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START PROGRAMMING ....................................................................................................................3 SETTING UP POWERFLEX 4M........................................................................................................26 COMMUNICATION SETTING FOR COMMUNICATION PORT..................................................................41 TESTING THE MODBUS COMMUNICATION PROGRAM........................................................................44 CONFIGURING THE KINETIX 3 DRIVE (20 MINUTES)_____________________________________51 CONFIGURE THE DRIVE COMMUNICATION SETTINGS FOR SERIAL....................................................51 CONNECT TO THE DRIVE USING ULTRAWARE..................................................................................54 CONFIGURE THE DRIVE USING ULTRAWARE...................................................................................59 CONFIGURE WITH REQUIRED INDEXING MOVES...............................................................................63 CONFIGURE THE REQUIRED HOMING PROCEDURE..........................................................................65 CONFIGURE THE DRIVE COMMUNICATION SETTINGS FOR MODBUS..................................................66 POWERFLEX AND PVC.................................................................................................................69 KINETIX AND PVC.........................................................................................................................72
Start Programming
This section of the lab will show you how to setup the communication setting and creating a program to communication between Micro800 controller and PowerFlex 4M drive. Setting up communication 1.Start the Connected Component Workbench for the Start Menu: Start Programs Rockwell Automation CCW Connected Components Workbench.
2. At the Connected Component Workbench window, drag 2080-L50-24QBB from the Catalog Window into the Project Organizer Window, a new project will be created.
4. Click OK
5. In the Project Organizer double click in Global Variables 6. Create the following variables shown in the table below PF_ON PF_STOP SERVO_ON SERVO_OFF START_INDEX SET_PFSPEED JOG_PF JOG_ON JOG_OFF JOG_SERV SET_SERVJOGS SPEED_PFREF JOG_PFSPEED SET_PF_JSP JOG_SPDSERV BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL INT INT BOOL INT
Then click OK
5. Repeat steps 3 and 4 for the others variables, and map them to the register addresses as shown below Micro 850:Modbusto PF4M Kinetix 3 y PVC V 2013 1.0 Page 7 of 75
Create a PanelView Component Application First you have to decide how you want to create the application, this can be as online or offline. A. Create an Online application The first one is by Ethernet. First of all energize your PanelView to get IP address.
1. Click Start >> Settings>> Network Connections 2. Click Local Area Connection
3. Click Properties 4. Double Click Internet Protocol (TCP/IP) 5. Mark Use the following IP address, and in IP address put your IP. Note: Remember the last number of IP address should be different from IP of the PanelView. 6. Click Ok Note: There are different ways to change the computer IP, verify the way, and change the IP.
Launch PanelView Explorer (Internet Explorer 7 web browser, Mozilla Firefox 2.0 or 3.0 Web Browser)
4. Follow the next section Create a PanelView application. 5. Once you create your application you need to transfer the Offline PVc Application to a PVc Terminal.
Micro 850:Modbusto PF4M Kinetix 3 y PVC V 2013 1.0 Page 13 of 75
Create PanelView Application Once you area in the Application dashboard you can create or edit an application. For this lab we are going to create a new application. If you are online just click Create & Edit button. If you are offline chose the platform and click the button. The application will launch in a new tab or window.
1.
2.
3.
Click the HIM Tags tab Click add
4.
Create the following tags as shown below-make sure to choose th correct data type
Create a screen display with objects linked to the tags you just created
Click on HMI Screens.
Configure the Connections Write Tag and Indicator Tag to PF_ON tag
1 7
2 6 12
3 5 8
4 9
In the Numeric Entry Properties panel, select the connections tab and configure the write tag and indicator tag to, SPEED_PFREF
1 2 3 4 5 6 7 8 9 10 11 12
PF_ON PF_STOP SERVO_ON SERVO_OFF START_INDEX SET_PFSPEED JOG_PF JOG_ON JOG_OFF JOG_SERV SET_SERVJOGS SET_PF_JSP
Drag and drop a numeric entry object from the entry object palette onto your display
1 2 3
1 2 3
6. If you are online you need to validate your application. Click Validate Application.
Wait for the next prompt. If there are any warnings the application is valid, but no with errors.
Save your work, and close the application with the next icon.
Setting Up PowerFlex 4M
Configuring the PowerFlex 4M In this section of the lab, the PowerFlex 4M drive will be configured to communicate with the Micro830 controller. The following is the overview of the steps to be taken for configuring the drive. Reset the Drive to Factory Default Setting up the control and the speed referencing of the Drive. Setting up the communication setting and the Node number of the Drive.
