FlexLogix User Manual - Rockwell Automation

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FlexLogixController SystemUser Manual1794-L34Firmware Revision 16User Manual

Important User InformationSolid state equipment has operational characteristics differing from those ofelectromechanical equipment. Safety Guidelines for the Application,Installation and Maintenance of Solid State Controls (publication SGI-1.1available from your local Rockwell Automation sales office or online athttp://literature.rockwellautomation.com) describes some importantdifferences between solid state equipment and hard-wired electromechanicaldevices. Because of this difference, and also because of the wide variety ofuses for solid state equipment, all persons responsible for applying thisequipment must satisfy themselves that each intended application of thisequipment is acceptable.In no event will Rockwell Automation, Inc. be responsible or liable forindirect or consequential damages resulting from the use or application of thisequipment.The examples and diagrams in this manual are included solely for illustrativepurposes. Because of the many variables and requirements associated withany particular installation, Rockwell Automation, Inc. cannot assumeresponsibility or liability for actual use based on the examples and diagrams.No patent liability is assumed by Rockwell Automation, Inc. with respect touse of information, circuits, equipment, or software described in this manual.Reproduction of the contents of this manual, in whole or in part, withoutwritten permission of Rockwell Automation, Inc., is prohibited.Throughout this manual, when necessary, we use notes to make you awareof safety considerations.WARNINGIMPORTANTATTENTIONIdentifies information about practices or circumstances thatcan cause an explosion in a hazardous environment, whichmay lead to personal injury or death, property damage, oreconomic loss.Identifies information that is critical for successfulapplication and understanding of the product.Identifies information about practices or circumstances thatcan lead to personal injury or death, property damage, oreconomic loss. Attentions help you to identify a hazard,avoid a hazard, and recognize the consequences.SHOCK HAZARDLabels may be on or inside the equipment, for example, adrive or motor, to alert people that dangerous voltage maybe present.BURN HAZARDLabels may be on or inside the equipment, for example, adrive or motor, to alert people that surfaces may bedangerous temperatures.Allen-Bradley, FlexLogix, Logix5000, RSLogix, RSLogix 5000, Rockwell Automation, RSNetWorx, and RSLinx are trademarks ofRockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.

Table of ContentsSummary of ChangesImportant User Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Updated Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7PrefaceDeveloping FlexLogix ControllerSystemsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Chapter 1Where to StartUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Install Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Chapter 2Directly Connect to the Controller Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Connect the Controller via the Serial Port. . . . . . . . . . . . . . . 15via the Serial PortConfigure the Serial Driver . . . . . . . . . . . . . . . . . . . . . . . . . 18Select the Controller Path . . . . . . . . . . . . . . . . . . . . . . . . . . 20Chapter 3Communicate over NetworksUse This Chapter . . . . . . . . . . . . . . .EtherNet/IP. . . . . . . . . . . . . . . . . . . .Connections over EtherNet/IP . . .ControlNet . . . . . . . . . . . . . . . . . . . .Connections over ControlNet . . . .DeviceNet. . . . . . . . . . . . . . . . . . . . .Define Data Blocks . . . . . . . . . . .Serial . . . . . . . . . . . . . . . . . . . . . . . .Communicate with DF1 devices . .Communicate with ASCII devices .Modbus support . . . . . . . . . . . . .DH-485. . . . . . . . . . . . . . . . . . . . . . .Third Party . . . . . . . . . . . . . . . . . . . .Communication Format . . . . . . . .Connection Parameters. . . . . . . . .212224252628303133353839424242Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . .Produce and Consume (Interlock) Data . . . . . . . . . . .Send and Receive Messages. . . . . . . . . . . . . . . . . . . .Determine whether to cache message connectionsConnection Overview . . . . . . . . . . . . . . . . . . . . . . . .Calculate Connection Use . . . . . . . . . . . . . . . . . . . . .Connections Example . . . . . . . . . . . . . . . . . . . . . . . .45454747495052Chapter 4Manage ControllerCommunications3Publication 1794-UM001G-EN-P - January 2007

4Table of ContentsChapter 5Place, Configure, and Monitor I/OUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . .Select I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . .Place Local I/O Modules . . . . . . . . . . . . . . . . . . . . .Selecting a Power Supply . . . . . . . . . . . . . . . . . .Configure I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I/O connections. . . . . . . . . . . . . . . . . . . . . . . . .Configure Distributed I/O on EtherNet/IP . . . . . . . .Configure Distributed I/O on ControlNet . . . . . . . . .Configure Distributed I/O on DeviceNet . . . . . . . . .Address I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . .Determine When Data Is Updated . . . . . . . . . . . . . .Monitor I/O Modules . . . . . . . . . . . . . . . . . . . . . . .Displaying fault data . . . . . . . . . . . . . . . . . . . . .Monitor a rack-optimized connection . . . . . . . . .Reconfigure an I/O Module . . . . . . . . . . . . . . . . . . .Reconfigure a module via RSLogix 5000 softwareReconfigure a module via a MSG instruction . . . .5353545455575960616263646465666667Chapter 6Develop ApplicationsPublication 1794-UM001G-EN-P - January 2007Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Manage Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Develop Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Defining tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Defining programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Defining routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Sample controller projects . . . . . . . . . . . . . . . . . . . . . . . 74Organize Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Select a Programming Language . . . . . . . . . . . . . . . . . . . . . 76Add-On Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Monitor Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Monitor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Determine if communication has timed out with any device80Determine if communication has timed out with a specificI/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Interrupt the execution of logic and execute the fault handler81Select a System Overhead Percentage . . . . . . . . . . . . . . . . . 82Use the Event Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Prioritizing Periodic and Event Tasks . . . . . . . . . . . . . . . 85Triggering the Event Task. . . . . . . . . . . . . . . . . . . . . . . . 86Programmatically Determine if an EVENT InstructionTriggered a Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Checklist for an EVENT Instruction Task . . . . . . . . . . . . . 87

