N999 PowerFlex 755 Programming with DeviceLogix

Presenter:

For Classroom Use Only!

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PowerFlex 755 programming with DeviceLogix

Contents

Before you begin......................................................................................................................................... 4 Background ................................................................................................................................................... 4

Lab objectives ............................................................................................................................................... 5 Tools & prerequisites .................................................................................................................................... 5

Lab Setup...................................................................................................................................................... 6

Connecting to the Drive.............................................................................................................................. 7

Disabling Safe Speed Monitoring Module ................................................................................................ 8

Disable DeviceLogix ................................................................................................................................. 11

Application Example 1: Diverter.............................................................................................................. 13 Downloading Predefined Parameter Set..................................................................................................... 14

Programming the Function Blocks .............................................................................................................. 16

Simulating the Application........................................................................................................................... 26

Application Example 2: Wet Well ............................................................................................................ 27 Background ................................................................................................................................................. 27

Example Application Operation................................................................................................................... 28

Disable DeviceLogix.................................................................................................................................... 29

Downloading the Configuration (Parameters & DeviceLogix)..................................................................... 31 Enable DeviceLogix .................................................................................................................................... 34

Simulating the Application........................................................................................................................... 36

Extra Challenge........................................................................................................................................... 37

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Before you begin

Background

DeviceLogix is a function that has been added to a number of Rockwell Automation devices to control and manage information locally with the device. This is accomplished through the DeviceLogix editor, the configuration tool for DeviceLogix-capable devices. The editor is a software tool that provides a graphical interface for configuring function blocks that allow local control within the DeviceLogix-capable device. Previously DeviceLogix was always tied to RSNetWorx for DeviceNet. With the PowerFlex 755, however,

programming DeviceLogix is accomplished through the DeviceLogix graphical editor ( icon) which is incorporated in the following drive software: DriveExplorer v6.01 (and higher) DriveTools SP v5.01 (and higher) RSLogix 5000 Drive Add-On Profiles v2.01 (and higher)

Note: Only the drive software tools listed above can be used to program the DeviceLogix component in the PowerFlex 755. Other DeviceLogix Editors, such as RSNetWorx for DeviceNet, can not be used.

Function Block Elements

The following function block elements are available with the PowerFlex 755 DeviceLogix:

Bit & Analog I/O

Process

Filter

Select / Limit

Statistical

Timer / Counter

Compare

Compute / Math

Move / Logical

The DeviceLogix Editor provides a graphical interface for configuring Function Blocks to provide local control within the drive.

Note: A DeviceLogix program in the PowerFlex 755 has a 5ms scan time for the first 45 function blocks and an additional 5ms scan time for the remaining 45 function blocks (10ms total for 90 function blocks). It is designed for basic logic capability for applications that can allow a 5-10ms scan time plus the time it takes to update the I/O. It is NOT a replacement for DriveLogix in the PowerFlex 700S or Function Blocks in the 1336 FORCE.

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Lab objectives

This lab is intended to familiarize the student with the DeviceLogix feature in the PowerFlex 755 and its programming. The goal is to get a view of the flexibility and strengths that DeviceLogix has to offer, and experience the ease of use while programming a couple of basic sample applications. The student will use predefined parameter files in which the startup for the application in question has already been performed. The focus will be on the DeviceLogix part.

This lab takes approximately 45 minutes to complete.

Tools & prerequisites

Windows XP PC with DriveExplorer software (the lab can also be adapted for use with DriveExecutive) PowerFlex 755 demo Ethernet switch and cables (or an Ethernet cross-cable) to connect the PC and the embedded

Ethernet port on the PowerFlex 755. (The lab can also be adapted for use with a 1203-USB converter)

Folder C:\Lab Files\DeviceLogix PF755 containing predefined drive parameter files for each sample application

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Lab Setup

Verify that the PC and PowerFlex 755 demo are properly connected via Ethernet On the PowerFlex 755 demo case, position switches IN2, IN3, IN4, IN5 to the left (OFF) Pull the Safe Off switch (red mushroom button) Turn on the drive with the Drive Power; this will supply the drive with mains power. Turn on the 24DC Control Power; this will supply the 24V Auxiliary Power Supply board. The Auxiliary

Power supply board keeps the control boards and logic of the drive powered when mains power is removed.