To complete this lab, the drive needs to be reset to the factory defaults. Follow these steps: Using the keypad 1. To verify if the drive is controlled by the integral keypad, check if the Green LED beside the green start button is lit. If the LED is on, the drive can be controlled by pressing the Start/Stop button in the keypad. To control the speed, turn the potentiometer above the Green Led. 2. Get familiar with the integral keypad:
Key
Esc Sel
Name
Escape Select Up Arrow, Down Arrow
Description
Back up one step in programming menu/ Cancel a change to a parameter value / Exit Program Mode. Advance one step in the programming menu / Select a digit when viewing parameter value. Scroll through groups and parameters/ Increase/decrease the value of a flashing digit.
Enter
V 2013 1.0
Advance one step in programming menu/ Save a change to a parameter Micro 850:Modbusto PF4M value. Kinetix 3 y PVC
Page 26 of 75
Resetting to factory defaults (Setting Parameter P112 to a value of 1) 3. Press the Esc key (multiple times if necessary) until the display shows 0.0 4. Press the Enter key once and the display should show xyyy where x is d,P,t,C or A and y is a numerical value. 5. Verify that the leftmost alphabet character (x) is flashing. 6. Press the Up Arrow or Down Arrow key until the leftmost character displayed is a flashing P. Press the Enter key and the P will stop flashing and the rightmost numeric character is flashing. 7. Press the Up Arrow or Down Arrow key until P112 is displayed. 8. Press the Enter key and a 0 will be displayed as the current value of parameter P112. 9. Press the Enter key again and 0 begins flashing. Press the Up Arrow key to adjust the value to 1 and press the Enter key to enable the default settings. 10. The display will flash F048 and the red FAULT LED will flash also. This fault indicates that the drive parameters have been reset to factory default. Press the Red Stop Button to clear the fault. 11. Since both green LEDs on the front of the drive are on, verify that you can:
Start the drive by pushing the Green Start Button (if the drive doesnt start and the display still reads 0.0, try rotating the speed potentiometer clockwise). Then verify that you can stop the drive by pushing the Red Stop Button (note that the drive does not stop immediately, but decelerates at a configured rate to zero). Start the drive again and verify that once the drive is done accelerating, the speed potentiometer can be used to speed up or slow down the drive. Now stop the drive by pressing the Red Stop Button.
Changing the Control and Speed References This lab shows communications between the Micro 830 and the PF4M drive. The drive needs to be set to accept remote control commands from the Micro 830. This is done by setting the parameters for the Start Source (P106) and Speed reference (P108) to a value of 5. Setting the start source to Remote. (Comm port) - P106 12. Press the Esc key (multiple times if necessary) until the display shows 0.0. 13. Press the Enter key once, the display show xyyy where x is and alphabet (d,P,t,C or A) and y is numerical number. 14. Press the Up Arrow or Down Arrow key until the leftmost alphapet value displayed is a flashing P. Press the Enter key. Now the P stops flashing and the rightmost numeric character is flashing. 15. Press the Up Arrow or Down Arrow key until P106 is displayed. 16. Press the Enter key and the current value of parameter P106 will be displayed, which by default is 0. 17. Press the Enter key again and 0 begins flashing. Press the Up Arrow key multiple times to adjust the value to 5 and then press the Enter key to accept this value. (5 should not be flashing any longer) Notice that the green LED next to the green Start button on the drive is now off. 18. Press the Esc key and P106 should be displayed (with the 6 flashing). Press the Up Arrow key twice so that P108 is displayed (with the 8 flashing). Setting the Speed Reference to Remote (Comm port) - P108 19. Press the Enter key and the current value of parameter P108 will be displayed. The value of 0 means Keypad. 20. Press the Enter key again and 0 begins flashing. Press the Up Arrow key multiple times to adjust the value to 5 and then press the Enter key to accept this value. (5 should not be flashing any longer) Notice that the green LED next to the Speed Potentiometer on the drive is now off. 21. Press the Esc key multiple times until 0.0 is displayed. The drive is now ready to be controlled by Modbus RTU communication commands initiated from the Micro 830 controller.
