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.

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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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

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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:

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Chapter

IMPORTANT

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.

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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.

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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.

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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

Gate PG1

E52_PG1_Z1

ActMod/F

E52_000_03.Bus

Gate 2StandbyGate 1

Select Logic

Bus

E52_000_04

MaGrp

Gate PG2

E52_PG2_M1

MotorD/W

Open

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

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

.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

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

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

o n

C t

d V a

a b l

E52_000_00.Bus

Y=Recirc X=Silo

Y=3S1 X=3S2

Check

E51_3S1_L1=PV

E51_3S1_LC

PidMod/W

I/O

I/OI/O

I/O

I/OI/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

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

+ 43 hidden pages

Rockwell Automation MMCL Using the Mining, Mineral, and Cement Library User Manual

Table of Contents

Preface

Introduction

Requirements

Before You Begin

MMCL Deliverables

Reference Documents

Creating a New Project

Configure Hardware I/O Modules

Import Tags with the Data Retrieval Tool CSV Files

Alias I/O Descriptor

Example of Tag Properties

Creating User Programs

Program Design and Application Tips

Example Application Overview

Grouping of Programs