLA SH, ControlLogix, DPI, DriveExplorer, DriveTools, Explorer, FactoryTalk, GuardLogix, HPK- Series, Integrated Architecture, Kinetix, LDC-Series, LDL-Series, Lo gix5000, MP-Series, PanelView, PowerFlex, ProposalWorks, RDD-Series, Rockwell Automation, Rockwell Software, RSLogix, R SLinx, SCANport, SMC, Stratix , Studio 5000, TL-S eries, and Ultra are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Follow this path to complete your Drives and Motion application.

Chapter 3

System Layout and Wiring

Chapter 1

Initial System Configuration

Using the DMAT Wizard

Chapter 4

Logic Configuration

Chapter 7

System Application Guide

Chapter 5

Fac toryTalk View ME Configuration

Chapter 6

System

Commissioning

Chapter 2

Bill of Materials Completion

Assembly

Packaging

POWERFLEX 4

AC DRIVE

Where to Start

Servo Drive

USER PROTECTED XXXVAC SUPPLY

MAINS DISCONNECT PROTECTION XXAMPS

FILTERED POWER

DRIVE

PROTECTION

Motion System Application Guide

755

Chapter 7

RESETTING

FIELD SIDE

MOTOR_01

MOTOR

RESET

The machine can go from any state in the shaded box to STOPPING.

START

STOP

IDLE

(enabled)

STOPPING

STOPPED (disabled)

STARTING

The machine can go from any state

in the solid box to ABORTING.

CLEARING

CLEAR

RUNNING

ABORT

ABORTING

ABORTED

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 3

Where to Start

Notes:

4 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Summary of Changes

This manual contains new and updated information.

New and Updated Information

This is a minor revision that reflects changes in the DMAT Wizard. As a result, the Module Definitions example dialog box for PowerFlex® 750-Series datalinks has changed. Refer to page 283 see the new dialog box.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 5

Summary of Changes

Notes:

6 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Preface

About this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Required Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chapter 1 Initial System Configuration Using the DMAT Wizard

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Review the DMAT Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Simple System and Drive Configuration Entries . . . . . . . . . . . . . . . . 19

Bill of Material Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Drawing Set Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Project File Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

FactoryTalk View Me Project File Output . . . . . . . . . . . . . . . . . . . . . 22

Review Other System Selection and Configuration Tools. . . . . . . . . . . . 23

Motion Analyzer Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engineering Assistant Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Product Selection Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Install Other System Selection and Configuration Tools . . . . . . . . . . . . 26

Install Motion Analyzer Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Install Engineering Assistant Software. . . . . . . . . . . . . . . . . . . . . . . . . . 26

Install Product Selection Toolbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Run the DMAT Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Launch the DMAT Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Edit the DMAT Wizard Configuration . . . . . . . . . . . . . . . . . . . . . . . . 31

Bill of Materials Completion

System Layout and Wiring

Chapter 2

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Import the Initial Project BOM File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Edit Your Project BOM File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Chapter 3

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Create a New Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Edit Power Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Edit Drive, Controller, and Safety I/O Drawings . . . . . . . . . . . . . . . . . . . 56

Edit System Communication Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 7

Table of Contents

Logic Configuration

Edit System Layout Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 4

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Import the Preconfigured Logix Designer Project . . . . . . . . . . . . . . . . . . . 74

Complete Drive and Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 76

Setting Drive Motor Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Set String Tag Names for Alarm History Faceplate . . . . . . . . . . . . . . . . . . 77

Set Visible Rows for Equipment Status Faceplate. . . . . . . . . . . . . . . . . . . . 79

Set Visible Rows for Equipment Status Faceplate for

Energy Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Set MSG Path in the E3 Plus Energy Monitoring Routine. . . . . . . . 81

Create Specific Application Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Application Code Logic Template Overview. . . . . . . . . . . . . . . . . . . . 82

Application Logic Creation Steps Using Application

Logic Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Application Logic Creation Steps Using Template . . . . . . . . . . . . . . 99

Verify and Save the Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

FactoryTalk View ME Configuration

Chapter 5

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Design From a Preconfigured HMI Application File . . . . . . . . . . . . . . . 104

Open FactoryTalk View ME Configuration Guide . . . . . . . . . . . . . 105

Restore and Open a Preconfigured HMI Application . . . . . . . . . . . 106

Delete Unused Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Delete Unused Parameter Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Configure Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Delete Unused Alarm Triggers and Tags. . . . . . . . . . . . . . . . . . . . . . . 115

Design From an Existing HMI Application File. . . . . . . . . . . . . . . . . . . . 117

Open Your Existing HMI Application File and Add Displays . . . 117

Add Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Configure Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Import Alarm Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Delete Unused Alarm Triggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Import and Edit Alarm Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Configure Goto Display Buttons on Startup Display . . . . . . . . . . . . . . . 132

Configure Equipment Status Faceplate Display . . . . . . . . . . . . . . . . . . . . 138

Add the Equipment Status Faceplate Display. . . . . . . . . . . . . . . . . . . 139

Add the ME_Equipment_Parameter File . . . . . . . . . . . . . . . . . . . . . . 140

Configure Goto Buttons on the Equipment Status Faceplate . . . . 142

Configure Additional Device Value Columns . . . . . . . . . . . . . . . . . . 144

Configure Equipment Status Faceplate for Energy Monitoring . . 145

8 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Chapter 6

Table of Contents

System Commissioning

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Download Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Download Logix Designer Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Configure and Download FactoryTalk Project to

PanelView Plus Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Commissioning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Commissioning CIP Motion Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Commissioning Sercos Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Commissioning PowerFlex 7-class Drives. . . . . . . . . . . . . . . . . . . . . . 159

Commissioning PowerFlex 5-class Drives. . . . . . . . . . . . . . . . . . . . . . 161

Commissioning PowerFlex 4-class Drives. . . . . . . . . . . . . . . . . . . . . . 162

Commissioning Kinetix 300 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Commissioning E3 Plus Overload Relays . . . . . . . . . . . . . . . . . . . . . . 164

Commissioning SMC-50 Soft Starter Modules . . . . . . . . . . . . . . . . 166

Commissioning Drives and Motion Systems. . . . . . . . . . . . . . . . . . . . . . . 167

Verify Network Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Operator (manual) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Program (automatic) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

System Application Guide

Chapter 7

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Machine Startup Faceplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Machine Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Machine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Program/Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

State Diagram Faceplate Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Motion Drives Faceplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Home View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Axis Status Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Axis Control Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Fault Indication View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Fault Diagnostic Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Configuration View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Trend Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

PowerFlex Drives Faceplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Home View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Control View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Fault Indication View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Fault Diagnostic Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Configuration Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 9

Table of Contents

Trend Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Energy Status Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Online Help Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

E3 Plus Overload Relay Faceplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Home/Control View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Fault Indication View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Fault Diagnostic Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Configuration View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Online Help Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Energy Status Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

SMC-50 Soft Starter Faceplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Home/Control View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Fault Indication View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Fault Diagnostic Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Configuration View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Online Help Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Energy Status Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Equipment Status Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Equipment Status Display for Energy Overview . . . . . . . . . . . . . . . . 202

Alarm History Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Logic Program Overview

Logic Module Customization

Appendix A

Machine/Application/Device Module Relationship . . . . . . . . . . . . . . . . 204

Module Routine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Machine Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Machine States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Machine Control Module Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Device and Application Status Rung Tags and Logic. . . . . . . . . . . . 211

Application Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Device Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Device Module Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Device Module Control Logic Example. . . . . . . . . . . . . . . . . . . . . . . . 217

Appendix B

Machine State Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Tag and Logic Modification Recommendations . . . . . . . . . . . . . . . . 222

State Display Tag Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Bypass Idle State Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Module Fault Customization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Alarm History Faceplate Logic Modification . . . . . . . . . . . . . . . . . . . . . . 227

Coordinated Reset Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Appendix C

Add Other Devices to the Equipment Status Faceplate

10 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Add Devices to the Equipment Status Faceplate. . . . . . . . . . . . . . . . . . . . 229

Add Optional Faceplate Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Appendix D

Table of Contents

Logix Designer Communication and Controller Configuration

Create and Add BOM Device Modules Without the DMAT Wizard

Assemble Project Drawing Set Without the DMAT Wizard

Configure Personal Computer Communication Properties . . . . . . . . . 235

Configure the EtherNet/IP Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Configure the Logix5000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Appendix E

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Select Initial BOM Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Add BOM Device Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Appendix F

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Select Drive Power Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Select Controller Power Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Select External Safety Relay Option Drawings . . . . . . . . . . . . . . . . . . . . . 260

Select Drive I/O Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Select Controller I/O Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Select System Communication Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . 264

Select System Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Select Power and Control Component Layout Footprint Drawings . 267

Controller, Network, and Device Configuration Without the DMAT Wizard

Appendix G

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Controller and Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Create a New Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Configure the Ethernet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Configure the Sercos Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Save the Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

PowerFlex Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Update PowerFlex Add-On Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . 278

PowerFlex 525 Add-On Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Add and Configure PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . 281

Set PowerFlex Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Download Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

CIP Motion Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Configure CIP Motion Drive Modules. . . . . . . . . . . . . . . . . . . . . . . . 293

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Configure Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 11

Table of Contents

Sercos Motion Drive Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Configure Sercos Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Configure the Motion Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Kinetix 300 Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Update Kinetix 300 Add-On Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . 310

Add Kinetix 300 Drives to Your Logix Designer Project . . . . . . . . 311

Configure Kinetix 300 Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

E3 Plus Overload Relay with Communication Auxiliary

Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Update E3 Plus Add-On Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Add E3 Plus Devices to Your Logix Designer Project . . . . . . . . . . . 322

SMC-50 Soft Starter Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Update SMC-50 Add-On Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Add SMC-50 Devices to Your Logix Designer Project . . . . . . . . . . 324

Download Soft Starter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

Import and Configure Logic Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Import and Configure the Machine Logic Module. . . . . . . . . . . . . . 328

Import and Configure Application Logic Modules . . . . . . . . . . . . . 332

Import and Configure Device Logic Modules . . . . . . . . . . . . . . . . . . 336

12 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Preface

IMPORTANT

About this Publication

This quick start provides step by step instructions for using the Drives and Motion Accelerator Toolkit to help you design, install, operate, and maintain a drive system. Included are selection tools, layout and wiring drawings, and pre-configured logic and HMI files to assist you in creating an Integrated Architecture™ solution for your application requirements.

The instructions also show how the Drives and Motion Accelerator Toolkit (DMAT) Wizard can automate the tasks needed to build the files used in the Integrated Architecture solution.

All of the supporting files are included on the Drives and Motion Accelerator Toolkit DVD, publication

IASIMP-SP017, including the DMAT Wizard. The DVD provides drive selection tools; CAD drawings for

panel layout and wiring; basic status, control, and diagnostic logic files; FactoryTalk® View ME and SE faceplates, and more. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. With these tools and the built-in best-practices design, the system designer is free to focus on the design of their machine control and not on design overhead tasks.

You can also download these same supporting files from the Rockwell Automation® Integrated Architecture Tools website, http://www.ab.com/go/iatools on the Beyond Getting Started tab.

Before using this quick start and the contents of the Drives and Motion Accelerator Toolkit DVD, read the Terms and Conditions READ ME.pdf on the DVD.

The beginning of each chapter contains the following information. Read these sections carefully before beginning work in each chapter.

• Before You Begin - This section lists the steps that must be completed and decisions that must be made before starting that chapter. The chapters in this quick start do not have to be completed in the order in which they appear, but this section defines the minimum amount of preparation required before completing the current chapter.

• What You Need - This section lists the tools that are required to complete the steps in the current chapter. This includes, but is not limited to, hardware and software.