Changing the communication settings of the drive The following steps will show how to change the communication setting of the PowerFlex 4M Drives for communication with Micro 830 via Modbus RTU communication. Modbus Communication Settings: Parameter C302 C303 C304 C305 C306 Description Comm. Data Rate (Baud Rate) 4 = 19200 bps Comm. Node Addr. Comm. Loss Action ( Action taken when loss communication) 0 = Fault with coast stop Comm. Loss Time (Time remain in communication before taking action set in C304) 5 sec ( Max. 60) Comm. Format (Data/Parity/Stop) RTU:8 Data Bit, Parity None, 1 Stop bit Setting 4 2 0 5 0
Setting the Baud Rate C302 22. Press the Esc key (multiple times if necessary) until the display shows 0.0. 23. Press the Enter key once, the display shows xyyy where x is and alphabet (d,P,t,C or A) and y is numerical number. 24. Press the Up Arrow or Down Arrow key until the leftmost alphanumeric value displayed is a flashing C. Press the Enter key. Now the C stops flashing and the rightmost numeric character is flashing. 25. Press the Up Arrow or Down Arrow key until C302 is displayed. 26. Press the Enter key and the current value of parameter C302 will be displayed, which by default is 3. 27. Press the Enter key again and 3 begins flashing. Press the Up Arrow key to change the baud rate of the drive to 19200 bps to 4 and then press the Enter key to accept this value. 28. Press the Esc key and C302 should be displayed (with the 2 flashing). Press the Up Arrow once so that C303 is displayed (with the 3 flashing). Setting the Node Address C303 29. Press the Enter key and the current value of parameter C303 will be displayed, which by default is 100. 30. Press the Enter key again and 100 begins flashing. Press the Down Arrow key to adjust the Modbus node address to 2 (for multiple drives, you would assign address 2 for the second drive, 3 for the third drive, etc.) and then press the Enter key to accept this value. 31. Press the Esc key and C303 should be displayed (with the 3 flashing). Verify Communications Loss Action C304, Communications Loss Time C305, Communications Format C306 32. Parameter C304, C305 and C306 should be the factory default value, which is 0, 5 and 0 respectively. Verify if C304 value is 0 by pressing the Enter key and the current value of parameter C304 will be displayed, which by default is 0. 33. Press the Esc key again and C304 should be displayed (with the 4 flashing). Press the Up Arrow once so that C305 is displayed (with the 5 flashing). 34. Press Enter key and the current value of parameter C305 will be displayed, which by default is 5. 35. Press the Esc key again and C305 should be displayed (with the 5 flashing). Press the Up Arrow once so that C306 is displayed (with the 6 flashing).
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36. Press Enter key and the current value of parameter C306 will be displayed, which by default is 0. 37. Press the Esc key (multiple times if necessary) until the display shows 0.0. 8. Turn off the power to the drive until the PowerFlex 4M display blanks out completely, then restore power to the PowerFlex 4M. The drive is now ready to be controlled by Modbus RTU communication commands initiated from the Micro 830 controller. 9. 10. Under the Project Organizer, right click on the Programs select Add and select New LD: Ladder Diagram.
11. Double click on Mod_Message. From the Toolbox ,drag a Block to the rung
Creating a Time On-Off (TONOFF) Block 12. From the Instruction Block Selector Window, select TONOFF.
14. Click on variable, and enter in T#2S for both PT and PTOFF
15. From the Toolbox, drag a Reverse Contact to the Rung 1, before the TONOFF_1.
Creating Variables 25. Create the following variables shown in the table below in the Mod_MessageVAR Tab. Variable Name 1. Cancel 2. D2_lcfg 3. D2_Tcfg 4. D2_laddr 5. D2_error 6. D2_errorc Data Type BOOL MODBUSLOCPARA MODBUSTARPARA MODBUSLOCADDR BOOL UINT
27. Double click on the Mod_Message, assign the variable to the parameters of the MSG_MODBUS_1.
28. Finally, build and save the Ladder Program. Right click on the Micro850 icon in Project Organizer and select Build.
29. At the Output window at the bottom center of the screen, the build should show succeeded.
66. Right-Click on the first <Empty>in the list, and select 2080-SERIALISOL.
Upon selection, the image of the Serial Communication Plug-in module will appear.
67. At the
Note: The Baud Rate for the PowerFlex 4M and Micro 830 Controller be the same .
69. Build the program again. Right click on the Micro830 icon in Project Organizer and select Build.
70. At the Output window at the bottom center of the screen, the build should show succeeded.
73. From the Connection Browser, select 2080-L30-16QWB, and click on OK.
74. The following dialog box will appear for confirmation of the downloading if the controller is in RUN mode. Click on Yes to proceed.
In the completion of downloading the program, the Output window will display Succeeded
75. The following window will appear to change from Program Mode to Run Mode. Click on Yes to proceed.
76. Click on the at the Debug Toolbar, the programming workspace will change from white background to beige background.
At the same time, the status and value of the parameters will be display on the screen.
