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REPORT ON

AB MLX 1400 PLC, HMI AND SERVO DRIVE

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AB MLX 1400 PLC

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AB MLX 1400 PLC

INTRODUCTION
Rockwell Automation offers enhanced MicroLogix 1400 controllers for your EtherNet/IP control systems so you can monitor data remotely via web pages. With the MicroLogix 1400 controller, you can access controller and control system data with different and remote access applications. With a web browser, you can easily monitor live MicroLogix 1400 controller data remotely. With the MicroLogix 1400 controller, you can access Simple web page view, and custom-designed User Provided page views. Simple web pages use only HTML tags and are useful in limited-communication environments where radio modems are used. You can access the MicroLogix 1400 controllers only with Internet Explorer 6.0, Opera 9.23 , FireFox 2.0.0.14, or Safari 3.0.4, or higher . To access data view pages, the browser requires Javascript and XML support. The supported display sizes start from 640 x 480. Smaller display sizes also work but require scrolling to view the information What is the I/O count of MicroLogix 1400 All MicroLogix 1400 controllers come with 32 embedded digital I/O (20 in and 12 out), three of the configurations come with six analog I/O (four in and two out). In addition, the controllers can be connected to a maximum of seven 1762. I/O, providing a total of 144 digital I/O (if 16 point 1762 I/O modules are used). ML1400 supports all the protocol that is supported by ML1100. In addition to these, MicroLogix 1400 supports DNP 3 Slave, which is commonly used in SCADA, RTUs and Intelligent Electronic Devices (IEDs). Similar to the rest of the MicroLogix family, RSLogix 500 (version 8.1 and above) can be used for programming the MicroLogix 1400. In addition, RSLogix Micro (a simplified version of RSLogix 500) provides support for MicroLogix 1400.

WORKING OF MLX 1400 PLC. STEP 1}

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Connect the MicroLogix 1400 controller to the Ethernet network. The RJ-45 connector is on the left-hand side of the module. Connect the HMI to the Ethernet network by using RJ-45 connector . The required voltage to operate the plc is 24v dc. The supply is given by 24v dc power supply. Give 24v to MLX1400 , to HMI and if required give to analog module.

STEP 2}

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By default, the MicroLogix 1400 controller is BOOTP enabled. If you connect the MicroLogix 1400 controller to a network that has a BOOTP server, that server will assign an IP address to the MicroLogix 1400 controller and the LCD screen of the MicroLogix 1400 controller will display BOOTP IP address. If your network does not have a BOOTP server, use one of the methods described in the MicroLogix 1400 Programmable Controllers . User Manual 1766-UM001 to assign an IP address to the MicroLogix 1400 controller. To interface computer and micrologix 1400 controller enter the IP address of the plc

STEP 3}
In your web browsers Address box, enter the IP address of the MicroLogix 1400 controller. The Home page is displayed.

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STEP 4}
Many of the features of the MicroLogix 1400 controller require you to log in with appropriate access. If you select a feature, such as Data Views, the MicroLogix 1400 controller prompts you to enter your user name and password. The user name is

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either administrator or guest. The password is ml1400 for administrator and guest for guest.

Enter network password.

I/O ADDRESSING

ADDRESSING DETAILS

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Since a PLC will be controlling real devices down on a plant floor, it has to have some way of communicating to the correct device. All PLCs use some sort of method of I/O Addressing to perform this function. Although addressing methods may vary, they all perform the same function. They all tie some symbolic representation, that you can use in a program, to a specific device.

EXAMPLE FOR ADDRESSING THE I/0 PORTS.

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I:0/1

O:0/1

I/O addresses are a means to tie a physical I/O point to a location in PLC memory An input address will represent the state of an input device, i.e. the switch is on or off. An output address will represent the commanded state for a device. i.e., turn the motor on or off.

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PROGRAMMING
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Software for programming: Rslogix 1400 Software for communication: Rslinx Software for IP address: Bootp. Software for HMI: panel view. Software for servo drive: Motion veiw Every PLC has associated Programming software, or a dedicated terminal, that allows the user to enter a program into the PLC. Most of the software used today is Windows based, and can be run on any PC. Software designed to program one controller may not be able to program other PLCs.

Before a PLC can perform any control task, it must be programmed to do so. The most popular language used to program a PLC is ladder logic.
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In our conveyor example in the PLC example system section of this CD, we had several different requirements that we needed to accomplish. This included things like timing and counting parts on the conveyor. Each of these requirements must be programmed into the PLC so that it knows how to respond to different events.