• Follow These Steps - This illustrates the steps in the current chapter and identifies which steps are required to complete the examples using specific networks.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 13

Preface

Conventions

Convention Meaning Example

Used as an abbreviation for Integrated Motion on the EtherNet/IP network. This term describes

CIP Motion

Click

Double-click

Right-click Click right mouse button once (assumes cursor is positioned on object or selection). Right-click the Fieldbus Networks icon.

Drag and drop

Select Click to highlight a menu item or list choice. From the pull-down menu, choose H1-1.

Check/uncheck Click to select a checkbox option.

> Shows nested menu selections as menu name followed by menu selection. Click File>Page Setup>Options.

Expand Click the + to the left of a given item /folder to show its contents. In the H1-1 dialog box, expand FFLD.

Enter Used when you can type from the keyboard or choose from a list. Enter the catalog number of the product.

Type Used when the only option is to type from the keyboard. Type the catalog number of the product.

Press

Rockwell Automation servo drives and high-power AC drives that use CIP Motion and CIP Sync technology from ODVA, all built on the Common Industrial Protocol (CIP) communicating over the EtherNet/IP network. Two drive platforms that apply are Kinetix® 6500 servo drives and PowerFlex 755 AC drives when used on the EtherNet/IP network.

Click left mouse button once (assumes cursor is positioned on object or selection). Click button to initiate action.

Click left mouse button twice in quick succession (assumes cursor is positioned on object or selection).

Click and hold the left mouse button on an object, move the cursor to where you want to move the object, and release the mouse button.

Press a specific button on the PanelView™ terminal or other component with touch-screen technology.

CIP Motion Drive Configuration

Click Browse.

Double-click the H1 icon.

Drag and drop the desired block into the Strategy dialog box.

Check Cons ider Case if yo u want to conduc t a case-s ensitive search.

Press Axis Control.

Required Software

Rockwell Automation Software Cat. No. Version Required For

Studio 5000™ Logix Designer application

RSLogix™ 5000

• Control FLASH™

• BOOTP/DHCP utility (EtherNet/IP)

• RSLinx® Classic

FactoryTalk View Studio for Machine Edition

• FactoryTalk Services

• RSLinx Enterprise

• RSLinx Classic

Motion Analyzer Rockwell Automation Configuration and Selection Tools

ProposalWorks™ 7.5 or later Bill of materials development

Drives and Motion Accelerator Toolkit DVD IASIMP-SP017 N/A

(1) When Kinetix 350 servo drives are used, version 20.00 or later is required.

9324-RLD300xxE

9701-VWSTMENE 5.1 or later PanelView Plus terminals

website http://www.rockwellautomation.com/en/e-tools or ask your Rockwell Automation sales representative for the Product Selection Toolbox DVD

21.00 or later

All Kinetix and PowerFlex drive

(1)

19.00 or later

5.2 or later Drive/motor sizing

applications

CAD files, wiring diagrams, application files, and other support information

14 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Preface

Studio 5000 Environment

The Studio 5000 Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Logix Designer application is the rebranding of RSLogix 5000 software and will continue to be the product to program Logix5000™ controllers for discrete, process, batch, motion, safety, and drive-based solutions.

The Studio 5000 environment is the foundation for the future of Rockwell Automation engineering design tools and capabilities. It is the one place for design engineers to develop all the elements of their control system.

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

PowerFlex 4 Adjustable Frequency Drive User Manual, publication 22A-UM001

PowerFlex 40 Adjustable Frequency Drive User Manual, publication 22B-UM001

PowerFlex 40P Adjustable Frequency Drive User Manual, publication 22D-UM001

PowerFlex 70 and 70EC Adjustable Frequency Drive User Manual, publication 20A-UM001

PowerFlex 400 Adjustable Frequency Drive User Manual, publication 22C-UM001

PowerFlex 525 Adjustable Frequency AC Drive User Manual, publication 520-UM001 Provides mounting and wiring instructions for PowerFlex 525 AC drives.

PowerFlex 700 Adjustable Frequency Drive User Manual, publication 20B-UM001

PowerFlex 700H Adjustable Frequency Drive User Manual, publication 20C-PM001

PowerFlex 700S High Performance Drive, Phase II User Manual, publication 20D-UM006

PowerFlex 700S High Performance Drive, Phase I User Manual, publication 20D-UM001

PowerFlex 700 Vector Controlled AC Drives User Manual, publication 20B-UM002

PowerFlex 750 Series AC Drives User Manual, publication 750-UM001

PowerFlex Family Selection Guide, publication PFLEX-SG002

Provides mounting and wiring instruct ions for PowerFlex 4-class AC drives. Also provides information on how to set drive parameters and troubleshoot the drive.

Provides mounting and wiring instruct ions for PowerFlex 7-class AC drives. Also provides information on how to set drive parameters and troubleshoot the drive.

Provides drive specifications for the PowerFlex 4-class, 5-class, and 7-class AC drive products.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 15

Preface

Resource Description

PowerFlex 70 EtherNet/IP Adapter User Manual, publication 20COMM-UM010

Provides details on how to install, configure, and use the adapter.PowerFlex 70 DeviceNet Adapter User Manual, publication 20COMM-UM002

PowerFlex 525 Embedded EtherNet/IP Adapter User Manual, publication 520COM-UM001

Kinetix 300 EtherNet/IP Indexing Drives User Manual, publication 2097-UM001

Kinetix 350 Single-axis EtherNet/IP Drives User Manual, publication 2097-UM002

Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-UM002

Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001

Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

Kinetix 2000 Multi-axis Servo Drives User Manual, publication 2093-UM001

Kinetix 7000 Multi-axis Servo Drives User Manual, publication 2099-UM001

Ultra™3000 Digital Servo Drives Installation Manual, publication 2098-IN003 Provides mounting and wiring instructions for Ultra3000 digital servo drives.

Ultra3000 Digital Servo Drives Integration Manual, publication 2098-IN005

Kinetix Motion Control Selection Guide, publication GMC-SG001

Kinetix Rotary Motion Specifications, publication GMC-TD001

Kinetix Linear Motion Specifications, publication GMC-TD002

Kinetix Servo Drives Specifications, publication GMC-TD003

Kinetix Motion Accessories Specifications, publication GMC-TD004

Kinetix 6000 and Kinetix 6200/6500 Drive Systems Design Guide, publication GMC-RM003

Kinetix 300 and Kinetix 350 Drive Systems Design Guide, publication GMC-RM004

Kinetix 2000 Drive Systems Design Guide, publication GMC-RM006

Kinetix 7000 Drive Systems Design Guide, publication GMC-RM007

Ultra3000 Drive Systems Design Guide, publication GMC-RM008

E3 and E3 Plus Solid-state Overload Relay User Manual, publication 193-UM002.

EtherNet/IP Communications Auxiliary User Manual, 193-UM014

SMC™-50 Solid-state Smart Motor Controller User Manual, publication 150-UM011. Provides mounting and installation instructions for SMC-50 soft-starter modules.

Sercos and Analog Motion Configuration and Startup User Manual, publication

MOTION-UM001

Motion Coordinate System User Manual, publication MOTION-UM002

Integrated Motion on the Ethernet/IP Network Configuration and Startup User Manual, publication MOTION-UM003

Integrated Motion on the Ethernet/IP Network Reference Manual, publication MOTION-RM003

Provides mounting, wiring, configuring, and troubleshooting instructions for the Kinetix Motion Control servo drives.

Provides configuring and troubleshooting instructions for the Ultra3000 digital servo drives.

Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirem ents.

Product specifications for MP-Series™ (Bulletin MPL, MPM, MPF, MPS), Kinetix 6000M (Bulletin MDF), TL-Series™, RDD-Series™, and HPK-Series™ rotary motors.

Product specifications for Bulletin MPAS and MPMA linear stages, Bulletin MPAR, MPAI, and TLAR electric cylinders, and LDC-Series™ and LDL-Series™ linear motors.

Product specifications for Kinetix Integrated Motion over the EtherNet/IP network, Integrated Motion over sercos interface, EtherNet/IP networking, and component servo drive families.

Product specifications for Bulletin 2090 motor and interface cables, low-profile connector kits, drive power components, and other servo drive accessory items.

System design guide to determine and select the required (drive specific) drive module, power accessory, connector kit, motor cable, and interface cable catalog numbers for your drive and motor/actuator motion control system. Included are system performance specifications and torque/speed curves (rotary motion) and force/velocity curves (linear motion) for your motion application.

Provides mounting and installation instructions for E3 and E3 Plus overload relays and Bulletin 193 EtherNet/IP communication auxiliary modules.

Information on configuring and troubleshooting your ControlLogix® and CompactLogix™ sercos interface modules.

Information to create a motion coordinate system with sercos or analog motion modules.

Information on configuring and troubleshooting your ControlLogix and CompactLogix EtherNet/IP network modules.

Provides descriptions of the AXIS_CIP_DRIVE attributes and Logix Designer application Control Modes and Methods.

You can view or download publications at http://www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

16 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Chapter 1

755

00300

Conveyor

Y-S er vo

X-Ser vo

X-Y Gantry

Kinetix 6500

Drives

Diverter

Kinetix 300

Drive

PowerFlex 753

Drive

nde

Assembly

Packaging

Initial System Configuration Using the DMAT Wizard

In this chapter you use the Drives and Motion Accelerator Toolkit (DMAT) Wizard to create an initial bill of materials, assemble a system drawing set, and create a Studio 5000 Logix Designer project file with a preconfigured controller, network, drives and initial system program logic. In addition, you are introduced to several Rockwell Automation system configuration tools that provide assistance in sizing your motor/drive combinations for a variety of load, transmission, and application types.

To assist you in architecture and hardware selection, the Widg-O-matic machine application is referenced in the selection steps. Hardware selection includes all power and control equipment to support two servo drives for the X-Y gantry, one PowerFlex drive for the conveyor, and one Kinetix 300 drive for the packaging diverter.

Widg-O-matic Machine Application Example

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 17

Chapter 1 Initial System Configuration Using the DMAT Wizard

Install Other System Selection and

Configuration Tools

page 26

page 28

Review Other System Selection and

Configuration Tools

page 23

Review the DMAT Wizard

page 19

Run the DMAT Wizard

Start

Before You Begin

Collect specific application data, for example:

• System Input Voltage

• Ambient temperature and Altitude Specifications

• Transmission Type

• Motor data

• Load Data – Inertia and Cycle Profiles

• Other System Sizing Info

What You Need

• The Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative.

• PowerFlex Family Selection Guide, publication PFLEX-SG002.

• Kinetix Motion Control Selection Guide, publication GMC-SG001.

Follow These Steps

Complete the following steps to create a bill of materials and size your drives and motion system components.

18 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

Review the DMAT Wizard

Once you have a general idea of the overall control architecture, relative size, and type of the drives in your system, you can use the DMAT Wizard to create a bill of material, assemble a system drawing set, and create a Logix Designer application project file with a preconfigured controller, network, drives, and initial system program logic. This can be accomplished in minutes by inserting simple system and drive configuration entries and running other system selection tools as needed.

Simple System and Drive Configuration Entries

Bill of Material Output

The initial BOM files include power and control distribution equipment, control circuit protection, operator devices, and system drives and accessories.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 19

Chapter 1 Initial System Configuration Using the DMAT Wizard

Insert images diagonal/down/partial overlap <Wizard01.jpg, TBT>, <Wizard02.jpg, TBT>

LIM Module

AC Line Filter

Drive Power Example

Drive I/O Example

System Layout Example

System Drawing Set Output

The assembled system drawing set includes power distribution, drive power and control wiring, communication, and system layout drawings in .dwg, .dxf, or .pdf formats.

20 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

Project File Output

The project file includes preconfigured controller, drives, network, and machine/application/ device program logic providing an integrated logic architecture to add your specific application logic to. The preconfigured file saves hours in logic configuration and assembly.

