Rockwell Automation MMCL Using the Mining, Mineral, and Cement Library User Manual
User Manual
Using the Mining, Mineral, and Cement Library
(MMCL) in RSLogix 5000 Applications
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
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.
available from
) describes some
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
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.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MMCL Deliverables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Developing an RSLogix 5000
Application
Rules and Recommendations
Creating a New Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Configure Hardware I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Import Tags with the Data Retrieval Tool CSV Files . . . . . . . . . . . . . 10
Alias I/O Descriptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Creating User Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Program Design and Application Tips . . . . . . . . . . . . . . . . . . . . . . 14
Example Application Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grouping of Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 2
Add-On Instruction Interface Definition . . . . . . . . . . . . . . . . . . . . . . . 19
Typical Add-On Instruction Function Call . . . . . . . . . . . . . . . . . . 20
Using Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Add-On Instruction Module Parameter . . . . . . . . . . . . . . . . . . . . . 21
Global Apply Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Enable Alarming in Analog Modules . . . . . . . . . . . . . . . . . . . . . . . 22
Control Group
Using the E3 Module
Chapter 3
Group Sequence Step Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Step “Ready” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Local Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Interlock Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power-Dip Suppression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Enabling Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
E3 Installation and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recommended Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RSNetworx for DeviceNet Software . . . . . . . . . . . . . . . . . . . . . . . 34
E3 Operational Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DeviceNet Tag Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Exchange Data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RSLogix 5000 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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4
Inter Process Communication
Application Examples
Chapter 5
Establish produced/consumed Controller Tags . . . . . . . . . . . . . . . . . 41
Step1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Step2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Step3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Interlock Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Communication Error Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 6
Example 1 –
One Group with Two Selectable Feeders. . . . . . . . . . . . . . . . . . . . . . . 47
Example 2 –
Two Groups with One Common Conveyor . . . . . . . . . . . . . . . . . . . . 51
Example 3 –
One Group with Two Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Example 4 -
Process Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Example 5 -
Inter Process Communication IPCom . . . . . . . . . . . . . . . . . . . . . . . . . 56
Additional Information
Appendix A
RSLogix 5000 Workstation Options. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Workflow Data Retrieval Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
New Product Satisfaction Return . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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Preface
Introduction
Requirements
Before You Begin
This document describes how to create an application with RSLogix 5000
using the Mining, Mineral, and Cement Library (MMCL). It does not show
product installation or setup of the IT infrastructure.
Item Requirements
Software • RSLogix 5000 version 17 or later
• Data Retrieval Tool Tag Import Files
CLX_TAGS_OUT.csv
CLX_STRUCTURES_OUT.csv
Library MMCL_V200_AOI_20100501.ACD or later
Hardware ControlLogix controller, 1756-L6x, firmware revision 17.xx
Skills Knowledge of communication networks and I/O modules
(a)
These files may be generated by the Data Retrieval Tool and created automatically by the MMCL
(MMCL_HDRS_DataTool_V132.mdb).
(a)
:
The creation of an RSLogix application is based on the MMCL and the
following data files.
Item Requirements Description
Library MMCL_V200_AOI_20100501.ACD Basic application with Add-On
Instructions, provided in the MMCL
Data
Retrieval
Tool
CLX_TAGS_OUT.csv Option to automatically create module
tags, created in the Data Retrieval Tool
CLX_STRUCTURES_OUT.csv Option to automatically create Add-On
Instruction structures, created in the Data
Retrieval Tool
5 Publication RA-UM002B-EN-P - November 2010
6 Preface
MMCL Deliverables
The base library project contains the following Add-On Instructions.