In most cases today, a programmer will use a personal computer and the associated PLC programming software to create a program. The
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programmer will connect their personal computer to the PLC through a network or cable and then download the program to the PLC.

LADDER LOGIC

Here, we can see an example of ladder logic. Each line of code is known as a rung. In this example there are 4 rungs, numbered 0, 1 and 2, and the end rung marking the end of the program. The PLC executes the program 1 rung at a time, starting with the first rung and then working down. Each individual rung is executed from the left to the right. Therefore, you typically find the inputs on the left and the outputs on the right. Ladder logic rungs are basically if then statements. If the input conditions are true, then command the outputs based on a true input. If the input conditions are false, then command the outputs based on a false input.

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Lets take a look at a sample rung. The first instruction is known as an XIC, which stands for examine if closed. This is an input instruction. This instruction checks to see if the input assigned to this instruction is on and then sets the rung to true if it is. If the input is off, then the rung will be set to false. If there were multiple XICs on the rung, then all would have to be on for the rung to be true. This instruction checks to see if the input assigned to this instruction is on and then sets the rung to true if it is. If the input is off, then the rung will be set to false. If there were multiple XICs on the rung, then all would have to be on for the rung to be true.

All the inputs have to be on for the rung to be true

The second instruction is known as an OTE, which stands for Output Energize. This is an output instruction.

This instruction turns on the output assigned to this instruction if the rung is true. If the rung is false, then the output will be turned off. If there were multiple OTEs on the rung, then all would be turned on or off based on the rung condition (true or false).

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All the outputs will turn on if the rung is true Therefore, this rung literally reads as: If the Start Button is on then turn on the motor. If the Start Button is off, then turn off the motor.

OTHER PROGRAMMING LANGUAGES

While ladder logic is the oldest and most popular language used in PLCs today, many other languages are gaining in popularity and are in wide use. Examples are: Sequential Function Chart (SFC). Function Block Structured Text Higher level languages such as C.

SEQUENTIAL FUNCTION CHART (SFC).

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FUNCTION BLOCK

STRUCTURED TEXT

HIGHER LEVEL LANGUAGES SUCH AS C.

HMI (HUMAN MACHINE INTERFACE)

These allow control systems to be much more interactive than before.
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The basic purpose of an HMI is to allow easy graphical interface with a process. These allow an operator to use simple displays to determine machine condition and make simple . The most common uses are, - display machine faults - display machine status - allow the operator to start and stop cycles - monitor part counts settings.

DESIGN CASES
Design an HMI for a press controller. The two will be connected by a Devicenet network.

A PLC With Connected HMI

The common trend is to adopt a user interface which often have, - Icons - A pointer device (such as a mouse) - Full color - Support for multiple windows, which run programs simultaneously - Popup menus - Windows can be moved, scaled, moved forward/back, etc. The current demands on user interfaces are, - on-line help - adaptive dialog/response - feedback to the user - ability to interrupt processes - consistent modules - a logical display layout
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- deal with many processes simultaneously To design an HMI interface, the first step is to identify, 1. Who needs what information? 2. How do they expect to see it presented? 3. When does information need to be presented? 4. Do the operators have any special needs? 5. Is sound important? 6. What choices should the operator have? ADAVANTAGES - colour coding allows for easy identification (eg. red for trouble) - pictures/icons allow fast recognition - use of pictures eases problems of illiteracy -screen can be changed to allow different levels of information and access

The general implementation steps are,

1. Layout screens on PC based software. 2. Download the screens to the HMI unit. 3. Connect the unit to a PLC. 4. Read and write to the HMI using PLC memory locations to get input and update screens.

KINETIX 300 SERVO DRIVE

The Kinetix 300 EtherNet/IP indexing drive: provides a cost-effective single axis solution for low axis count motion control applications.
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uses one standard Ethernet/IP network for an entire machine - including Motion, Control, I/O, and HMI, simplifying wiring and reducing panel layout costs allows easy integration into manufacturing and enterprise systems features safe torque-off functionality to help protect personnel while increasing machine productivity.