Table of Contents5Chapter 7Configure PhaseManagerUse This Chapter . . . . . . . . . . . . . . . . . . . . . .PhaseManager Overview . . . . . . . . . . . . . . . . .State Model Overview . . . . . . . . . . . . . . . . . . .How equipment changes states . . . . . . . . .Manually change states . . . . . . . . . . . . . . .Compare PhaseManager to Other State Models.Minimum System Requirements . . . . . . . . . . . .Equipment Phase Instructions . . . . . . . . . . . . .8989919294949495.97979899Chapter 8Maintain the BatteryUsing this Appendix . . . . . . .Storing Replacement BatteriesEstimating Battery Life. . . . . .Replacing a Battery . . . . . . . .Appendix AFlexLogix System StatusIndicatorsController LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Appendix BFlexLogix Back-Up on DeviceNetUsing This Appendix. . . . . . . . . . . . . . . . . . . .How the Back-up Works . . . . . . . . . . . . . . . . .Requirements of the Back-Up . . . . . . . . . . .Power-Up and System Start-up . . . . . . . . . . . .Developing the FlexLogix Back-Up ApplicationBack-up Heartbeat Configuration Rungs . . .Reading Back-up State Rung. . . . . . . . . . . .Reading Back-up Status . . . . . . . . . . . . . . .Using Indicators to Check Status . . . . . . . . . . .Development and Debugging Tips. . . . . . . . . .103104105106108108112114115115Appendix CInstruction LocatorIndexWhere to Find an Instruction . . . . . . . . . . . . . . . . . . . . . . . 117Publication 1794-UM001G-EN-P - January 2007

6Table of ContentsPublication 1794-UM001G-EN-P - January 2007

Summary of ChangesIntroductionThis release of this document contains new and updated information.To find new and updated information, look for change bars, as shownnext to this paragraph.Updated InformationThe document contains these changes.7TopicPageDF1 radio modem31Add-On Instructions77Where to Find an Instruction117Publication 1794-UM001G-EN-P - January 2007

8Summary of ChangesNotes:Publication 1794-UM001G-EN-P - January 2007

PrefaceDeveloping FlexLogix Controller SystemsIntroductionUse this manual to become familiar with the FlexLogix controller andits features. This version of the manual corresponds to controllerfirmware revision 16.This manual describes the necessary tasks to install, configure,program, and operate a FlexLogix system. In some cases, this manualincludes references to additional documentation that provides themore comprehensive details.Related DocumentationThese core documents address the Logix5000 family of controllers:For this information:Use this publication:where to start for a new user of a Logix5000 controller Logix5000 Controllers Quick Startpublication 1756-QS001program and test a simple projecthow to complete standard tasksprogram logic using sequential function charts (SFC),ladder diagram (LD), structured text (ST), and functionblock diagram (FBD) languagesLogix5000 controller reference: LED patternsLogix5000 Controllers Common Procedurespublication 1756-PM001Important: SFC and ST Programming Languages Programming Manual,publication 1756-PM003, is an excerpt from the Logix5000 Controllers CommonProcedures ManualLogix5000 Controllers System Referencepublication 1756-QR107 controller features instruction set quick referenceprogram sequential applicationsladder diagram and structured text instructionsprogram process control and drives applicationsfunction block diagram instructionsprogram motion applicationsladder diagram motion instructionsconfigure and program motion interface modulescreate and configure motion groups and axesLogix5000 Controllers General Instruction Set Reference Manualpublication 1756-RM003Logix5000 Controllers Process Control/Drives Instruction Set Reference Manualpublication 1756-RM006Logix5000 Controllers Motion Instruction Set Reference Manualpublication 1756-RM007Logix5000 Motion Module Configuration and Programming Manualpublication 1756-UM006configure a coordinated system time master device9Publication 1794-UM001G-EN-P - January 2007

10Developing FlexLogix Controller SystemsThe documents address network communications:For this information:Use this publication:configure and use EtherNet/IP networksEtherNet/IP Communication Modules in Logix5000 Control Systemspublication ENET-UM001communicate over EtherNet/IPconfigure and use ControlNet networkscommunicate over ControlNetconfigure and use DeviceNet networkcommunicate over DeviceNetControlNet Communication Modules in Logix5000 Control Systemspublication CNET-UM001DeviceNet Communication Modules in Logix5000 Control Systemspublication CNET-UM004These documents address specific controller applications:For this information:Use this publication:use a state model for your controllerLogix5000 Controllers PhaseManager User Manualpublication LOGIX-UM001configure equipment phase programs To view or download manuals, visitwww.rockwellautomation.com/literature. To obtain a hard copy of a manual, contact your local RockwellAutomation distributor or sales representative.Publication 1794-UM001G-EN-P - January 2007

Chapter1Where to StartUse This ChapterThe FlexLogix controller offers state-of-art control, communications,and I/O elements in a distributed control package.1794 I/O modulesconnected to theFlexLogix controllerFlexLogix controllerFor a more flexible system, use: multiple