MODULE COMMANDS

RESET

Machine Commands

Mach_Ctrl.Cmd.RESET

<WidgOmatic.Cmd.RESET>

Machine Commands

Mach_Ctrl.Cmd.STOP

<WidgOmatic.Cmd.STOP>

Machine Commands

Mach_Ctrl.Cmd.CLEAR

<WidgOmatic.Cmd.CLEAR>

Machine Commands

Mach_Ctrl.Cmd.ABORT

<WidgOmatic.Cmd.ABORT>

Module OK (NOT

Faulted)

Module.OK

<Gantry_X_Drive.OK>

ONS[0].5

ONS

<Gantry_X_Axis_Ctrl.Status.OK>

Module OK (NOT

<Gantry_X_Drive.OK>

Module OK (NOT

Module.OK

<Gantry_X_Drive.OK>

ONS[0].7

ONS

Servo Ready for Use

Servo_Ctrl.Status.Ready

<Gantry_X_Axis_Ctrl.Status.Ready>

STOP

CLEAR

Servo OK (NOT

Faulted)

Servo_Ctrl.Status.OK

Faulted)

Module.OK

ABORT

Faulted)

ONS[0].6

ONS

<Gantry_X_Axis_Ctrl.Cmd.ClearFaults>

MOV Move Source 1

Dest ResetSEQ[0]

FLL Fill File Source 0 Dest ResetSEQ[0] Length 4

Clear Faults

Servo_Ctrl.Cmd.ClearFaults

FLL Fill File Source 0 Dest AbortSEQ[0] Length 4

FLL Fill File Source 0 Dest ResetSEQ[0] Length 4

MOV Move Source 1

Dest AbortSEQ[0]

NOP

(End)

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 21

Chapter 1 Initial System Configuration Using the DMAT Wizard

Factory Talk View ME Configuration Guide

This guide was created based on your DMAT Wizard selections and is meant to assist you in designing your Factory Talk View ME application using the DMAT Pre-configured HMI application files. Use this document as a supplement to the Design From a Preconfigured HMI Application File section in Chapter 5 of the Drives and Motor Accelerator Toolkit Quick Start guide, IASIMP-QS019A-EN-P.

This document will define specific steps to help you:

Restore and Open a Preconfigured HMI Application Delete Unused Displays Delete Unused Parameter Files Configure Parameter Files Delete Unused Alarm Triggers and Tags Configure Goto Display Buttons on Startup Display Configure Equipment Status Faceplate Display

Design From a Preconfigured HMI Application File

Restore and Open a Preconfigured HMI Application

1. Navigate to the Panelview Plus 1000 folder

2. Double-click the PVP1000_Application.apa archive file

Delete Unused Displays

List of Required Faceplates

[ALARM]

[DIAGNOSTICS]

[INFORMATION]

CIPMotion Faceplate

K300_Faceplate

PowerFlex_753_755_Faceplate

PVP1000_Startup_Faceplate

PVP1000_StateDiagram_Faceplate

PVP1000_AlarmHistory_Faceplate

PVP1000_EquipmentStatus_Faceplate

Delete Unused Parameter Files

List of Required Parameter Files

CIPMotion_Parameter

K300_Parameter

PF_Parameter

Startup_Parameter

StateDiagram_Parameter

EquipmentStatus_Parameter

FactoryTalk View Me Project File Output

The FactoryTalk View Me ConfigurationGuide folder contains two files. The FactoryTalk View Me (.apa) file contains the basic screens and parameters needed for a DMAT Wizard application. The folder also includes a Word document with custom instructions on how to adopt the example file to your application drive set and prepare it to add any additional screens.

22 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

Review Other System Selection and Configuration Tools

Rockwell Automation provides a variety of other system selection and configuration tools.

Motion Analyzer Software

Motion Analyzer software is a comprehensive standard-drives and motion-control application sizing tool used for analysis, optimization, selection, and validation. Motion Analyzer software includes configuration of load types, profiles, and mechanisms for a variety of applications.

Load Type and Data

Mechanism Type and Data

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 23

Chapter 1 Initial System Configuration Using the DMAT Wizard

Profile Data

Solution Options

Engineering Assistant Software

Engineering Assistant software provides inertia, power/ torque, braking, and other application specific calculators and formulas to assist you in sizing the motor, drive, and transmission for your application. Use this software as a supplement to Motion Analyzer.

24 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Product Selection Toolbox

The Rockwell Automation Product Selection Toolbox (PST) offers a complete suite of user tools for product selection and configuration across produc t lines from project conception through final design. From push buttons to drives to motor control centers and fully networked control systems, you’ll find the product information and configuration assistance you need to help you and your customers succeed with Rockwell Automation.

• Provides access to information on a broad range of Allen-Bradley® products and services

• Easy product selec tion interface to make it a snap to determine the exact catalog numbers for the item you need

• Access to current list pricing, and a comprehensive supplemental product information list

• Contains features, such as product selection wizards, agreement pricing, a spare parts generator, and the ability to separate par t numbers to see what Rockwell Automation components comprise them

• All of these features and more can help you select the correct product based on your requirements and give your customers the information they need fast

• Lets you quickly develop Logix/NetLinx control system configurations with BOM and reports

• Integration with configurator allows configuration of PowerFlex drives and ArmorStart motor controllers

• Motion control drive/motor combinations and accessories can be added through links to Motion Analyzer software

• New Ethernet capabilities include Stratix™ switches and physical media with enhanced graphical views

• IAB output can be easily exported to ProposalWorks to take advantage of extended proposal generation features, and supplementary data

Product Selection & System Design Tools

• Assists the user in selecting correct motor for application, proper drive, and gearbox

(if required)

• Effective optimization capabilities allow user to get the most out of the selected motor and drive combination

• Allows users to have the most up-to-date applications, product, price, and supplementary information

• All programs are scheduled for update every three weeks

• Assists in crossing competitive part numbers to Rockwell Automation equivalents

• Gives users the ability to submit crosses directly to PST and they will provide a cross or users

can go to: ab.com/e-tools

and look up existing cross references in the database

• Allows you select product 3D CAD drawings in AutoCAD software

• Provides you with access to thousands of drawings for a wide range of Allen-Bradley

products as well as assistance configuring catalog numbers

• Helps you config ure Motor Control System starters for rated motor voltage s from 230…690V

• Program provides the correct catalog number, wiring diagram, and layout drawing for starters

of your choice

• Provides assistance in selecting and dimensioning all of required busbar rack components

• Simplifies the design of custom terminal block rails

• Allows you to select and place terminal blocks on mounting rail along with

specifying labeling of terminal blocks, locating jumper bars between blocks, automatically selecting end barriers, and partition plates

• Intuitive software application designed specifically for configuring Motor Control Centers

• User friendly inter face helps reduce error and enables customers to get their MCCs quickly

Initial System Configuration Using the DMAT Wizard Chapter 1

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 25

Chapter 1 Initial System Configuration Using the DMAT Wizard

Install Other System Selection and Configuration Tools

You can install the system selection and configuration software tools from the Drives and Motion Accelerator Toolkit DVD or download them from the Web.

Install Motion Analyzer Software

1. Navigate to and select the Motion Analyzer Installation application on the toolkit DVD.

The Motion Analyzer Welcome dialog box opens.

2. Click Next and follow installation instructions.

Install Engineering Assistant Software

Follow these steps to install the Engineering Assistant Software tool from the Drives and Motion Accelerator Toolkit DVD.

1. Navigate to and select the Engineering Assistant Installation application on the toolkit DVD.

The initial Engineering Assistant Setup dialog box opens.

2. Click OK and follow installation instructions.

26 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

Install Product Selection Toolbox

Follow these steps to install desired tools from the Product Selection Toolbox. ProposalWorks software installation is the minimum requirement for completing your system bill of materials in the next chapter.

1. Navigate to and select the System Selection and Configuration Tools Installation application on the Drives and Motion Accelerator Toolkit DVD.

The Product Selection Toolbox Software InstallShield Wizard opens.

2. Check all features that you wish to have installed.

3. Click Next and follow all install wizard instructions to complete the software installation.

ProposalWorks software installation is the minimum requirement for completing your system bill of materials in the next chapter.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 27

Chapter 1 Initial System Configuration Using the DMAT Wizard

Run the DMAT Wizard

The DMAT Wizard creates an initial bill of materials, assembles a system drawing set, and creates a Logix Designer project file with preconfigured controller, network, drives, and initial system program logic. All this in just minutes by executing the following steps.

If you prefer to build these initial files using the traditional application tools, skip over this section and go directly to Chapter 2.

Launch the DMAT Wizard

Follow these steps to launch the DMAT Wizard and set up your wizard configuration.

1. Navigate to and select the DMAT Wizard .exe file on the Drives and Motion Accelerator Toolkit DVD image.

The DMAT Wizard opens and a dialog box opens, explaining the general scope of the wizard.

2. Read the DMAT Wizard dialog box and click OK to continue wizard configuration.

28 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

The Open or Create a Project dialog box opens.

3. Click Create New to initiate a new project.

Another configuration information dialog appears explaining machine, application, and drive configuration.

4. Read configuration information dialog box and click OK to continue.

5. The New Project Wizard dialog box opens.

a. Enter Project Name.

b. Enter Project Description (optional).

c. Click Next.

6. From the Number of Machines pull-down menu, choose the number of machines in your project.

Initial System Configuration Using the DMAT Wizard Chapter 1

A machine, as defined by the wizard, is a control system using a single controller and housed in a single enclosure.

7. Click Next.

8. Click the Machine Name edit field and enter the desired

machine name.

For the Widg-O-matic example, the machine name entered is WidgOmatic.

9. Click the Power Voltage Class edit field and from the pull-down menu choose the power voltage for your system.

For the Widg-O-matic example, the voltage level is 400/ 460V AC.

10. Click the Application Qty edit field and from the pulldown menu choose the number of applications you are configuring.

For the Widg-O-matic example, the quantity is set to 2.

11. Click Next.

The WidgoMatic machine displays with the number of applications specified in step 10.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 29

Chapter 1 Initial System Configuration Using the DMAT Wizard

12. Click the Application_x edit fields and rename the application names.

For the Widg-O-matic example, the two applications were renamed Assembly and Packaging.

13. From the Low-Voltage drives pull-down menus, choose the number of low-voltage drives to assign to each application.

For the Widg-O-matic example, the quantity was set to 0 for the Assembly application and 1 for the Packaging application.

14. From each of the Servo Drives pull-down menus, choose the number of servo drives to assign to each application.

There are three types of servo drives. For the Widg-O-matic example, the CIP Motion Servo Drives quantity was set to 2 for the Assembly application and the EtherNet/IP Indexing Servo Drives quantity was set to 1 for the Packaging application. Also, you can set the number of electronic overload relays and soft-starter modules for your application.

15. Click Finish.

The DMAT Wizard dialog box opens.

16. Review the wizard information and click OK.

The DMAT Wizard configuration dialog box opens.

30 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

Edit the DMAT Wizard Configuration

Follow these steps to continue editing the DMAT Wizard configuration.

1. Edit your Machine Configuration.

a. Click the machine in your project configuration tree.

In this example, the machine name is WidgOmatic. The Machine editing window appears to the right of the project tree.

b. Click the Machine Name edit field to change the machine name.

c. Click each of the other machine configuration pull-down menus or check boxes and choose the

appropriate power and control options.

d. Select the Programming Software you intend to use for your application.

e. Repeat step 1 for each of your machines in your project.

2. Edit the Application Names.

a. Click an application in the project configuration tree.