KINETIX 300 PRODUCT POSITIONING

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Target Applications
Indexing tables Automatic assembly machines Tool changing machinery Intermittent vertical form, fill and seal equipment Intermittent horizontal form fill and seal equipment Laboratory automation equipment Simple sleevers Intermittent shrink wrappers Simple case packers and erectors Medical technology applications Light manufacturing systems Solar panel tracking equipment Feed and withdrawal equipment

KINETIX 300 ANATOMY

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KINETIX 300 BENEFITS

Standard Unmodified Ethernet Lower wiring costs
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Simplified integration of the entire control solution on one network. including HMI, PAC, I/O and motion. Integration with L2x and L3x CompactLogix PACs with Add On Profile. Cost effective motion solution Safe Torque Off standard on all models Help protect personnel and increase machine productivity Built in web server for configuration and diagnostics No motion software to install or maintain. Flexible Control to satisfy many application requirements Indexing Five different Indexing types S-Curve and trapezoidal moves 32 Index capability Commanded Control Over EtherNet/IP Velocity and Current Absolute and Incremental Position with or without Registration Electronic gearing Analog Input Control Step and Direction Control Scalable Platform to meet global machine standards 120V models drive 240V motors at full speed 240V single phase w/ integrated filters 240 and 460 3-phase voltage models 400W 3kW power ranges Enhancing Machine Productivity Integrated Safe Torque Off helps reduce machine downtime Memory Module for Automatic Device Replacement Seamless integration of Rockwell Automation MP-Series and TL-Series (TLY) motors and cylinders Kinetix 300

KINETIX 300 I/O RATINGS

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I/O CONNECTOR

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Pin

Name

Description

1 MA+ Master Encoder A+ / Step+ Input 2 MAMaster Encoder A- / Step- Input 3 MB+ Master Encoder B+ / Direction+ Input 4 MBMaster Encoder B- / Direction- Input 5 GND Drive Logic Common 6 Unused in the Kinetix 300 7 BA+ Buffered Encoder Output: Channel A+ 8 BABuffered Encoder Output: Channel A9 BB+ Buffered Encoder Output: Channel B+ 10 BBBuffered Encoder Output: Channel B11 BZ+ Buffered Encoder Output: Channel Z+ 12 BZBuffered Encoder Output: Channel Z13 21 Unused in the Kinetix 300 22 ACOM Analog Common 23 AO Analog Output 24 AIN1+ Positive (+) of Analog Signal Input 25 AIN1- Negative (-) of Analog Signal Input 26 IN_A_COM Digital Input Group ACOM Terminal 27 28 29 30 IN_A1 IN_A2 IN_A3 IN_A4 Digital Input A1 Digital Input A2 Digital Input A3 Digital Input A4

Pin 31 32 33 34

Name

Description

IN_B_COM Digital Input Group BCOM Terminal IN_B1 Digital Input B1 NETTUR TECHNICAL TRAINING FOUNDATION IN_B2 Digital Input B2 DTC IN_B3 Digital Input B3
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FEEDBACK CONNECTOR

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24V DC BACK UP POWER CONNECTOR

2-pin quick-connect terminal block that can be used with an external 24 VDC power supply to provide Keep Alive capability: during a power loss, the logic and communications will remain active. When the enable input remains asserted, the back up circuit shall restart the motor upon restoration of mains power. If this action is not desired, then disable the enable input prior to re-application of input power.

Pin 1 4

Name 24 VDC Return

Function Positive 24 VDC Input 24V power supply return

BRAKING RESISTOR AND DC BUS CONNECTOR

5-pin quick-connect terminal block that can be used with an external braking resistor (the indexing drive has the regeneration circuitry built-in). The Brake Resistor connects between the Positive DC Bus (either P6.1 or 2) and P6.3.

Pin 1 2 3 4 5

Name B+ BBR BB-

Function Positive DC Bus / Brake Resistor Brake Resistor Negative DC Bus

DRIVE BASED BACK UP MEMORY

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The drive based ADR is done through the memory module. The memory module is based on EEPROM technology, and is good for 100,000+ write cycles. All configured tags are stored in the memory (when drive is not in run mode). Any tags that get changed via Ethernet during runtime are not written to memory module.

KEYPAD
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The Kinetix 300 drive is equipped with a diagnostic LED display and three push buttons that are used to select displayed information and to edit a limited set of parameter values. Parameters can be scrolled by using the UP and DOWN buttons. To view a value, press Enter . To return back to scroll mode press Enter again. After pressing the Enter button on editable parameters, the yellow LED C will blink indicating that parameter value can be changed. Use UP and DOWN buttons to change the value. Press Enter to store new setting and return back to scroll mode.