77. To test the Modbus Communication, assign the following value to the variables:
Description Serial Port Channel no. for communication 2, 5 or 6 depending on application. 0: for one shot, 1: for continuous trigger ( 1 continuous Trigger Function not available yet)
Value 5
D2_Icfg. TriggerType
D2_lcfg.Cmd
Modbus Communication Function Code 03(Read Single Coil), 06 (Write Single Coil) or 16 (Write Multiple Coil)
No of data to Read or Write Register Address of the Slave to Read or Write Slave Node Number Data to Write/ Return data from Slave if read command is issued. ( Bit 2 of 8193 = Start)
1 8193 2 2
The following Variable Monitoring window will appear. 79. Click on to expandable the variables tree.
80. To change the value of the D2_lcfg.Channel, double click on Logical Value of D2_lcfg.Channel. Change the value with respect to the table shown above, 5.
Note: The Channel number is determine by the serial port used for communication. The following is the port number assignment.
Channel 2 Channel 4
Channel 5
Channel 6
81. Repeat Steps 10 till all the respective variables values had been changed. When the last parameter D2_laddr.[1], is enter, the RUN Led on the PowerFlex 4M will turn ON. This indicated that a Start Command was send to the Drive. 82. Change the respective value of the following variables to as shown. Variable Name D2_Tcfg.Addr D2_laddr[1] Description Register Address of the Slave to Read or Write Data to Write/ Return data from Slave if read command is issued. ( Bit 1 of 8193 = Start) Value 8194 200
Notice that the Display on the PowerFlex 4M will show 20.0 (200 x 0.1), and the motor will start running.
Note: Address 8194 is the Speed Reference address for the PowerFlex 4M. To vary the speed of the drive, change the value writing to 8194. Please note a multiplier of 0.1 will be applied.
83. Change the value of the following variables as shown: Variable Name D2_Tcfg.Addr D2_laddr[1] Description Register Address of the Slave to Read or Write Data to Write/ Return data from Slave if read command is issued. ( Bit 2 of 8193 = Start) Value 8193 1
Notice that the Display on the PowerFlex 4M will ramp down till 0.0 and the motor will stop running. Note: Address 8193 is the control register, where Bit 0 of 8193 is Stop, and Bit 1 of 8193 is Start.
4. Disconnect any communication cables from the Up Port and the Down Port of the Kinetix 3 drive.
5. Press and release the Mode/Set key until the message Pr-0.00 is displayed.
This is the Parameter Edit mode for changing drive parameters. TIP: Other modes available include Index Edit mode for changing the indexing profile values and Display mode for observing operating values of the drive and motor. 6. Use the Up button to change the display to Pr-0.09 and press the Enter key.
Pr-0.09 is the communication protocol setting for the serial port on the Kinetix 3 drive. It will have (2) unique settings for our usage in the lab: Pr-0.09 = 0005 for communicating with a PC using Ultraware (serial ASCII) Pr-0.09 = 1102 for communicating with the Micro830 using Modbus RTU
Micro 850:Modbusto PF4M Kinetix 3 y PVC V 2013 1.0 Page 52 of 75
7. Use the Left/Right and Up/Down arrows on the keypad to change Pr-0.09 to 0005 for use with Ultraware. The drive was likely left in the Modbus mode from the previous user. Ultraware will not communicate in the Modbus mode. 8. PRESS and HOLD the Mode/Set key until the display flashes.
For the next step, a serial port extension cable has been provided for you at your workstation. This means there is no need to crawl on the floor. 9. Connect the Up Port of the Kinetix 3 drive to your workstations PC using the 2090CCMPCDS-23AA03 serial cable.
NOTE: Use the serial extension cable provided at your station, not the PCs port. 10. Open Ultraware from Start > Programs > > Ultraware > Ultraware.
12. You may be prompted with a Tip of the Day. Simply answer OK to the prompt. The software will then attempt to scan the network for connected servo drive.
The scan will fail after not finding any drives. Your default serial settings will likely not match those required by the Kinetix 3 drive.
13. From the drop-down menu, select Tools > Serial Port.
14. Change your Baud Rate to 57600 as shown and press OK.
15. Check for drives again by selecting Tools > Rescan from the menu.
16. When a node is scanned, the following dialog box will appear. Click on No to continue.
NOTE: This wizard currently assists users with stepper and analog operations. However, we will be using the Indexing operation mode.
17. Double click on the Drive under On-Line Drives in the workspace on the left (the actual name may differ). The parameter summary screen will be shown on the right.