For the WidgOmatic example, Assembly was selected. The Application editing window appears to the right of the project configuration tree.

b. Click the Application Name edit field to change the application name.

c. Repeat step 2 for each of the applications in your project.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 31

Chapter 1 Initial System Configuration Using the DMAT Wizard

3. Edit the SERCOS, CIP Motion, and Ethernet/IP Indexing Servo Drive Configurations.

a. Select a servo drive in the project configuration tree.

For the WidgOmatic example, CIP_Motion_Servo_Drive_1 was selected. The drive editing window appears to the right of the project configuration tree.

b. Click the Drive Name edit field and enter the desired drive name.

For the WidgOmatic example, Gantry_X was entered as the initial drive name.

c. Click the Drive Type pull-down menu to choose the drive family.

For the WidgOmatic example, the Kinetix 6500 drive was chosen.

d. For assistance in sizing complex motor/drive combinations, click Motion Analyzer or Kinetix Motion

Control Selection Guide, then return to this wizard section to complete your drive/motor configuration.

32 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

4. For multi-axis servo drive types, select an integrated axis module (IAM) for the first drive of its type.

For the WidgOmatic example, the Gantry_X drive is configured as an IAM module.

a. From the Spare Slot Count pull-down menu, choose the number of spare slots available on the Bulletin

2094 power rail.

b. From the Inverter Current Rating pull-down menu, choose the inverter current rating for your drive.

c. From the Converter Power Rating pull-down menu, choose the converter power rating for your drive.

d. Check Shunt Module if the Bulletin 2094 (rail-mounted) shunt module is included on your power rail.

e. Note the Slot Count value.

This is the total number of slots used on the 2094 power rail. You are prompted if the slot count exceeds the power rail capacity.

f. Check Velocity and Torque Mode Only if you would like the servo drive axis to be configured for

Velocity mode. To select Torque mode, use the Axis Properties configuration in the Logix Designer application. If this

box is clear, the axis configuration defaults to Position mode.

g. From the pull-down menus, choose the Motor Type and Motor Series being paired with the drive.

For the WidgOmatic example, the Gantry_X drive is configured for the Rotary Motor Type and the MPL Motor Series.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 33

Chapter 1 Initial System Configuration Using the DMAT Wizard

5. For single-axis drive types or secondary multi-axis servo drives, select the appropriate axis module (AM) configuration option.

For the WidgOmatic example, the Gantry_Y drive is a Kinetix 6500 (K6500) AM module.

a. From the Inverter Current Rating pull-down menu, choose the inverter current rating for your drive.

b. From the Parent IAM Drive pull-down menu, select the parent IAM module this AM module is

assigned to (applies to multi-axis systems only). AM modules must be assigned to a parent IAM module of the same drive family.

c. From the pull-down menus, choose the Motor Type and Motor Series being paired with the drive.

For the WidgOmatic example, the Gantry_Y drive is configured for the Rotary Motor Type and the MPL Motor Series.

d. Repeat step 3…step 5 for all of the remaining servo drives in your project.

34 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Initial System Configuration Using the DMAT Wizard Chapter 1

6. Edit the Low-Voltage Drive configurations.

a. Select Low_Voltage_Drive_x in the project configuration tree.

For the WidgOmatic example, Low_Voltage_Drive_1 was selected. The drive editing window appears to the right of the project configuration tree.

b. Click the Drive Name edit field and enter the desired drive name.

For the WidgOmatic example, Conveyor_Drive was entered as the initial drive name.

c. From the Drive Type pull-down menu, choose the drive family.

For the WidgOmatic example, the PowerFlex 753 (PF753) drive is selected.

d. Select the appropriate output current for the drive.

e. Repeat step 6 for all of the remaining low-voltage drives in your project.

7. Edit all electronic overload relays and soft starter modules in your application.

Current and other selection pull-down menus are similar to the drive menus.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 35

Chapter 1 Initial System Configuration Using the DMAT Wizard

8. Generate the Output Files.

Before you can generate a DMAT file, all red highlighted items must be cleared in your configuration.

a. Click Generate on the DMAT Wizard toolbar.

The Generate Outputs dialog box opens.

b. Check the Drawing Types you wish to have generated as part of the output files.

c. Click Generate.

The DMAT Wizard generates a folder containing the output files. If the Drives and Motion Accelerator Toolkit was installed in the default directory, you will find the folder located in: C:\Documents and Settings\My Documents\DMAT\<projectname>.

For the WidgOmatic example, the path is: C:\Documents and Settings\My Documents\DMAT\WidgOmatic.

d. Double-click the machine folders to view the different output folders and files created.

36 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Chapter 2

Bill of Materials Completion

In this chapter you use Rockwell Automation ProposalWorks software to complete the drives and motion system bill of materials that the DMAT Wizard created.

If you chose not to use the DMAT Wizard, follow the procedures in Appendix ProposalWorks file before executing the following steps in this chapter. If you do not have ProposalWorks software, you may use the Microsoft Excel file that the DMAT Wizard provides as a starting point in creating a bill of materials with the help of your local Allen-Bradley distributor.

E to assemble the initial BOM

Before You Begin

• Complete the initial system configuration using the DMAT Wizard (refer to Chapter 1) or

• Assemble the initial BOM using ProposalWorks software (refer to Appendix E)

What You Need

• The Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative

• ProposalWorks software, version 7.5 or later, or Microsoft Office Excel 2010 Download ProposalWorks software from http://www.rockwellautomation.com/en/e-tools/ local Allen-Bradley distributor for the Product Selection Toolbox DVD.

• The user manual for your Drives and Motion hardware. Refer to Additional Resources on page 15 for publication numbers.

or ask your

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 37

Chapter 2 Bill of Materials Completion

page 38

Import the Initial

Project BOM File

Edit Your Project BOM File

page 40

Start

Follow These Steps

Complete these steps to complete the commissioning process for your drives and motion application.

Import the Initial Project BOM File

Follow these steps to import the initial project BOM file.

1. Open ProposalWorks software, navigate to File Menu>Utilities, and select Import.

If you chose to assemble the initial BOM file using ProposalWorks software, open the ProposalWorks (.prp) file you created in Appendix E and skip to step 2.

38 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Bill of Materials Completion Chapter 2

2. Navigate to your projects .bom file and click Open.

If the default DMAT Wizard directory was used, your project's .bom import file is in C:\Documents and Settings\PC Name\My Documents\DMAT\ProjectName\MachineName\BOM directory.

The Widg-O-matic example file may be found in: C:\Program Files\RA_Simplification\DMAT\B-Files\ 6-Project Examples\Widg-O-matic.

The ProposalWorks file opens.

3. Click Refresh to update prices in local currency.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 39

Chapter 2 Bill of Materials Completion

Edit Your Project BOM File

The DMAT Wizard you used in Chapter 1 or the steps you followed in Appendix E created an initial bill of materials (BOM), however, individual preconfigured product listings should be reviewed and possibly edited to fit your specific application needs.

ProposalWorks software includes a variety of specific product configuration tools to make further BOM adjustments easy. These steps provide examples of using ProposalWorks Product Configuration Assistants to edit your initial project BOM file to meet your specific application needs.

Follow these steps to edit the BOM file you imported or assembled for your specific application.

1. Edit a product for your specific application.

a. Double-click a product catalog number to activate the Product Configuration Assistant.

In this example, catalog number 1489-A2D250 was selected. The Product Configuration Assistant dialog box opens. You can browse and select from a variety of

product options.

40 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

b. Click the Current Rating attribute.

Bill of Materials Completion Chapter 2

In this example, the Current Rating option is 25 A. For more in-depth product selection information, refer to product selection guides or Motion Analyzer software.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 41

Chapter 2 Bill of Materials Completion

c. For this example, select 15 A under the Current Rating field.

The catalog number field is replaced with 1489-A2D150.

d. Click Accept to make the product change within the Product Configuration Assistant.

The Product Configuration Assistant closes and your BOM file reflects the change.

42 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

2. Edit a product group for your specific application.

Product group refers to an item (catalog number) that includes one or more sub items.

a. Double-click a product group catalog

number to activate the Product Configuration Assistant.

In this example, item 13 (catalog number 2094-BMP5-M) with sub items 13.1 and

13.2 was selected.

The Product Configuration Assistant dialog box opens. You can browse and select from a variety of product options.

Bill of Materials Completion Chapter 2

b. Click the Inverter Current Rating attribute.

In this example, the Inverter Current Rating product option is 4 A. The sub items (13.1 and 13.2) include the control module and connector kit accessory. For more in-depth product selection information, refer to product selection guides or Motion Analyzer software.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 43

Chapter 2 Bill of Materials Completion

c. For this example, select 15 A under the Inverter Current Rating field.

The catalog number field was replaced with 2094-BM02-M. In addition, the 2094-EN02D-M01-S1 control module was chosen to replace the 2094-EN02D-M01-S0.

d. Click Accept to make the product change within the Product Configuration Assistant.

Sub item (13.2) also reflects the updated catalog number and description.

44 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

3. Delete products not required for your specific application.

a. Select the product or product group not required for your application.

In this example, items 37 and 38 were selected.

b. From your keyboard, press delete.

The product or products are deleted from the BOM project file.

4. Save your edited BOM project file.

Bill of Materials Completion Chapter 2

5. Send the BOM project file to your Rockwell Automation distributor for a quote.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 45

Chapter 2 Bill of Materials Completion

Notes:

46 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Chapter 3

Drive Power Example

Drive I/O Example

System Layout Example

System Layout and Wiring

In this chapter you edit the set of layout and wiring drawings from the DMAT drawing library that the DMAT Wizard created. If you chose not to use the DMAT Wizard, follow the procedures in Appendix F to assemble the initial project drawing set before executing the steps in this chapter.

Power, I/O, and Layout Drawing Examples

AC Line Filter

LIM Module

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 47

Chapter 3 System Layout and Wiring

To assist you in understanding how to best use the drawing libraries, the Widg-O-matic machine application example is used in the drawing editing steps provided. The Widg-O-matic machine includes the following drive, power, and control devices:

• Two Kinetix 6500 (400V-class) servo drives and motors (home and enable inputs)

• One PowerFlex 753 (400V-class) drive and induction motor

• One Kinetix 300 (400V-class) servo drive and electric cylinder

• One Bulletin 2094 line interface module (LIM)

• One ControlLogix controller and EtherNet/IP network module

Before You Begin

• Complete the initial system configuration using the DMAT Wizard (refer to Chapter 1) or

• Assemble the initial project drawing set without the DMAT Wizard (refer to Appendix F)

What You Need

• Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017

• AutoCAD Electrical or AutoCAD software to open the DWG or DXF files

• Adobe Reader software to open PDF files

• Line Interface Module Installation Instructions, publication 2094-IN005

• System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

• System Design for Control of Electrical Noise Video, publication GMC-SP004

• The user manual for your Drives and Motion hardware. Refer to Additional Resources on page 15 for

publication numbers.

48 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

System Layo ut and Wiring Chapter 3

page 50

Create a New Project

page 51

Edit Power Drawings

Edit Drive, Controller, and Safety

I/O Drawings

Edit System Communication

Drawings

Edit System Layout Drawings

page 56

page 61

page 62

Start

Follow These Steps

Complete the following steps to create your system layout and wiring drawings. These steps provide general instructions for how to maximize the use of the toolkit’s drawing library in creating a complete drives-andmotion system layout and wiring drawing set. AutoCAD or AutoCAD Electrical software is recommended to take full advantage of the drawing editing steps included in this chapter and the library’s device wiring references and attributes that move with the devices as you edit your project drawing set. Some of the initial project creation steps are illustrated using AutoCAD Electrical software, but most are generic and can be used with a variety of software drawing packages.