IN2

IN3,IN4,IN5

Control Power

Drive Power

Safe Off

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Connecting to the Drive

1. Start DriveExplorer by double-clicking the DriveExplorer icon

2. Click on the Connect Ethernet icon in the taskbar. If this icon is shown instead, DriveExplorer is configured to communicate serially. Go to Explore Configure communication Select Ethernet ok

3. Select the drive to connect to. The status needs to show that the drive is online before clicking Connect. If no Network name and or IP address is shown, type in a name for your network (i.e. PowerFlex 755) Click Add Node type in the IP address of your drive (192.168.1.20) click ok wait for status to show online click Connect. The drive now starts to upload all parameters.

4. When all parameter have been uploaded, the screen should look like this. You are now connected.

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Disabling Safe Speed Monitoring Module

If the Safe Speed Monitoring module is installed in the PowerFlex 755 demo, the safety mode needs to be disabled prior to conducting the lab. If the safety mode has not been disabled, the drive will not operate according to the lab procedure.

Consult with your instructor before performing the following procedure:

1. Navigate to the Safe Speed Monitoring module in tree structure on the left hand side. Expand Device Parameters.

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2. Set Operating Mode to Program. Double-click on parameter #6 - Operating Mode. Select Program in the pull down and click OK.

3. Set Safety Mode to Disabled. Double-click on parameter #21 Safety Mode. Select Disable in the pull down and click OK.

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4. Set Operating Mode to Run. Double-click on parameter #6 - Operating Mode. Select Run in the pull down and click OK.

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Disable DeviceLogix

Disable DeviceLogix before downloading preconfigured parameter file to drive. Downloading will cause an error if the DeviceLogix is running while trying to download. Locate the 14 - DeviceLogix Embedded in the tree structure on the left hand side. Expand Host Groups and Double-Click on Status & Control.

Note: Enabling/Disabling the DeviceLogix in this manner is required when using DriveExplorer. If downloading using DriveExecutive, the software will disable the DeviceLogix before download and enable DeviceLogix after download.

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Disable Logic. Double-Click on DLX Operation. Select DisableLogic in the pull down click on OK.

After the DeviceLogix is disabled, DLX Operation will display as follows:

The drive will fault when disabling the DeviceLogix. Clear the fault by pressing the STOP key on the HIM.

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Application Example 1: Diverter

This example demonstrates basic control logic to operate a diverter in a conveyor system. The diverter directs parts from an upstream conveyor to one of two downstream conveyors. It alternately sends x parts towards each downstream conveyor. The PowerFlex 755 DeviceLogix program triggers a relay output every time the diverter needs to change. The diverter itself could be operated hydraulically, pneumatically or also by another drive-motor combination running a position profile.

The application consists of the following discrete I/O:

Type Name Description Inputs Part Present Sensor Identifies that a part is present

Outputs Diverter Actuator Controls the diverter actuator to direct the flow of parts

Logic requirements: If Part Present Sensor is ON, then increment the parts counter If Counter preset is reached, reset the counter and alternately set or reset the diverter actuator.

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Downloading Predefined Parameter Set

1. Select the Node 1: - PowerFlex 755 in the tree structure on the left hand side. Then go to the pull down menu menu Actions and select Upload/Download All.

2. Click Download and Yes.

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3. Open the C:\Lab Files\DeviceLogix PF755 folder. (For convenience, a shortcut has been placed on the desktop). Select the Diverter-All Ports file and click Open.

4. Click Download to download to all the ports. This will download a predefined parameter set to the drive.

When the download is complete, click Close.

The drive is now configured for the PF755 in the demo case with start/stop control from the HIM. If required, clear the fault via the HIM by using the CLR soft-key button.

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Programming the Function Blocks

1. Click DeviceLogix icon in the taskbar to open the editor. Notice that it is grayed out if you have not selected Port 14 DeviceLogix Embedded first. It may take some time to load the editor.

2. Once the editor has opened it should look like the following image. The white area is where you will place the function blocks and interconnect them. You can find out the different functions by placing the cursor on the buttons/icons. To start editing, you need place the editor in Edit mode, click the

Edit icon, and click Yes on the warning message.

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3. When you are in Edit mode the function blocks will become visible. Add a Bit Input by clicking on the button or by drag & drop. This will become the parts present sensor input.