Name of Element Description
SysGrp_AOI System Group (one only per CLX)
CtrlGrp_AOI Control Group
MaGrp_AOI Machine Group
IPCom_AOI Inter-process Communication
MotorN_AOI Motor Normal Drive (one direction)
MotorR_AOI Motor Forward/Reverse Drive (two directions)
MotorD_AOI Motor Damper/Flap Drive
E3p_AOI RA E3 Plus Motor Starter
SubSys_AOI Sub-System
Valve1_AOI Valve with 1 Coil
Valve2_AOI Valve with 2 Coils
DigInp_AOI Digital Input
DigInp2_AOI Digital Input for two input (drift switch)
Digpulse_AOI Digital Pulse Input
AnInp_AOI Analog Input
AninpC_AOI Analog Input and Control Outputs
ActMod_AOI Actuator Module
ActPos_AOI Actuator Positioning
PidMod_AOI PID Module
MotorN_Sim_AOI Motor Normal Drive Simulator
MotorR_Sim_AOI Motor Forward/Reverse Drive Simulator
MotorD_Sim_AOI Motor Damper/Flap Drive Simulator
MotorNE3p_Sim_AOI Motor Normal Drive with E3P Simulator
MotorRE3p_Sim_AOI Motor Forward/Reverse Drive with E3P Simulator
MotorDE3p_Sim_AOI Motor Damper/Flap Drive with E3P Simulator
Valve1_Sim_AOI Valve with 1 Coil Simulator
Valve2_Sim_AOI Valve with 2 Coils Simulator
DigInp_Sim_AOI Digital Input Simulator
DigInp2_Sim_AOI Digital Input for 2 Inputs Simulator
DigPulse_Sim_AOI Digital Pulse Input Simulator
AnaInp_Sim_AOI Analog Input Simulator
ActMod_Sim_AOI Actuator Module Simulator
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PID_SIM_AOI PID Module Simulator
Name of Element Description
L_CPU_17_AOI Processor Utilization
P_Intlk_AOI Interlocks
P_Perm_AOI Permissives
Preface 7
Reference Documents
These documents contain additional information concerning related
Rockwell Automation products.
• Integrating Mining, Mineral, and Cement Library (MMCL) into
RSLogix 5000 Software Reference Manual, publication RA-RM002
• Platform Architecture Guide rev2.0.pdf or later
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8 Preface
Notes:
Publication RA-UM002B-EN-P - November 2010
Chapter
IMPORTANT
1
Developing an RSLogix 5000 Application
Creating a New Project
Configure Hardware I/O Modules
1. In RSLogix, open the MMCL_V200_AOI_YYYYMMDD.acd file
provided in the MMCL.
This application contains all Add-On Instructions.
2. Under File, select Save As.
3. Type your desired project name (for example,
UserProject_yyyy_mm_dd.acd) and click Save.
All I/O modules used by the application are inserted and configured with the
I/O configuration tool.
1. Configure all hardware I/O modules located in the chassis.
For remote I/O modules (Networks), the adapters and required I/O
modules must be configured.
The I/O module Name must correspond to the Data Retrieval Tool tag designation (import file).
This is necessary for later export of I/O Module data and backup import to the Data Retrieval Tool
data base.
The backup import is used to store the proper hardware addresses, in the Data Retrieval Tool data
base.
For Tag names and Alias designations using Asset Code (AC), refer to
N_050817_HDRS_RSLogix_Concept.pdf.
9 Publication RA-UM002B-EN-P - November 2010
10 Developing an RSLogix 5000 Application
Import Tags with the Data Retrieval Tool CSV Files
When using the AC for tag designations, you can export a.csv file, from the
Data Retrieval Tool and import the data to RSLogix 5000. This import
automatically creates the tags and its members, for all devices specified in Data
Retrieval Tool. The .csv files are created by the Data Retrieval Tool export
function and imported into RSLogix 5000.
The Data Retrieval Tool export procedure is described in document:
HDRS-DataRetrievalTool_100.pdf
The RSLogix 5000 import procedure requires Microsoft ACCESS program:
MMCL_HDRS_DataTool_V132.mdb
The import procedure is described in document:
MMCL_HDRS-DataRetrievalTool_V130.pdf
1. Under Tools, select Import.
2. Browse to the CLX_TAGS_OUT.CSV file and click Import.
Publication RA-UM002B-EN-P - November 2010
3. Complete this process for the CLX_STRUCTURES_OUT.CSV file.
Refer to the Workflow Data Retrieval Tool on page 60 for more information.