If you chose not to use the DMAT Wizard, follow the instructions in Appendix F before executing the following steps in this chapter.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 49

Chapter 3 System Layout and Wiring

Create a New Project

1. Open your drawing software.

2. Create and name your new project.

3. Add and select the toolkit library drawings assembled by the DMAT Wizard.

4. Navigate to the appropriate DWG or DXF Drawing directory that was created by the DMAT Wizard.

If the default DMAT Wizard directory was used, your project's drawing set is in C:\Documents and Settings\PC Name\My Documents\DMAT\ProjectName\MachineName\Drawings\filetype directory.

The Widg-O-matic example drawing files may be found in: C:\Program Files\RA_Simplification\ DMAT\B-Files\6-Project Examples\Widg-O-matic\WidgOmatic_CAD\filetype directory.

If you chose to assemble the Project Drawing Set without using the DMAT Wizard, navigate to the drawing directory you created in Appendix F.

50 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

System Layo ut and Wiring Chapter 3

Edit Power Drawings

1. Open your initial drive power drawing that includes the main power distribution components.

For the Widg-O-matic machine application example, the 010_K6500_460VAC_w_LIM.dwg file is opened. Refer to the figure on page 52.

2. Delete drives not used in your project.

For the Widg-O-matic machine application example, only two Kinetix 6500 drives are required, so the third drive is deleted. Refer to the shaded area in the figure on page 52.

3. Open all additional drive drawings and delete drives not used in your project.

For the Widg-O-matic machine application example, both the 020_K300_460VAC_Additional_Drives.dwg file and the 020_PF750_Series_460VAC_Additional_Drives.dwg file are opened and unused drives are deleted. Refer to the figures on page 53 and page 54.

4. Open all controller control power drawings and edit power connections and devices as necessary.

For the Widg-O-matic machine application example, no changes to the 030_CLX_GLX_120VAC_Control_Power.dwg files were required. Refer to the figure on page 55.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 51

Chapter 3 System Layout and Wiring

Select and delete

this drive.

Kinetix 6500 (460V) Drive with LIM Module

52 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Kinetix 300 (460V) Additional Drives

Select and delete

this drive.

Select and delete

this drive.

Select and delete

this drive.

System Layo ut and Wiring Chapter 3

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 53

Chapter 3 System Layout and Wiring

Select and delete

this drive.

Select and delete

this drive.

Select and delete

this drive.

PowerFlex 750 (460V) Additional Drives

54 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

ControlLogix/GuardLogix® (120V) Control Power with LIM Module

System Layo ut and Wiring Chapter 3

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 55

Chapter 3 System Layout and Wiring

Select and delete these drive

I/O blocks.

Edit Drive, Controller, and Safety I/O Drawings

1. Open all drive, controller, and safety I/O drawings as required for your application.

For the Widg-O-matic machine application example, the 060_K6500_Digital_IO.dwg file is opened.

2. Delete devices not used in your project.

For the Widg-O-matic machine application example, only two Kinetix 6500 drives are required, so the third and fourth I/O blocks are deleted.

Kinetix 6500 Digital I/O Example

56 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

System Layo ut and Wiring Chapter 3

3. Add standard or unique I/O devices and connections required for your application.

For the Widg-O-matic machine application example, the Enable on-off switches and Home proximity switches are added to both Kinetix 6500 drives (input 1 and 2 respectively).

Kinetix 6500 Drives (add digital I/O devices)

4. Repeat step 1…step 3 for all I/O drawings within your project.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 57

Chapter 3 System Layout and Wiring

Additional I/O library drawings, used for the Widg-O-matic machine example, are available from the Drives and Motion Accelerator toolkit DVD. These drawings represent a sample of drive and controller I/O drawings.

Additional I/O Library Drawing Examples

I/O Library Drawings File Name Page

Kinetix 6500 Drive Safety I/O 070_K6500_Safety_IO.dwg 58

Kinetix 6500 Drive Feedback 080_K6500_Feedback.dwg 59

ControlLogix Controller Digital Inputs 090_CLX_Digital_Inputs.dwg 60

Kinetix 6500 Safety I/O

58 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Kinetix 6500 Feedback

System Layo ut and Wiring Chapter 3

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 59

Chapter 3 System Layout and Wiring

ControlLogix Digital Inputs

60 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

System Layo ut and Wiring Chapter 3

Select and

delete

this drive

and cable.

Edit System Communication Drawings

1. Open the communication drawing for your application.

For the Widg-O-matic machine application example, the 060_120_Ethernet_Communication.dwg file is opened.

2. Delete network devices not used in the project.

For the Widg-O-matic machine application example, one of the Kinetix 300 drives and associated cable is deleted.

Ethernet Communication

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 61

Chapter 3 System Layout and Wiring

Copy this

Kinetix 6500

AM module.

Copy th is Kinetix 6500 IAM module.

FP_2094-B_6500

FP_2094-BM_6500

3. Add any network device footprints required for your application.

a. Navigate to and open the required footprint drawings that were added to your Project Drawings folder

from the toolkit library.

b. Copy device footprints from the footprint drawings.

In this example, Kinetix 6500 IAM and AM module footprints are copied.

Kinetix 6200/6500 Footprint Drawings

c. Paste the device footprints onto your communication drawing.

d. Re-route or copy cables on the communication drawings to the added devices.

Edit System Layout Drawings

1. Open the panel layout drawing for your application.

For the Widg-O-matic machine application example, the 150_CLX_w_LIM_Sm_Panel_Layout.dwg file is opened.

The panel layout includes a power distribution, drives, and control section. The panel is designed to accommodate best-practice techniques used to minimize electrical noise. Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

62 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Small Panel Layout Drawing (power distribution)

DIRTY

CLEAN

LIM Module

AC Line Filter

CLEAN wireway for noise sensitive device circuits.

DIRTY wireway for noise generating device circuits.

Power Distribution Section

System Layo ut and Wiring Chapter 3

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 63

Chapter 3 System Layout and Wiring

FP_2090-UXLF-136

FP_2090-UXLF-HV330

FP_2090-XXLF-X330B

FP_2090-XXLF-375B_3d

2. Replace or add power components to your panel layout drawing.

a. Inspect power section on layout drawing for proper component footprints for the project.

b. Open the associated power footprint drawings that were added to your project drawings from the

toolkit library. In this example, the 510_Line_Filter_Footprints.dwg file is opened.

Line Filter Footprint Drawing Examples

c. If the desired component is not represented in the current panel layout drawing, copy the proper

component footprint from the footprint drawings.

d. Delete the current component in the panel layout drawing and paste the desired component footprint

into its place.

e. Add any other required power components for your system.

64 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

3. Insert drives into the Drives Placement section.

DIRTY

CLEAN

LIM Module

AC Line Filter

CLEAN wireway for noise sensitive device circuits.

DIRTY wireway for noise generating

device circuits.

Drives Section

a. Open the panel layout drawing for your application.

Small Panel Layout Drawing

System Layo ut and Wiring Chapter 3

b. Open the associated drives footprint drawings that were added to your project drawings from the

toolkit library. For the Widg-O-matic machine application example, the 430_Kinetix_6200_6500_Footprints.dwg file

is opened.

c. Copy the desired drive components from the footprint drawings for your panel layout drawing.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 65

Chapter 3 System Layout and Wiring

Copy this

Kinetix 6500

AM module.

Copy th is Kinetix 6500 IAM module.

FP_2094-B_6500

FP_2094-BM_6500

DIRTY

CLEAN

LIM Module

AC Line Filter

CLEAN wireway for noise sensitive device circuits.

DIRTY wireway for noise generating device circuits.

Drives Section

Kinetix 6200/6500 Drive Footprint Drawings

d. Paste the drive footprints onto the panel layout drawing.

For the Widg-O-matic machine application example, two Kinetix 6500 servo drives, one PowerFlex 753 drive, and one Kinetix 300 drive was added to the layout drawing.

Small Panel Layout Drawing (drive placement)

66 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

4. Inspect control section for required control components and proper footprints.

DIRTY

CLEAN

LIM Module

AC Line Filter

CLEAN wireway for noise sensitive device circuits.

DIRTY wireway for noise generating device circuits.

Controller and I/O Section

a. Open the panel layout drawing for your application.

Small Panel Layout Drawing (control)

System Layo ut and Wiring Chapter 3

b. Inspect controller for required processor, I/O chassis, and I/O and communication modules, and add

footprints from the standard library as required.

c. Add any other required control components for your system.

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 67

Chapter 3 System Layout and Wiring

5. Edit your Enclosure Layout Drawing.

a. Open the enclosure layout drawing for your application.

For the Widg-O-matic machine application example, the 140_SM_Enclosure_Layout.dwg file is opened.

Small Enclosure Layout Drawing

b. Inspect the drawing for operator equipment required for your system.

c. Open the associated enclosure footprint drawings that were added to your project drawings from the

toolkit library. For the Widg-O-matic machine application example, the 600_PanelView_Plus_Footprints.dwg file is

opened.

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PanelView Plus Footprint Drawings

FP_2711P-B6C20A_FRONT

FP_2711P-B10C

FP_2711P-B15C

FP_2711P-T7C

FP_2711P-T10C

FP_2711P-T15C

FP_2711P-T6C

System Layo ut and Wiring Chapter 3

d. Copy the desired enclosure components from the footprint drawings for your enclosure layout drawing.

e. Paste the enclosure component footprints onto your panel layout drawing.

f. Add any other required enclosure components for your system.

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Chapter 3 System Layout and Wiring

Notes:

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Chapter 4

Machine

Module

Application

Module

Device

Module

PanelVie w Plus Terminal

Machine Faceplate

Device Faceplate

Controller Logic

HMI Application

Application

Status

Machine

Commands

Device

Commands

Device

Status

Operator

Commands

Machine Status

Logic Configuration

In this chapter you edit the preconfigured logic file that the DMAT Wizard created for your specific application.

Besides initial controller, network, and device configurations, the preconfigured logic file includes machine, application, and device logic modules that significantly speed-up your application logic development. In addition, the logic modules include control, status, and diagnostic code that provides information to preconfigured operator interface faceplates that you can run on personal computers or PanelViewPlus terminals.

If you chose not to use the DMAT Wizard or desire to add or edit controller, networks, or drives since the DMAT Wizard was executed, refer to instructions in Appendix G before executing the steps in this chapter.

Logic Modules

The machine module provides a state machine model that coordinates multiple devices and application logic for coordinated drives and motion applications. It provides overall machine commands, for example, start, stop, abort, clear, and reset to the application modules and the individual device modules based on the status of the applications and devices.

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Chapter 4 Logic Configuration

The application modules execute the machine commands and provide the more specific application commands to the drives and devices. It also coordinates the machine and application status, and executes the application fault commands. In addition, the toolkit includes motion logic examples to help you create your specific application logic.

The device modules translate the uniform machine and application commands and provide uniform status and diagnostics from the very specific device tags and parameters. This reduces much of the non-inventive code required to control and monitor the many unique devices.

For more information on the machine, application, and device logic modules, refer to Appendix A on page 203.

To assist you in understanding how to best use the preconfigured logic files, the Widg-O-matic machine application is used as an example in all of the logic configuration steps.

Preconfigured Logic Modules Used in Widg-O-matic Example

Module Type File Names

Machine

Application

Device

Machine_Module

Device&Application_Status

Application_Module

Motion_Simple_Move

PF_Run_Spd

K300_EIPMove

CIPMotion_Drive_Module

PF753_Drive_Module

K300_Drive_Module

Before You Begin

Run the DMAT Wizard (refer to Chapter 1) or complete Appendix G.

What You Need

• The Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative

• RSLogix 5000 software, version 19.0 or later, or the Logix Designer application, version 21.0 or later.