4. At this point you need to define the input. Double clicking on the blue area (with question mark) will open a drop-down box. Click on the drop-down arrow, expand the Hardware Boolean list, and double-click DIP1 (Digital InPut 1). Right now this is just a logical input that is not yet linked to any real physical input (this will be done later). In total 16 logical inputs can be defined (DIP116).

5. Add a description to DIP1. Right click on the DIP1 then select Edit Main Operand Description. Call it Part Present Photoeye and then click outside the edit box to close it.

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6. According to the logic requirements of the application, the parts present sensor needs to trigger a counter. Add an UP COUNTER by clicking on the Timer/Counter tab and then dragging & dropping the CTU to the program area. Right-click on the counter, select Edit Main Operand Description, and enter Parts Counter for the name. Click outside the edit box to close it.

Note: You can click & drag a Function Block to reposition it on the screen. Use the Delete key to delete any mistakes.

7. Interconnect both items. Click on the connection pin of DIP1.

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Move the cursor to the CUEnable pin of the UP Counter. Notice that a connection line is being made.

Click on the CUEnable pin to complete the connection.

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8. The counter must reset itself when the counter has reached its preset value. Link the DN (counter DoNe) connection pin to the Reset pin.

The DN output will become 1 or high when the counter accumulator reached its preset value, when this happens DN output will activate the Reset input and the counting process can start over again.

9. Preset the counter with a value. This will be the amount of parts that are detected before the diverter changes over. Double click on the Count Up function block or click on the icon. Select the Parameters tab and enter 2 in the PREConstantvalue (2 parts before the diverter moves). Click OK to accept the change and close the Counter Properties window.

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10. The DN output of the counter needs to trigger circuitry that will set and reset the diverter actuator. This can be done by creating a Set-Reset Flip Flop circuit (see below). Add two BAND (Boolean AND) blocks and one SETD (SET Dominant) block. Make the following connections and settings: Output of BAND1 to Set of SETD Output of BAND2 to Reset of SETD Output of SETD to In2 of BAND1 Negate this data by right clicking on the connection wire and

selecting Negate Output of SETD to In2 of BAND2 DN Output of Count Up to IN1 of BAND1 and BAND2

Note: Your screen may look slightly different, but as long as you made the same connections it will function the same way. You can also click & drag an item to reposition it on the screen and the connecting wiring will automatically adjust.

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11. Add a Bit output that will be used to control the diverter actuator. Choose DOP1 (Digital OutPut 1) and call it Diverter actuator. DOP1 is right now only a logical output.

12. It now looks like you have completed the programming of the function blocks. Let the editor verify the

logic by clicking the icon in the taskbar. What happens?

13. The configuration failed verification because it Failed to determine execution order. Click OK. Since you looped back the connection to the BAND function blocks, the editor does not know in which order to process the data. The connection at issue will be highlighted in red. Help the editor by telling it which data is to be processed first. Right click on the (Output of SETD to In2 of BAND1) connection and set Assume data available.

Verify by the clicking the icon and you will see the same error for the second BAND. Right click on the (Output of SETD to In2 of BAND2) connection and set Assume data available. Verify the logic again and the configuration should have passed. Click OK.

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14. Once your configuration passed the verification notice how each function block has received a number. This number defines the execution order in the program scan.

15. You are ready to download this logic configuration to the DeviceLogix (Port 14). Take the editor out of Edit mode by clicking the Edit icon.

Download the logic by clicking the button. Click OK when the download is finished.

Enable the logic execution by clicking the button.

16. Minimize the DeviceLogix window so you can continue working with the DriveExplorer. The logical input DIP1 (Part Present Sensor) and output DOP1 (actuator) need to be assigned to physical I/O. In the DriveExplorer device tree, select the I/O module in Port 7 and expand the Host Groups.

Double Click on the Digital Outputs group.

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Assign the DOP1 to Relay Output 0. Double click on RO0 Select and make the following selections and click OK.

The value for RO0 Select should be as follows when you are finished:

Assign logical input DIP1 (Part Present Sensor) to physical I/O.

In the DriveExplorer device tree, select the 14 -DeviceLogix Embedded, open the Host Groups and select Digital Inputs.

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Assign DIP1 to digital input 0. Locate the DeviceLogix in the tree structure and open the Digital Inputs group. Double click on DLX DIP 1, make the following selections and click OK.