This will eliminate a lot of little issues along the way. 19. Confirm any prompts to complete the reset process. The motor used in the demo has a smart encoder that allows the drive to identify it automatically. Thats one less step we have to consider within the lab. 20. Select Operation Modes from the pull-down menu, select the Indexing/None. Answer Yes to confirm the reset.
This is to configure the Kinetix 3 as a stand-alone indexing drive. 21. Expand the Communications branch.
These settings will allow us to update parameters from the controller over Modbus but issue commands from the drive I/O. We would have to create a Modbus message for enable/disable, start index, stop index and fault reset if we changed the Input Function Control to Enable. We simply dont have time in the lab to create all of these messages. NOTE: We will eventually change these settings to Modbus Protocol as well, but changing them now would knock us offline with Ultraware. 23. Expand the Drive tree and select Digital Inputs by double clicking.
24. Assign Input 1 as the Drive Enable input. Selection can be made from the pull down menu.
Assign the remaining inputs according to the table shown below. Parameter Input 1 Input 2 Input 3 Input 4 Input 5 Value Drive Enable Start Indexing Stop Indexing Start Homing Fault Reset
Upon completion, the Digital Input parameter should look like the following.
26. Assign Output 1 as Ready. Selection can be made from the pull down menu.
Assign the remaining outputs according to the table shown below. Parameter Output 1 Output 2 Output 3 Value Ready Axis Homed Brake
Note that none of the outputs should be on currently on the demo unit.
The servo motor used in this demo unit includes an encoder that produces 131,072 counts per motor rev. We will make each index move a factor of this. 28. Expand Index 0 Setup and configure the index as follows:
1 rev forward
This means 1 motor rev in the forward direction. 29. Then expand and configure Index 1 Setup as follows:
When the Start Index input is activated, Index 0 will execute. Upon completion, Index 1 will execute immediately before coming to a stop.
2 revs backwards
Although we wont be testing this particular move (Index 2) in the next section, you will have the opportunity to use it in Extra Task if time permits. Stay tuned. TIP: The drive also allows the user to use custom positioning and velocity units, which only appear in Ultraware software. The commands from any external controllers over Modbus would still use encoder counts and motor RPM. 31. Click on Save to save the parameters upon completion. Answer Yes to upload a copy of the drives parameters. Select a location (like My Documents) and give the file a name in order to complete the process.
33. Configure the Homing Type as Home to Marker by selecting from the pull down menu.
35. On a topic related to homing, move to the Encoders branch and set the Encoder Backup Battery setting to Not Installed. Our demo units do not have batteries and will cause an error.
TIP: Ignore the E.030 fault (it is caused by our modified demo units). 39. Press and release the Mode/Set key until the message Pr-0.00 is displayed.
40. Use the Up button to change the display to Pr-0.09 and press the Enter key.
41. Use the Left/Right and Up/Down arrows on the keypad to change Pr-0.09 to 1102 for use with Ultraware. 42. PRESS and HOLD the Mode/Set key until the display flashes.
43. Connect the 2090-CCMCNDS-48AAxx cable between the Up Port on the Kinetix 3 and the 8-pin mini-DIN connector on the Micro830 controller. This is the serial Modbus communication cable. See your instructor if you cannot find the cable.
The drive is now ready for use with the Micro850 controller. To test the Modbus Communication and write your new speed value, we will assign the following values on rung 1 to the variables. The steps that follow will guide you through this task.
Description Serial port channel number for the physical communication port you have chosen (see figure below): - 2 for the embedded serial port - 5 for the plug-in serial module if in slot 1 - 6 for the plug-in serial module if in slot 2
Value 2
SPEED_Lcfg. TriggerType
SPEED_Lcfg.Cmd
Modbus Communication Function Code 03 (Read Single), 06 (Write Single) or 16 (Write Multiple)
No. of data words to Read or Write Register Address of the Slave to Read or Write Slave Node Number Data to Write/ Return data from Slave if read command is issued. This is the new 50 RPM speed command. Crear variables a enclavar Variables on of y set
1 6601 1 50
This is for set the reference speed 4. Build the program again. Right click on the Micro850 icon in Project Organizer and select Build.
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6. In Local Variable tab create the next variables Variable Name 1. KCancel 2. K2_lcfg 3. K2_Tcfg 4. K2_laddr 5. K2_error 6. K2_errorc 7. Kofon 8. Kon 9. Koff 10. Indxaddr 11. Indx Data Type BOOL MODBUSLOCPARA MODBUSTARPARA MODBUSLOCADDR BOOL UINT UDINT WORD WORD UDINT WORD 3001 1 0 3003 1 Initial Value
8. Build the program again. Right click on the Micro850 icon in Project Organizer and select Build.