Developing an RSLogix 5000 Application 11
Tag Name imported from the Data
Retrieval Tool CSV file
I/O Address, where:
_E1A_F002 = Adapter Name
1:I.0 = Slot 1:Input Module.Bit 0
IMPORTANT
Alias I/O Descriptor
The Alias I/O descriptor specifies the exact hardware terminals and the
particular I/O module. It is therefore, necessary to know how the I/O
modules are installed and wired.
Example of Tag Properties
Do not assign the same Alias twice. We recommended that
you check for duplicate addresses prior to using the
application. Select Controller Tags and sort Alias by
ascending order, then check the list for possible
duplications.
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12 Developing an RSLogix 5000 Application
The following is an example I/O Configuration with Controller Tags and Alias
I/O addresses:
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Developing an RSLogix 5000 Application 13
User Programs are called in the Periodic Task. This is to improve overall
system performance. To allow proper interaction between MMCL Add-On
instruction standard functions, when multiple period tasks are used, the
Period and Priority configuration for all tasks should be the same. If different
Period and Priority is configured, then customized code has to be added to
synchronize module scan in different tasks.
Periodic Task with all User Programs
Call all User Programs including. System Rungs
For example, User Program for Network Status
MMCL AOI Standard Functions called by User
All MMCL User Data Types (UDT)
All I/O modules listed here
Creating User Programs
The RSLogix 5000 project originates from the MMCL_V200_20100501.acd
file. The following program and data folders are included in the project.
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14 Developing an RSLogix 5000 Application
Program Design and Application Tips
• User Programs can be called by the Continuous or Period Tasks. When
Periodic Tasks are used, certain rules have to be followed because the
MMCL Add-On Instruction Standard Functions are originally designed
for Continuous Tasks.
• Setup the I/O module, or device parameters, immediately after a new
module is installed.
• The System Group Module, SysGrp_AOI, must be called only once in
the application. Its input, ApplyPar, signals all analog modules to read
changed parameters on-line.
• The User Program, ap_Network, is an example that shows how to get
the Network Status from an I/O Module and make it visible to the
HMI.
• The main program, MainRoutine, contains some System Rungs. These
rungs may be extended and/or adapted as required.
• Analyze the desired functions before programming. Outline the Control
and Machine Groups. Specify the calling order and start and stop
sequences of Modules within a Group.
Publication RA-UM002B-EN-P - November 2010
Developing an RSLogix 5000 Application 15
Bus
E51_BF1_C1
SubSys/W
E51_RF2_M1
MotorN/W
E51_FN1_M1
MotorN/W
Bus
E51_000_02
MaGrp
Bus Bus
E51_MW1_V1
Valve1/F
Level
Max
Level
Max
E51_000_00
CtrlGrp
Bus
Rotary
Feeder
Filter
Fan
Bag
Filter
Last Drive
Position
Actuator
Bus
E52_000_03
MaGrp
.0
Gate PG1
E52_PG1_Z1
ActMod/F
E52_000_03.Bus
Gate 2StandbyGate 1
Select Logic
Bus
E52_000_04
MaGrp
.0
Gate PG2
E52_PG2_M1
MotorD/W
Open
Close
E52_000_04.Bus
E52_000_01
MaGrp
Bus
E52_BE1_M1
MotorN/F
E52_BE1_M2
MotorN/W
E52_000_01.Bus
Bus
E52_000_02
MaGrp
.0
E52_FA1_M1
MotorN/F
E52_3B1_WC
PidMod/W
E52_000_02.Bus
Position Feedback
Fan
Aeration
Bucket
Elevator
E52_000_00
CtrlGrp
Bus
Throttle
Gate
E52_PG0_C1_SBY
E53_BC1_M1
MotorN/F
E53_000_00
CtrlGrp