The value for DLX DIP 1 should be as follows when you are finished:

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Simulating the Application

1. Maximize the DeviceLogix editor to monitor the values in real time.

2. Start the drive via the HIM and make it run at half speed. (Reference at 30Hz). The conveyor is now running. Note that the drive does not have to be running for DeviceLogix to run.

3. Push the IN 0 pushbutton (Part present photo-eye) to simulate a part detection. Notice how OUT 0 Indicator Light changes state (together with DOP1 in the Editor) every time 2 parts have been detected. You can monitor how many parts have counted by opening the parameters of the counter. Double click Counter Up and select the Parameters tab. Monitor the ACC while triggering the part present input.

4. You can also change the Preset value of the counter while the logic is active. Change PREConstantValue to a higher value and apply.

5. Turn off the Drive Power (switch to the left); this removes mains power. What happens? Is the DeviceLogix still executing the logic and triggering the output relay?

Congratulations! You have now successfully programmed a diverter application with DeviceLogix.

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Application Example 2: Wet Well

Background

Lift stations in sewage collection systems are normally designed to handle raw sewage that is fed from underground gravity pipelines. Sewage is fed into and stored in an underground pit, commonly known as wet well. The well is equipped with electrical instrumentation to detect the level of sewage present. When the sewage level rises to a predetermined point, a pump will be started to lift the sewage upward through a pressurized pipe system from where the sewage is discharged into a gravity manhole. From here the cycle starts all over again until the sewage reaches its point of destination.

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Example Application Operation

The application consists of the following discrete I/O:

Type Name Description Fault Reset pushbutton Used to reset any faults or alarms

Critical High Level sensor Indicates a critically high level. It is normally a backup to the High Level sensor and is also used to detect if the High Level sensor is faulty. When ON, the drive will operate at an even higher output frequency in case it is due to a high inflow.

High Level sensor Indicates the well is at a high level and it is time to start pumping (normal operation). The drive operates at a normal rate unless the Critical High Level was reached. Inputs

Low Level sensor When OFF, it is used to indicate that the well is empty (as long as the High and Critical High Level sensors are also OFF). The drive stops operating (end of pumping cycle). Sensor Fault pilot light Indicates that there is a problem with either the High Level or Low Level sensors

Too Much Time Alarm pilot light If the drive operates for more than the normal amount of time it takes to empty the well, there may be increased inflow or perhaps the Low Level sensor is stuck ON. An alarm indication is made and the drive continues to operate.

Outputs

Critical High Fault flashing light / alarm horn Indicates a critically high level that requires immediate attention.

Logic requirements: If Critical High Level or High Level sensor is ON, then start the drive

If Critical High Level sensor is ON, then switch to higher rate (75Hz) for the rest of the pump cycle. Else run at normal rate (45Hz)

Run until all three level sensors are OFF Pump should run at least x minutes (minimum time). If the Low sensor fails, this prevents the High

Level sensor from cycling the pump On/Off too quickly. For the lab, we are only using 5 seconds. Annunciate a Sensor Fault condition

The Low Level sensor should never be OFF when the critical High Level sensor or High Level sensor are ON

The High Level sensor should never be OFF when the Critical High Level sensor is ON The Critical High Level sensor should never be ON when either the High Level or Low Level

sensors are OFF Annunciate a Critical High Level condition

The Critical High Level output should never be ON Annunciate if pumping cycle time is longer than normal (y minutes)

Monitor the amount of time a pump cycle takes by timing how the drive is operating. If greater than y minutes, energize the Too Much Time Alarm output. For the lab, we are only

using 15 seconds Reset alarms/Faults with a Reset pushbutton input

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Disable DeviceLogix

1. Disable DeviceLogix before downloading to drive. Downloading will cause an error if the DeviceLogix is running while attempting to download. Locate the 14 - DeviceLogix Embedded in the tree structure on the left hand side. Expand Host Groups and Double-Click on Status & Control.

Note: Enabling/Disabling the DeviceLogix in this manner is required when using DriveExplorer. If downloading using DriveExecutive, the software will disable the DeviceLogix before download and enable DeviceLogix after download.

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2. Disable Logic. Double-Click on DLX Operation. Select DisableLogic in the pull down click on OK.