• RSLogix 5000 software, version 20.0 or later or the Logix Designer application, version 21.0 or later, to

configure Kinetix 350 servo drives, and when using ControlLogix 1756-L7xS controllers.

• The user manual for your Drives and Motion hardware. Refer to Additional Resources on page 15 for publication numbers.

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Logic Configuration Chapter 4

page 77

Set String Tag Names for

Alarm History Faceplate

page 82

Create Specific Application Logic

page 88

Application Logic Creation Steps Using

Application Logic Examples

page 99

Application Logic Creation Steps Using

Tem p la te

page 79

Set Visible Rows for Equipment

Status Faceplate

Optional Step

Complete if Alarm History faceplate is used in application.

Optional Step

Complete if Equipment Status faceplate is used in application.

page 76

Complete Drive and Motor

Confi guration

Are you familiar with

the Logix Designer application

programming environment,

motion instructions, and

programming

PowerFlex drives?

No Yes

Start

page 74

Import the Preconfigured Logix

Designer Project

page 99

Verify and Save t he Pro ject Fi le

Follow These Steps

Complete these steps to import and configure logic modules for your drives and motion application.

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Chapter 4 Logic Configuration

Import the Preconfigured Logix Designer Project

Follow these steps to open the preconfigured RSLogix 5000 or Studio 5000 Logix Designer project. This procedure is written for the Logix Designer application, but RSLogix 5000 software is similar.

1. From the Start menu, launch the Studio 5000 Logix Designer application.

The Studio 5000 dialog box opens.

2. Under the Create menu, click From Import.

3. Navigate to the Logic directory within the DMAT project.

If the Drives and Motion Accelerator Toolkit was installed in the default directory you will find the XML file in: C:\Documents and Settings\My Documents\DMAT\ProjectName\MachineName.

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Logic Configuration Chapter 4

IMPORTANT

For the Widg-O-matic example, the path is: C:\Program Files\RA_Simplification\DMAT\D-Wizard\WidgOmatic\WidgOmatic\Logic.

4. Select the logic xml file and Click Open.

5. From the Revision pull-down menu, choose the version of RSLogix 5000 software, versions 18, 19, or 20,

or the Logix Designer application, version 21 or later, to import into.

RSLogix 5000 software must be version 19.0 or later. RSLogix 5000 software, version 20.0 or later, is required to configure Kinetix 350 servo drives and when using ControlLogix 1756-L7xS controllers.

6. Click Import to save and open the project as an ACD file.

After the import process is complete, the project opens and the controller organizer displays all of the preconfigured project components including the controller, network, device configurations, the preconfigured logic program files, and the faceplate and control AOI files.

From this point on, you complete the logic module configuration for your specific drives and motion application guided by the remaining sections of this chapter.

To gain a complete understanding of the preconfigured project organization and logic refer to Appendix A on page 203.

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Chapter 4 Logic Configuration

Complete Drive and Motor Configuration

The DMAT Wizard uses default values for module properties (creating your axes) and axis properties (configuring your axes). When your application requires modifications to these fields, refer to the appropriate steps in Appendix G.

Changing Default Properties in Appendix G

Procedure Go To Do This

Complete CIP motion drive module configuration step 19 on page 298 Calculate and enter a value for the Bus Capacitance field.

Complete CIP motion axis properties step 8 on page 302 Review the Scaling, Load, and Actions categories. Make changes, if necessary.

Complete sercos drive module configuration step 13

Complete sercos drive axis properties step 8 on page 308 Review the Motor Feedback, Units, Conversion, and Fault Actions tabs. Make changes, if necessary.

Setting Drive Motor Ratings

You must manually change the motor series and motor type for each axis imported into your Logix Designer project file. The DMAT Wizard Logix Designer import file sets all drive motor type selections to Rotary, MPL, and to the largest available power rating as default. This is true even if you change the motor series and type in the DMAT Wizard. Those selections are reflected in the BOM only.

on page 306 Calculate and enter a value for the Additional Bus Capacitance field.

Follow these steps to edit the Drive/Motor tab.

1. Under My_MotionGroup in the Controller Organizer, double-click the Servo_Drive_x_Axis.

In the WidgOmatic example, Gantry_X_Axis was selected.

2. In the Axis Properties window, select Motor in the Categories tree.

3. Click Change Catalog.

The Change Catalog Number dialog box opens.

4. Scroll though the available catalog numbers and select the desired motor catalog number for your actual hardware configuration.

5. Click OK.

6. Repeat for each axis configured in My_MotionGroup.

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Logic Configuration Chapter 4

Set String Tag Names for Alarm History Faceplate

If you plan to use the Alarm History faceplate with your HMI application, follow these steps to set the application and device string tag names to match your application and device module names. These string names are used within the alarm messages indicating the device or application origin of the alarm.

1. Expand the Controller folder in your Controller Organizer and double-click Controller Tags.

The controller tags open in the workspace.

2. Expand one of your application status tags (UDT_AppStatus) and/or module status tags (UDT_ModuleStatus) and select the value field of the string tag named XXX.Name.

For the Widg-O-matic application example, the Assembly tag (UDT_AppStatus data type) is expanded and the Assembly.Name string tag value field is selected.

3. Click .

The String Browser dialog box opens.

4. Type the name of the associated application or device module.

This string name is used within the alarm history messages providing the fault origin.

5. Click OK.

The string tag value field updates with the name you typed in. For the Widg-O-matic application example, the value is Assembly.

6. Repeat step 1…step 5 for each application status (UDT_AppStatus) tag and device status (UDT_ModuleStatus) tag within the Controller Tags of your project.

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Chapter 4 Logic Configuration

For the Widg-O-matic application example, these application and device string tag names were entered.

Packaging

Conveyor_Drive

Diverter_Drive

Gantry_X_Drive

Gantry_Y_Drive

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Logic Configuration Chapter 4

Set Visible Rows for Equipment Status Faceplate

If you plan to use the Equipment Status faceplate with your HMI application, follow these steps to set the Inp_NumRowsVis tag value within the faceplate AOI of the device you intend to place in the first row.

1. Determine how many of the nine available rows you will use in the Equipment Status faceplate.

Refer to Chapter 5 beginning on page 101 for an overview of the faceplate so you can determine how many status rows you require and what device you would like to place in the first row.

For the Widg-O-matic application example, all four devices are included in the Equipment Status faceplate, with the Gantry X Axis placed in the first row.

• Gantry X Axis

• Gantry Y Axis

• Conveyor

• Diverter

2. Open the R02_Monitor routine for the device located in the first row of the Equipment Status faceplate

and navigate to the device specific faceplate AOI.

For the Widg-O-matic application example, the R04_Monitor routine in the P04_Gantry_X_Drive program was opened.

3. Click (View Configuration Dialog ) to open the AOI properties.

4. Navigate to the Inp_NumRowsVis tag and

select the Value.

5. Enter the number of devices you determined in step 1

For the Widg-O-matic application example, 4 was entered.

6. Click OK to close AOI properties and complete the update.

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Chapter 4 Logic Configuration

IMPORTANT

Set Visible Rows for Equipment Status Faceplate for Energy Monitoring

If you plan to use the Equipment Status faceplate with Energy Monitoring in your HMI application, follow these steps to set the Inp_NumRowsVis tag value within the energy object AOI of the device you intend to place in the first row.

1. Determine how many of the nine available rows you will use in the Equipment Status faceplate for Energy.

Refer to Chapter 5 on page 145 for an overview of the faceplate so you can determine how many status rows you require and what device you would like to place in the first row.

2. Open the controller tags and expand the energy object tag for the device located in the first row of the Equipment Status faceplate for Energy (DriveName_BEO).

3. Enter the number of required rows as the tag value for the Inp_NumRowsVis attribute.

In this example, the number of required rows is 5.

You must use the device module routines with energy support if you plan to use the equipment status faceplate for energy monitoring.

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Logic Configuration Chapter 4

Set MSG Path in the E3 Plus Energy Monitoring Routine

If the device modules with energy monitoring are used, an additional routine is included in the device program named R05_Energy. This routine gathers the energy data and energy related status and stores the data in the base energy object tag (UDT_BEO).

Rung 2 of the energy routine includes at least one explicit message for getting energy attributes from the device (some devices require more than one explicit message). The path for each MSG instruction is configured on import of the device module. However, for E3 Plus device modules, the path must be configured to include the port number of the 193-DNENCAT device (3) and the node address of the E3 Plus overload relay.

Follow these steps to configure the path for your E3 Plus device:

1. Click the ellipse button on the MSG instruction in rung 2 to launch the Message Configuration dialog box.

2. Click the Communication tab.

3. Add the 193-DNENCAT port number and your E3 Plus node address to your path configuration in the

following format: _DeviceName, 3, #.

4. Click OK.

Rung 4 of the energy routine monitors the energy rate and sets a status bit if the value exceeds the high alarm limit. The high-alarm limit default setting is 100. Configure this value to set the kW high-alarm limit for your device.

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Chapter 4 Logic Configuration

IMPORTANT

Create Specific Application Logic

Now that you have imported and configured all of the machine, application, and device modules, you can begin creating the specific application logic for your machine. You create your application logic within the R10_ApplicationCode routine of the application module. There are two methods for creating specific application logic for your machine.

The first method involves selecting and importing preprogrammed logic examples into the Application Code routine. These logic examples help familiarize less experienced users with the basics behind motion instructions and/or controlling PowerFlex drives via their add-on profiles. These preprogrammed logic examples are designed to work seamlessly with the application module and can help further reduce programming time.

The second method provides a blank template with placeholders if you choose to write your application-specific logic from scratch. This method is recommended for users who feel comfortable with the Studio 5000 Logix Designer programming environment and who also have experience with motion instructions and/or controlling PowerFlex drives via their add-on profiles.

Application Code Logic Template Overview

To assist you in creating specific-application logic that interfaces with the preconfigured machine, application, and device modules, a logic template is included in the R10_ApplicationCode routine of the application module. It includes placeholders for both run and stop sequences. All of the application logic examples also follow this same template.

Program the stop sequence to make sure all active devices are properly stopped.

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Logic Configuration Chapter 4

============================================

BY DEFAULT THE FOLLOWING RUNGS WILL BE ERRORED AND THEREFORE MUST BE ADDRESSED...

MODIFY OR OVERWRITE THESE RUNGS WITH THE APPLICATION SPECIFIC LOGIC

***PLEASE NOTE THE STOP SEQUNCE IS LOCATED DIRECTLY BELOW THE RUN SEQUENCE***

============================================

0 NOP

BY DEFAULT THE FOLLOWING RUNGS WILL BE ERRORED AND THEREFORE MUST BE ADDRESSED...

MODIFY OR OVERWRITE THESE RUNGS WITH THE APPLICATION SPECIFIC LOGIC

***PLEASE NOTE THE STOP SEQUNCE IS LOCATED DIRECTLY BELOW THE RUN SEQUENCE***

============================================

RUN SEQUNCE

============================================

1 NOP

SEQUENCE INITIATE

This rung is a placeholder where Application specific logic can be inserted.

By default, RunSEQ[0] is initially set to 1 following a Machine START command (i.e. "MachineName".Cmd.START).

Refer to the Machine Commands rungs located in the R03_Control routine of the Application Module.

e e e e e e e e e e e e e e e e

Equal Source A RunSEQ[0]

Source B 1

Move Source 10

Dest RunSEQ[0]

SEQUENCE PLACEHOLDER

This rung is a placeholder where Application specific logic can be inserted.

e e e e e e e e e e e e e e

Equal Source A RunSEQ[0]

Source B 10

Move Source 20

Dest RunSEQ[0]

SEQUENCE PLACEHOLDER

This rung is a placeholder where Application specific logic can be inserted.

e e e e e e e e e e e e e e

Equal Source A RunSEQ[0]

Source B 20

Move Source 30

Dest RunSEQ[0]

This rung can easily be duplicated if addtional sequence steps are needed.