Bus
.1
.0
.1
.0 .1
E51_BC1_FC
PidMod/W
Flow
Controller
AllRun/AllStopAllRun/AllStopAllRun/AllStop
EnAutoStart
EnAuto
E51_000_03.Bus
Legend
= HMI PreSelect (Toggle)
= HMI Sel ected Indication
/W = Warning Device
/F = Failure Device
E51 Bin Extraction / Silo Feed
Group
Master
Group
Master
Group
Master
Belt
Conveyor
E52 Bin Feed E53 Recirculation
E52_PG2_C1_SEL
.0
E51_000_04
MaGrp
E51_000_01
MaGrp
E51_000_03
MaGrp
Silo 3S1Recirc Silo 3S2
E53_BC1_C1_SEL E51_3S1_C1_SEL E51_3S2_C1_SEL
.0 .1 .0 .0 .0
Silo 3S2Silo 3S1
Recircu-
lation
Local only
operation
3S1_LM
DigInp/F
3S2_LM
DigInp/F
EnAutoStart
EnAuto
EnAuto
EnAutoStart
E51_BC2_M1
MotorR/F
E51_BC1_M1
MotorN/F
E51_RF1_M1
MotorN/F
E51_RF1_S1
ActMod/F
Speed
Actuator
Rotary
Feeder
Belt
Conveyor
RdyAuto
EnAutoStart
Distribution
Gate
E51_000_01.Bus
Belt
Conveyor
Last Drive
E51_SG1_M1
MotorD/F
Slide
Gate
E51_000_04.Bus
Level
Controller
Auxiliary
Drive
Weight
Controller
RdyAutoX/Y
E52_PG2_Z1
ActMod/F
Ctrl'd Variable=SP
Position=Feed Forward FF Setpoint SP
Ctrl'd Variable=SP
E52_3B1_W1=PV
E51_BC1_F1=PV
RdyAuto
E53_000_00.Bus
P
o
s
i
t
i
o
n
C
t
r
l
'
d
V
a
r
i
a
b
l
e
E52_000_00.Bus
Y=Recirc X=Silo
Y=3S1 X=3S2
Check
Check
Check
E51_3S1_L1=PV
E51_3S1_LC
PidMod/W
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/OI/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/OI/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
Example Application Overview
PG1_C1_SEL
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16 Developing an RSLogix 5000 Application
Grouping of Programs
For a clear program structure, it is recommended, to specify separate programs
for each Control Group. To start a new program, right-click the MainProgram
and select New Routine.
A Control Group may also be split functionally, using a ladder program, for
motor control I/O status and interlocking, a Sequential Function Chart
(SFC), for module start and stop sequences (including structured text) and a
Function Block Diagram (FBD), for analog process controls. The different
methods are supported by the corresponding RSLogix 5000 Editors. The
MMCL Add-On Instructions are available for Ladder, Function Block and
Structured Text.
For automatic start and stop sequences, use an SFC, especially if devices
must be stopped individually, rather than by a common shutdown command.
If, however, a common shutdown or delay time is suitable, then an SFC is not
required and a group can be stopped by the Control Group's built-in
stop-delay timer, using standard ladder interlocking only.
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For analog signal processing, use a FBD, which is more comprehensive,
showing the signal flow better than a Ladder diagram.
Developing an RSLogix 5000 Application 17
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18 Developing an RSLogix 5000 Application
Notes:
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Add-On Instruction
Function Name and Description
Backing Tag, for example _512_BC3_D1
Module Data Structure, for example
_512_BC3_D1_C
I/O connection from/to application
Bus connection to Parent Module
All Modules access the same
Global Data
Interface Definition
Rules and Recommendations
Chapter
2
The Backing Tag (instance name of the Add-On Instruction) must be unique.
The name of the ModuleData Tag is the same as the Backing Tag extended by
"_C " (for control). For example, if the Backing Tag is _512_BC3_D1, then
the ModuleData Tag is _512_BC3_D1_C.
19 Publication RA-UM002B-EN-P - November 2010
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