After the DeviceLogix is disabled, DLX Operation will display as follows:

The drive will fault when disabling the DeviceLogix. Clear the fault by pressing the STOP key on the HIM.

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Downloading the Configuration (Parameters & DeviceLogix)

1. Place all switches as stated in the Lab Setup paragraph. IN2, IN3, IN4, IN5 = OFF.

2. Select the Node 1: - PowerFlex 755 in the tree structure on the left hand side. Then go to the pull down menu menu Actions and select Upload/Download All.

5. Click Download and Yes.

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6. Open the C:\Lab Files\DeviceLogix PF755 folder. (For convenience, a shortcut has been placed on the desktop). Select the Wet Well All Ports file and click Open.

7. Click Download to download to all the ports. This will download a predefined parameter set to the drive.

When the download is complete, click Close.

The drive is now configured for Fan/pump V/Hz control with the right motor details of the demo case. Start and stop as well as the speed reference will controlled by the DeviceLogix code.

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The following parameter indirects have been made.

PowerFlex 755 IO DLX IO Description Digital Input 3 DLX DIP 1 Critical High Level Sensor input Digital Input 4 DLX DIP 2 High Level Sensor input Digital Input 5 DLX DIP 3 Low Level Sensor input Digital Input 1 DLX DIP 4 Alarm / Fault Reset pushbutton input Relay Output 0 DLX DOP 1 Sensor Fault output Relay Output 1 DLX DOP 2 Critical High Level Fault output N/A DLX DOP 3 Too Much Time Alarm output

Other important parameter settings that have been made in this parameter file

PowerFlex 755 Value Speed Ref A Sel Preset Speed 1 Preset Speed 1 45Hz Preset Speed 3 60Hz

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Enable DeviceLogix

1. Enable DeviceLogix after logic entry and configuration. Locate the 14 - DeviceLogix Embedded in the tree structure on the left hand side. Expand Host Groups and Double-Click on Status & Control.

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2. Enable Logic. Double-Click on DLX Operation. Select EnableLogic in the pull down click on OK.

After the DeviceLogix is enable, DLX Operation will display as follows:

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Simulating the Application

The goal is to simulate this application and try to follow the sequencing in the DeviceLogix editor.

1. Open the DeviceLogix editor to monitor values in real-time. Take some time to study the logic. Can you figure it out?

2. Simulate normal operation of the well. First the Low Level sensor will turn ON (IN 5) as the well fills. What happens? Then the High level sensor will turn ON (IN 4). What happens?

3. If the pump is working correctly the level in the well would gradually decrease. Turn OFF the High Level sensor (IN 4); does the drive stop? Turn OFF the Low Level sensor (IN 5); what happens?

4. Simulate a very high supply to the well. Repeat step 2 Turn ON the Critical High sensor (IN 3); what happens? Turn OFF all sensors in sequence, as they would do in real life. Critical High High Low.

5. Simulate some of the faults that could occur in the field: Turn ON just the High level sensor (IN 4). What happens? What would now be the normal course of actions? Turn ON the Critical High sensor (IN 3) with the other sensors OFF. What happens?

6. To prevent the motor for only running a short period of time and potentially cycling on and off rapidly, a timer is used to force a minimum run time Turn ON just the High level sensor (IN 4) and then immediately turn it OFF. What happens?

7. A timer is also used to check if the well empties in the normal amount of time. Turn ON the Low Level sensor (IN 5) and then turn ON the High level sensor (IN 4). Turn OFF the

High Level sensor and wait at least 15 seconds. What happens?

Congratulations! You have now successfully simulated a wet well application with DeviceLogix.

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Extra Challenge

1. Modify the DeviceLogix program so that the potentiometer on the demo case is simulating the level of the wet well. The logical DIP inputs representing the level sensors should not be triggered anymore by the physical switches on the demo case, use the value of the potentiometer to trigger the different functions.

TIP: Use compare functions

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Solution to be added in the back of lab book Replace DIP inputs with LEQ function blocks Transfer Analog Input 0 value (=Potentiometer) to DeviceLogix via DevLogix In 01 (P1.14.17) Set detection levels (8Volts LL, 6Volts HL, 2Volts CHL) in properties of LEQ function block (Note

that the signal is inverted so a signal loss equates to a Critical High Level) Modify data format to REAL in properties LEQ function block

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Notes