Logic Placeholder

Run Sequence Template

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Chapter 4 Logic Configuration

The run sequence is initiated by a machine START command via the start logic in the R03_Control routine of the application module. By default, the run sequence is initiated by placing a value of 1 in the RunSEQ[0] tag. When the RunSEQ[0] tag is set to 1, the first step in the run sequence is executed, starting the run sequence. Each of the rungs in the run sequence provides a placeholder where you can insert application-specific step logic. The Run-sequence logic may include, for example, motion instructions, drive commands, and/or other conditional diagnostic logic.

The move (MOV) instruction is a placeholder to advance the run sequence to the next step by incrementing the RunSEQ[0] tag. Each step in the run sequence requires a unique value assigned in ascending order. The steps typically increase by multiples of five or ten. By default, the run-sequence template steps 1…10…20…30, and so on. Before moving to the next step, a predetermined condition must normally be met to make sure the current step is complete.

First Run Sequential Step Example

This Widg-O-matic application code first-run step (RunSEQ[0] = 1) example includes a motion axis move (MAM) instruction, an instruction error detection check, and an process complete (PC) check. Before the MOV instruction indexes to the next sequence step (for example, value 5 into RunSEQ[0] tag), the PC check must be met indicating that the move is complete. The instruction error detection check is used to detect a module fault in the application, preventing the run sequence from inadvertently hanging on a step.

84 Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013

Final Run Sequential Step Example

Logic Configuration Chapter 4

Much like the first run-step example rung, this Widg-O-matic final run step example also includes a motion axis move (MAM) instruction, an instruction error detection check, and an process complete (PC) check. The only difference is that the PC bit is used to reset the RunSEQ[0] tag back to a value of 1, which will repeat the motion sequential steps for continuous operation. If continuous operation is not required, the final step could just simply end the Run Sequence or just remain at this step indefinitely.

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Chapter 4 Logic Configuration

============================================

STOP SEQUENCE

============================================

5 NOP

============================================

STOP SEQUENCE

============================================

SEQUENCE INITIATE

This rung is a placeholder where Application specific logic can be inserted.

By default, StopSEQ[0] is initially set to 1 following a Machine STOP command (i.e. "MachineName".Cmd.STOP).

Refer to the Machine Commands rungs located in the R03_Control routine of the Application Module.

e e e e e e e e e e e e e e e e e

Equal Source A StopSEQ[0]

Source B 1

Move Source 10

Dest StopSEQ[0]

SEQUENCE INITIATE

This rung is a placeholder where Application specific logic can be inserted.

By default, StopSEQ[0] is initially set to 1 following a Machine STOP command (i.e. "MachineName".Cmd.STOP).

Refer to the Machine Commands rungs located in the R03_Control routine of the Application Module.

SEQUENCE PLACEHOLDER

This rung is a placeholder where Application specific logic can be inserted.

This rung can easily be dulpicated if addtional sequence steps are needed.

e e e e e e e e e e e e e e

Equal Source A StopSEQ[0]

Source B 10

Move Source 20

Dest StopSEQ[0]

SEQUENCE PLACEHOLDER

This rung is a placeholder where Application specific logic can be inserted.

This rung can easily be dulpicated if addtional sequence steps are needed.

SEQUENCE COMPLETE

By default, the Application is STOPPED when StopSEQ[0] reaches 999.

Refer to the Application Status rungs located in the R02_Monitor routine of the Application module to modify the

conditions that detemine when the Application is STOPPED (i.e. "ApplicationName".Stopped).

8 Equal

Source A StopSEQ[0]

Source B 20

Move Source 999

Dest StopSEQ[0]

SEQUENCE COMPLETE

By default, the Application is STOPPED when StopSEQ[0] reaches 999.

Refer to the Application Status rungs located in the R02_Monitor routine of the Application module to modify the

conditions that detemine when the Application is STOPPED (i.e. "ApplicationName".Stopped).

(End

)

Logic Placeholder

Stop Sequence Template

The stop sequence is initiated by a machine STOP command via the stop logic in the R03_Control routine of the application module. By default, the stop sequence is initiated by placing a value of 1 in the StopSEQ[0] tag. When the StopSEQ[0] tag is set to 1, the first step in the stop sequence is executed, starting the stop sequence. Each of the rungs in stop sequence provides a placeholder where application specific step logic can be inserted. The stop sequence logic may include, for example, motion instructions, drive commands and/or other conditional diagnostic logic.

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The move (MOV) instruction is a placeholder to advance the stop sequence to the next step by incrementing the StopSEQ[0] tag. Each step in the stop sequence requires a unique value be assigned in ascending order. The steps typically increase by multiples of five or ten. By default, the stop sequence-template steps 1…10…20…30 …999. Before moving to the next step, a predetermined condition must normally be met to make sure the current step is complete.

By default, the stop sequence ends when the StopSEQ[0] tag value reaches 999. The StopSEQ[0] tag is then monitored in the R02_Monitor routine of the application module for a value of 999 and then sets the ApplicationName.Stopped tag. The machine module monitors the ApplicationName.Stopped tag to determine when the application was properly stopped.

First Stop Sequential Step Example

This Widg-O-matic first-stop step example includes two motion axis stop (MAS) instructions, an instruction error detection check, and axis stopped check. Before the MOV instructions indexes to the next sequence step (for example, value 10 into the StopSEQ[0] tag), both axes must be stopped. An error detection check is used to detect a module fault in the application module, preventing the stop sequence from inadvertently hanging on a step.

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Chapter 4 Logic Configuration

Final Stop Sequential Step and Sequence Complete Example

This Widg-O-matic final-stop step and complete logic example includes logic to disable the two axes and confirm that the axes are disabled before confirming the application is stopped. Identical to the stop-sequence template, the stop-sequence complete rung sets the StopSEQ[0] tag value to 999 which indicates the stop sequence is complete.

Application Logic Creation Steps Using Application Logic Examples

If you are unfamiliar with Rockwell Automation’s general Logix5000 commands, Logix5000 motion commands, PowerFlex parameters, and/or are seeking common application methods for creating specific application logic, use these steps to create your specific application logic.

Toolkit Application Logic Example Overview

The toolkit provides a variety of common application logic examples designed to help you create your specific application logic. The logic examples are organized by the device modules they support.

• K300 Logic Examples – Supporting Kinetix 300 Ethernet drives

• Motion Logic Examples – Supporting CIP Motion, sercos, and virtual motion drives

• PF Logic Examples – Supporting all PowerFlex drives

• Widg-O-matic Example – Supporting a combination of two Kinetix 6500 CIP Motion drives, one

PowerFlex 753 drive, and one Kinetix 300 Ethernet drive.

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Logic Configuration Chapter 4

Kinetix 300 Logic Examples

Application Example File Name Description

EIP Position K300_EIPMove_App Enter position, speed, and accel/decel rates to perform incremental position moves.

EIP Velocity K300_EIPVel_App Run Kinetix 300 drive at a speed reference.

Index K300_Index_App Configure and run Kinetix 300 drive in indexing mode.

Motion Logic Examples

Application Example File Name Description

2-Axis Gear Motion_Gear_App Gear two axes together.

Adv/Retard Phasing Motion_Jog_PhaseMove_App Perform advance/retard phase moves with a MAM instruction on top of MAJ instruction.

2-Axis PCAM Motion_PCAM_App Jog an axis and Position Cam another axis to it.

Simple Move Motion_Simple_Move_App Move single axis with MAM instruction by using incremental moves.

Safe Limited Speed Motion_SLS_App For single axis, monitor SLS request in module. Reduce speed when SLS request detected.

TCAM Motion_TCAM_App Time Cam an axis.

PowerFlex Logic Examples

Application Example File Name Description

Run Forward / Reverse PF_Fwd_Rev_App Run PowerFlex drive forward, stop, and then run reverse.

Run at Speed PF_Run_Spd_App Run PowerFlex drive at a speed reference.

PF525 Run Forward / Reverse PF525Only_Fwd_Rev_App.L5X Run PowerFlex drive forward, stop, and then run reverse.

PF525 Run at Speed PF525Only_Run_Spd_App.L5X Run PowerFlex drive at a speed reference.

Widg-O-matic Logic Examples

Application Example File Name Description Applic ation Created From

Widg-O-Matic Assembly WOm_Assy_App1 Execute 2-axis simple moves for gantry. Motion_Simple_Move_App

Widg-O-Matic Packaging WOm_Pack_App2

Intermittently run PowerFlex drive for conveyor and execute Kinetix 300 position commands for diverter.

PF_Run_Spd_App K300_EIPMove_App

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Chapter 4 Logic Configuration

755

00300

Conveyor

Y-Se rvo

X-Ser vo

X-Y Gantry

Kinetix 6500

Drives

Diverter

Kinetix 300

Drive

PowerFlex 753

Drive

Assembly

Packaging

Widg-O-matic Logic Example Overview

To assist you in understanding how to best use the logic examples, the Widg-O-matic machine application is used as an example.

We recommend you study the Widg-O-matic assembly and packaging applications to see the interaction of the machine, application, and device modules within the application logic. The Widg-O-matic examples are created by using basic drives and motion application examples included in the toolkit. After you’ve studied these examples, create your own applications using the basic drives and motion examples.

The Widg-O-matic application example is an excellent canvas to experiment with the other application examples. The Widg-O-matic example includes two servo axes, one PowerFlex drive, and one Kinetix 300 drive. So, it is possible for you to import and study all of the application examples.

Widg-O-matic Machine Application Example

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The Widg-O-matic machine example has two applications (assembly and packaging) and has the following run sequences.

Assembly Application

Step Simple X-Y Gantry Run Sequence Value

1 Lower Y-axis, incremental distance 2.0 revs

2 Dwell, time 1.0 s

3 Raise Y-axis, incremental distance 2.0 revs

4 Extend X-axis, incremental distance 3.0 revs

5 Lower Y-axis, incremental distance 2.0 revs

6 Dwell, time 1.0 s

7 Raise Y-axis, incremental distance 2.0 revs

8 Retract X-axis, incremental distance 3.0 revs

9 Repeat and run continuously until the stop sequence is initiated by a machine abort or stop command.

Packaging Application

Step Conveyor and Diverter Run Sequence Drive

1 Verify diverter is in EIP Incremental Position mode Kinetix 300

2 Set conveyor drive direction forward and speed reference at 50 Hz PowerFlex 753

3 Enable diverter Kinetix 300

4 Configure diverter position, speed, accel/decel and start an incremental move Kinetix 300

5 Start conveyor, run at speed 3.0 seconds PowerFlex 753

6 Stop conveyor PowerFlex 753

7 Configure diverter position, speed, accel/decel and start an incremental move Kinetix 300

8 Start conveyor, run at speed 4.0 seconds PowerFlex 753

9 Stop conveyor PowerFlex 753

10 Repeat and run continuously until the stop sequence is initiated by a machine abort or stop command.

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Chapter 4 Logic Configuration

Import Application Logic Examples

Follow these steps to add logic examples to your R10_ApplicationCode routine within your application modules.

1. Expand the Tasks folder in the Controller Organizer.

2. Navigate to and open the R10_ApplicationCode routine within your first application program file.

For the Widg-O-matic application example, the R10_ApplicationCode routine within the P02_Assembly program was opened.

3. Select all rungs of the R10_ ApplicationCode routine.

4. Right-click the selected rungs and choose Import Rungs.

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5. Navigate to the 02_Application Logic folder within the toolkit’s files folder.