STATUS DISPLAY BEHAVIOR

By default, if there is no activity on the input keypad for 30 seconds, the Kinetix 300 drive continuously scrolls the drives IP address.
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Upon power up, the display shows its status: diS (disabled) or run (enabled), then after 30 seconds, the drive alternately scrolls the drives IP address along with its status. If the Kinetix 300 is faulted, the drive displays the fault code (non-scrolling). Then after 30 seconds, the drive alternately scrolls the drives IP address along with its fault code.

SAFE OFF
The Kinetix 300 has an ISO 13849-1 Safety Category 3 Performance Level d, compliant safety circuit. Safety functionality is implemented to allow the drive output to the motor to be disabled so that the drive cannot generate torque in the motor.
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6-pin quick-connect terminal block for the safety function interface.

SAFETY BYPASS WIRING

If Safe Off is not used, the safety circuit must be wired to bypass the safety function, as shown above. By default, the Safe Off is NOT bypassed

ANALOG INPUTS
Analog Reference Input
The analog reference input accepts up to a 10V analog signal across AIN1+ and AIN1-. The analog signal will be converted to a digital value with 13 bit resolution (12 bit plus sign). If used in single-ended mode, one of the inputs must be connected to a voltage source while the other one must be connected to Analog Common (ACOM).

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AB MLX 1400 PLC If used in differential mode, the voltage source is connected across AIN1+ and AIN1- and the driving circuit common (if any) needs to be connected to the drive Analog Common (ACOM) terminal.

ANALOG OUTPUT
Analog Output The analog output is a single-ended signal (with reference to Analog Common (ACOM)) which can represent the following motor data: Not Assigned RMS Phase Current RMS Peak Current Motor Velocity Phase Current R Phase Current S Phase Current T Iq Current Id Current The analog output resolution is 10 bit, and supplies a maximum of 10 mA from -10 to +10 VDC

DIGITAL INPUTS
The Kinetix 300 has twelve digital inputs that can be utilized by the drive. Example uses includes travel limit switches, proximity sensors, push buttons and hand shaking with other devices. Each input can be assigned an individual de-bounce time via tags.

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Some inputs can have additional special functionality such as Travel Limit switch, Enable input, Homing, and Registration input and can only be used on certain digital inputs as shown below:

Input Special Function A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 Negative Limit Switch Positive Limit Switch Inhibit/Enable Input Not Assigned Not Assigned Not Assigned Not Assigned Not Assigned Not Assigned Not Assigned Registration Not Assigned

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The inputs listed as Not Assigned are configurable to be any of the following inputs: Abort Homing Start Homing Home Sensor Start Index Abort Index Reset Faults The digital inputs are optically isolated and will source/sink up to 24 VDC.

DIGITAL OUTPUTS
Digital Outputs There are a total of five digital outputs (OUT1 - OUT4 and RDY) available on the Kinetix 300. Outputs are open collector/emitter and are fully isolated from the rest of the drive circuits. These outputs can be used as Special Purpose, each output (OUT1-OUT4) can be assigned to one of the following functions: Not assigned Zero speed In-speed window Current limit Run-time fault Ready Brake (motor brake release) The RDY Output has a fixed function that will become active when the drive is enabled and the output power transistors become energized.

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The digital outputs are optically isolated open collector/emitter circuits with a maximum output of 30 VDC and 100 mA,

OPERATING MODES
Master Gearing Step and Direction Analog Input (Velocity or Current) EtherNet/IP External Reference Indexing

KINETIX 300 COMPONENT SOLUTION

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KINETIX 300 REQUIRED ACCESSORIES

Kinetix 2000 Feedback Connector for all motors Battery for TLY motors only Catalog Numbers 2090-K2CK-D15M, 2090-DA-BAT2
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I/O Breakout board, Catalog number 2097-TB1 Increases width of drive by 9.7 mm.

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KINETIX 300 OPTIONAL ACCESSORIES

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Side Mount EMI Filters Footprint Mount EMI Filter Shunt Resistors Memory Module 12 pack Memory Module Programmer Spare Connector Set

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MICROLOGIX 1400 USER MEMORY

The MicroLogix 1400 controller supports 20K of memory. Memory can be used for program files and data files. The maximum data memory usage is 10K words as shown.

To find the memory usage for specific instructions, see MicroLogix 1400Memory Usage and Instruction Execution Time on page 569. The MicroLogix 1400 controller also supports 128K bytes of battery backed memory for data logging or recipe operations. See Chapter 25 forData Logging and Recipe information.