Logic Configuration Chapter 4

Your personal computer’s harddrive path is C:\Program Files\RA_Simplification\DMAT\B-Files\02_Application Logic.

6. Double-click the logic examples folder of choice.

For the Widg-O-matic application example, the Widg-O-matic_Logic_Examples folder was opened.

7. Select the desired logic example file to start your application logic.

For the Widg-O-matic application example, the WOm_Assy_App1.L5X file is selected.

8. Check Overwrite Selected Rungs.

9. Click Import.

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Chapter 4 Logic Configuration

The Import Configuration dialog box opens.

10. Click Tags within the Import Content organizer.

The Configure Tag References dialog box opens.

11. Replace tag names in the Final Name column with the associated axis or drive names for your application.

For the Widg-O-matic application example, _X_AxisName was replaced with Gantry_X_Axis and _Y_AxisName was replaced with Gantry_Y_Axis.

12. Click OK to complete rung import.

13. Repeat step 2…step 12 for each logic example you wish to import.

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SERCOS / CIP MOTION

SIMPLE INCREMENTAL MOVE

The following application example demonstrates how to control a SERCOS / CIP MOTION drive using sequencers &

Motion Instructions.

While the Machine is STARTING / RUNNING, the drive will be operated as follows:

1) Lower Y-Axis - Incremental Distance -2.0 revs

2) DWELL - Time 1 sec

3) Raise Y-Axis - Incremental Distance 2.0 revs

4) Extend X-Axis - Incremental Distance 3.0 revs

5) Lower Y-Axis - Incremental Distance -2.0 revs

5) DWELL - Time 1 sec

6) Raise Y-Axis - Incremental Distance 2.0 revs

7) Retract X-Axis- Incremental Distance -3.0 revs

8) Repeat

The Run Sequence is continuously repeated until the Stop Sequence is initiated by a Machine ABORT or STOP

command.

============================================================================================

0 NOP

============================================================================================

============================================

SERCOS / CIP MOTION

SIMPLE INCREMENTAL MOVE

The following application example demonstrates how to control a SERCOS / CIP MOTION drive using sequencers &

Motion Instructions.

While the Machine is STARTING / RUNNING, the drive will be operated as follows:

1) Lower Y-Axis - Incremental Distance -2.0 revs

2) DWELL - Time 1 sec

3) Raise Y-Axis - Incremental Distance 2.0 revs

4) Extend X-Axis - Incremental Distance 3.0 revs

5) Lower Y-Axis - Incremental Distance -2.0 revs

5) DWELL - Time 1 sec

6) Raise Y-Axis - Incremental Distance 2.0 revs

7) Retract X-Axis- Incremental Distance -3.0 revs

8) Repeat

The Run Sequence is continuously repeated until the Stop Sequence is initiated by a Machine ABORT or STOP

command.

============================================================================================

============================================

RUN SEQUENCE

============================================================================================

============================================

1 NOP

============================================================================================

============================================

RUN SEQUENCE

============================================================================================

============================================

INCREMENTAL MOVE

Lower Y-Axis

Incremental Distance -2.0 revs

2 Equal

Source A RunSEQ[0]

Source B 1

Motion Axis Move

Gantry_Y_Axis ... Motion Control Gantry_Y_Axis_Ctrl.MI.MAM[1] Move Type 1

Position -2

Speed Gantry_Y_Axis_Ctrl.Data.MoveSpd[1]

1.0

Speed Units Units per sec

Gantry_Y_Axis_Ctrl.Data.MoveAccel[0]

50.0

% of Maximum Decel Rate Gantry_Y_Axis_Ctrl.Data.MoveDecel[0]

50.0

Decel Units % of Maximum

MAM

Motion Axis Move

INCREMENTAL MOVE

Lower Y-Axis

Incremental Distance -2.0 revs

For the Widg-O-matic Assembly application example, the following rungs are imported. The rungs include a series of five incremental moves.

Sercos/CIP Motion Simple Incremental Move

14. Repeat step 1…step 12 for every application program you have in your drives and motion system.

Axis

Rockwell Automation Publication IASIMP-QS019E-EN-P - August 2013 95

Accel Rate

Accel Units

Chapter 4 Logic Configuration

For the Widg-O-matic application example, the R10_ApplicationCode routine within the P03_Packaging program was also opened and the WOm_Pack_App2.L5X file was imported.

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Logic Configuration Chapter 4

IMPORTANT

For the Widg-O-matic WOm_Pack_App2.L5X file import, the PowerFlex 753 faceplate _Conveyor_DriveName is replaced with Conveyor_Drive and the Kinetix 300 input, output, and control tag _Diverter_DriveName are replaced with Diverter_Drive.

For application examples with Kinetix 300 devices, it is required that you also configure the component reference tag name for the Kinetix 300 drive.

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Chapter 4 Logic Configuration

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K300/POWERFLEX

K300- EIP POSITION MODE

POWERFLEX-RUN FORWARD

Widg-O-Matic Packaging Example

The following application example demonstrates how to control a K300 and a PowerFlex drive using sequencers.

Note that the K300 MUST be in EIP Incremental Position mode ( EIP mode = 1, Reference Source = 2)

For this example, the mode is set in the K300 Module Reset Sequence. Tag K300_Ctrl.Cmd.DriveMode is set to 2.

The Run sequence will Configure and run incremental position moves using K300 EIP Move AOI and Set a speed

reference

and Start/Stop a PowerFlex Drive.

While the Machine is STARTING / RUNNING, the drives will be operated as follows:

1) Verify K300 is in EIP Incremental Position mode.

1) Set Direction FWD, Speed Reference 50 Hz

2) Enable K300 drive.

3) Configure Position, Speed, Accel/Decel and start an Incremental Move.

2) Start drive, run at speed 3 sec

3) Stop drive

4) Configure Position, Speed, Accel/Decel and start an Incremental Move.

2) Start drive, run at speed 4 sec

3) Stop drive

6) Repeat

The Run Sequence is continuously repeated until the Stop Sequence is initiated by a Machine ABORT or STOP

command.

============================================================================================

============================================

0 NOP

============================================

K300/POWERFLEX

K300- EIP POSITION MODE

POWERFLEX-RUN FORWARD

Widg-O-Matic Packaging Example

The following application example demonstrates how to control a K300 and a PowerFlex drive using sequencers.

Note that the K300 MUST be in EIP Incremental Position mode ( EIP mode = 1, Reference Source = 2)

For this example, the mode is set in the K300 Module Reset Sequence. Tag K300_Ctrl.Cmd.DriveMode is set to 2.

The Run sequence will Configure and run incremental position moves using K300 EIP Move AOI and Set a speed

reference

and Start/Stop a PowerFlex Drive.

While the Machine is STARTING / RUNNING, the drives will be operated as follows:

1) Verify K300 is in EIP Incremental Position mode.

1) Set Direction FWD, Speed Reference 50 Hz

2) Enable K300 drive.

3) Configure Position, Speed, Accel/Decel and start an Incremental Move.

2) Start drive, run at speed 3 sec

3) Stop drive

4) Configure Position, Speed, Accel/Decel and start an Incremental Move.

2) Start drive, run at speed 4 sec

3) Stop drive

6) Repeat

The Run Sequence is continuously repeated until the Stop Sequence is initiated by a Machine ABORT or STOP

command.

============================================================================================

============================================

============================================================================================

============================================

RUN SEQUENCE

============================================================================================

============================================

1 NOP

============================================================================================

============================================

RUN SEQUENCE

============================================================================================

============================================

SET K300 MODE

Set drive mode specific for this application.

This tag is used in Reset Routine in K300 Drive module to set Mode.

2 Move

Source 2

Dest Diverter_Drive_Ctrl.Data.AppMode

MOV

K300 Drive Mode for

applicatio

SET K300 MODE

Set drive mode specific for this application.

This tag is used in Reset Routine in K300 Drive module to set Mode.

For the Widg-O-matic packaging example, the following rungs are imported. The rungs include a series of incremental moves for the Kinetix 300 Diverter_Drive and Start/Stop and Speed reference commands for the PowerFlex Conveyor_Drive.

Kinetix 300 and PowerFlex Drives Incremental Move

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Logic Configuration Chapter 4

IMPORTANT

Application Logic Creation Steps Using Template

If you are familiar with Rockwell Automation’s general Logix5000 commands, Logix5000 motion commands, PowerFlex parameters, and have a good idea of your specific run/stop sequences, use these steps to guide you through your specific application logic creation.

1. Formulate and list your run sequence steps.

2. Add your initial run sequence step (RunSEQ[0] = 1) to the R10_ApplicationCode routine of your

imported application module.

3. Add remaining run sequence steps (RunSEQ[0] > 1) and interlocks to remaining R10_ApplicationCode routine rungs and adding run sequence rungs as required.

4. Formulate and list your stop sequence steps.

5. Add your initial stop sequence step (StopSEQ[0] = 1) to the R10_ApplicationCode routine of your

imported application module.

6. Add remaining stop sequence steps (1 < StopSEQ[0] < 999) and interlocks to remaining R10_ApplicationCode routine rungs and adding stop sequence rungs as required.

7. Add your final stop sequence step (StopSEQ[0] = 999) to the R10_ApplicationCode routine of your imported application module.

8. Determine any special reset logic requirements for your application and edit the R04_Reset Routine in the application module. Refer to Appendix B on page 219 for more information on logic module customization.

For other common application code requirements, not included in preprogrammed application modules or logic examples, refer to Appendix B on page 219.

Verify and Save the Project File

1. Click on the Logix Designer application toolbar to verify your controller.

This software function verifies your controller programs and displays errors/warnings, if any.

2. Make corrections to programs as needed.

If a PowerFlex 70 drive is used as part of the Low Voltage Drive configuration, you need to manually set the data type for each PowerFlex 70 drive AOI.

3. Click to save your Logix Designer project file.

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Chapter 4 Logic Configuration

Notes:

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Rockwell Automation 193 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

New and Updated Information

Table of Contents

Preface

About this Publication

Conventions

Required Software

Studio 5000 Environment

Additional Resources

Before You Begin

What You Need

Follow These Steps

Review the DMAT Wizard

Simple System and Drive Configuration Entries

Bill of Material Output

System Drawing Set Output

Project File Output

FactoryTalk View Me Project File Output

Review Other System Selection and Configuration Tools

Motion Analyzer Software

Engineering Assistant Software

Product Selection Toolbox

Install Other System Selection and Configuration Tools

Install Motion Analyzer Software

Install Engineering Assistant Software

Install Product Selection Toolbox

Run the DMAT Wizard

Launch the DMAT Wizard

Edit the DMAT Wizard Configuration

Before You Begin

What You Need

Follow These Steps

Import the Initial Project BOM File

Edit Your Project BOM File

Before You Begin

What You Need

Follow These Steps

Create a New Project

Edit Power Drawings

Edit Drive, Controller, and Safety I/O Drawings

Edit System Communication Drawings

Edit System Layout Drawings

Before You Begin

What You Need

Follow These Steps

Import the Preconfigured Logix Designer Project

Complete Drive and Motor Configuration

Setting Drive Motor Ratings

Set String Tag Names for Alarm History Faceplate

Set Visible Rows for Equipment Status Faceplate

Set Visible Rows for Equipment Status Faceplate for Energy Monitoring

Set MSG Path in the E3 Plus Energy Monitoring Routine

Create Specific Application Logic

Application Code Logic Template Overview

Application Logic Creation Steps Using Application Logic Examples

Toolkit Application Logic Example Overview

Widg-O-matic Logic Example Overview

Import Application Logic Examples

Application Logic Creation Steps Using Template

Verify and Save the Project File