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MICROLOGIX 1400 LIST OF INSTRUCTIONS AND FUNCTION FILES

Instruction- Description Page ABL - Test Buffer for Line 378 ABS - Absolute Value 210 ACB - Number of Characters in Buffer 379 ACI - String to Integer 380 ACL - ASCII Clear Buffers 371 ACN - String Concatenate 382 ACS - Arc Cosine 224 ADD - Add 208 AEX - String Extract 383 AHL - ASCII Handshake Lines 385 AIC - ASCII Integer to String 372 AND - Bit-Wise AND 261 ARD - ASCII Read Characters 387 ARL - ASCII Read Line 388 ASC - String Search 390 ASN - Arc Sine 222 ASR - ASCII String Compare 391 ATN - Arc Tangent 225 AWA - ASCII Write with Append 373 AWT - ASCII Write 376 BSL - Bit Shift Left 276 BSR - Bit Shift Right 278 CLR - Clear 209 COP - Copy File 273 COS - Cosine 218 CPT - Compute 238 CPW - Copy Word 272 CTD - Count Down 189 CTU - Count Up 189 DCD - Decode 4 to 1-of-16 248 DEG - Radians to Degrees 227 DIV - Divide 209 DLG - Data Log Instruction 549 ENC - Encode 1-of-16 to 4 249 END - Program End 304 EQU - Equal 195 FFL - First In, First Out (FIFO) Load 281 FFU - First In, First Out (FIFO) Unload 283 FLL - Fill File 275 FRD - Convert from Binary Coded Decimal (BCD) 250 GCD - Gray Code 257 GEQ - Greater Than or Equal To 196 GRT - Greater Than 195 HSL - High-Speed Counter Load 134 IIM - Immediate Input with Mask 307 INT - Interrupt Subroutine 316 IOM - Immediate Output with Mask 309 JMP - Jump to Label 301 JSR - Jump to Subroutine 302 LBL - Label 302

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AB MLX 1400 PLC LCD - LCD instruction 566 LEQ - Less Than or Equal To 196 LES - Less Than 195 LFL - Last In, First Out (LIFO) Load 286 LFU - Last In, First Out (LIFO) Unload 288 LIM - Limit Test 198 LN - Natural Log 231 LOG - Base 10 Logarithm 233 Memory Module Information Function File 63 MUL - Multiply DIV - Divide 209 NEG - Negate 209 NEQ - Not Equal 195 NOT - Logical NOT 264 ONS - One Shot 175 OR - Logical OR 262 OSF - One Shot Falling 177 OSR - One Shot Rising 177 OTE - Output Energize 173 OTL - Output Latch 174 OTU - Output Unlatch 174 PID - Proportional Integral Derivative 336 PTO - Pulse Train Output 143 PWM - Pulse Width Modulation 162 RAC - Reset Accumulated Value 135 RAD - Degrees to Radians 231 RCP - Recipe 535 REF- I/O Refresh 310 RES - Reset 190 RET - Return from Subroutine 303 RTO - Retentive Timer, On-Delay 185 SBR - Subroutine Label 302 SCL - Scale 212 SCP - Scale with Parameters 213 SIN - Sine 215 SQC- Sequencer Compare 292 SQL - Sequencer Load 298 SQO- Sequencer Output 295 SQR - Square Root 215 STS - Selectable Timed Start 317 SUB - Subtract 208 SUS - Suspend 303 SWP - Swap 290 TAN - Tangent 220 TND - Temporary End 303 TOD - Convert to Binary Coded Decimal (BCD) 254 TOF - Timer, Off-Delay 184 TON - Timer, On-Delay 183 UID - User Interrupt Disable 318 UIE - User Interrupt Enable 319 UIF - User Interrupt Flush 320 XIC - Examine if Closed 171 XIO - Examine if Open 171 XOR - Exclusive OR 263 XPY - X Power Y 235 BHI - Base Hardware Information 65

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AB MLX 1400 PLC CS - Communications Status 66 EII - Event Input Interrupt 326 ES - Ethernet Status 83 HSC - High Speed Counter 104 IOS - I/O Status 92 LCD-LCD Information 557 MCR - Master Control Reset 304 MEQ - Mask Compare for Equal 197 MMI - Memory Module Information 63 MOV - Move 265 MSG - Message 402 MUL - Multiply 209 MVM - Masked Move 268 PTOX - Pulse Train Output 147 PWMX - Pulse Width Modulation 163 RTC - Real Time Clock 59 STI - Selectable Timed Interrupt 322

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