EtherNet/IP Safety with the PF527

ETHERNET SAFETY WITH THE PF527 _________________________________________________________ 6

ABOUT THIS HANDS-ON LAB ___________________________________________________________ 6

LAB MATERIALS ____________________________________________________________________ 6

DOCUMENT CONVENTIONS ____________________________________________________________ 7

BEFORE YOU BEGIN _________________________________________________________________ 7

LAB 1: POWERFLEX DRIVES IN AN INTEGRATED MOTION SYSTEM _____________________________________ 8

ABOUT THIS LAB ___________________________________________________________________ 8

SECTION 1: CREATING THE PROJECT ______________________________________________________ 9

ADD AND CONFIGURE THE I/O HARDWARE _________________________________________________ 9

DOWNLOAD THE MOTION PROJECT _____________________________________________________ 12

PROGRAMMING MOTION COMMANDS ___________________________________________________ 13

DOWNLOAD THE MOTION PROJECT _____________________________________________________ 14

TUNING AND COMMANDING MOTION _______________________________________________________ 15

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EtherNet Safety with the PF527
About This Hands-On Lab
In this lab the Integrated Safety over EtherNet/IP will be demonstrated.

The following sections explain what you’ll be doing in this lab session, and what you will need to do to
complete the hands-on exercises.

What You Will Accomplish In This Lab

As you complete the exercises in this hands-on session, you will see how easy it is to create an Integrated
Safety Solution by doing the following:

▪ Creating and configuring motion axes using Logix Designer.

▪ Programming basic motion-direct commands.
▪ Demonstrating the EtherNet/IP Safety capability.

Lab Materials
For this Hands-On lab, we have provided you with the following materials that will allow you to complete
the labs in this workbook.

Hardware
This hands-on lab uses the following hardware:
• Computer with Windows 7 operating system
• ControlLogix 1756-L63 Demo (ABT-TDCLX3K-A)

• PowerFlex 755 Workstation

• PowerFlex 527
• Ethernet Patch Cables

Software
This hands-on lab uses the following software:

▪ Logix Designer v24.00

▪ RSLinx Classic v3.61

Lab Files
This hands-on lab does not need any pre-configured files.

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Document Conventions
Throughout this workbook, we have used the following conventions to help guide you through the lab
materials.
This style or symbol:
Words shown in bold italics
(e.g., RSLogix 5000 or OK)
Words shown in bold italics,
enclosed in single quotes (e.g.,
'Controller1')
Indicates:
Any item or button that you must click on, or a menu name from
which you must choose an option or command. This will be an
actual name of an item that you see on your screen or in an
example.
An item that you must type in the specified field. This is
information that you must supply based on your application (e.g., a
variable).
Note: When you type the text in the field, remember that you do
not need to type the quotes; simply type the words that are
contained within them (e.g., Controller1).
The text that appears inside of this gray box is supplemental
information regarding the lab materials, but not information that is
required reading in order for you to complete the lab exercises.
The text that follows this symbol may provide you with helpful
hints that can make it easier for you to use this product. Most
often, authors use this “Tip Text” style for important information
they want their students to see.

Note: If the mouse button is not specified in the text, you should click on the left mouse button.

Before You Begin

Prerequisite is to be familiar with Logix Designer software and programming.

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Lab 1: PowerFlex Drives in an Integrated Motion System
About This Lab
PowerFlex 755 & 527 drives can be utilized within Logix control systems utilizing Integrated Motion over
EtherNet/IP. The PF755 can also run as a standalone drive or as a drive connected to a controller in I/O
mode. The PF527 however, is designed to only operate within an Integrated Motion system. It cannot be
used in a standalone mode.

In this lab, you will (describe just this part of the lab):

▪ Create a new Logix Motion Project

▪ Add the hardware which will include I/O modules, a PF755 and later a PF527 to the project
▪ Configure the system by creating the required tags and adding the programming to operate the drives
▪ Download, test and debug the system

Follow the steps below to complete Lab Section 1.

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Section 1: Creating the Project
In this section of the lab, you will create the project.

1. Open Studio 5000 by double-clicking on the shortcut on the desktop.

2. Create a new project.

3. Select the 1756-L72S for the controller (found under GuardLogix) and SafetyDemo for Name. Select
Next. On the next dialog box, Select V24, 1756-A10, 10 slot chassis and slot 0 for the controller location,
then select Finish.

4. Open the Controller Properties screen by clicking on the controller icon or by Right clicking on the
controller in the controller organizer and selecting Properties.

5. Select the Date/Time tab.

6. Check the box for Enable Time Synchronization. This sets Time Synchronization between the controller
and axes (Drives). Press Apply and then OK when ready.

7. Since one of the requirements is use of motion commands, the project needs a Motion Group.

8. Right-click on the Motion Groups folder in the Controller Organizer and choose New Motion Group.

9. Name the new motion group ‘MotionGroup’, select Open Motion_Group Configuration and pick Create.

10. At the first window, click next. Change the Base Update Period to 1ms. We will come back to the
schedule once all of the Axes have been added. Click Finish.

Add and Configure the I/O Hardware

11. To set up the communications, a module needs to be added.

12. In the I/O Configuration folder choose the 1756-EN3TR module and press OK. Name your module
‘Ethernet’ and enter the IP Address of 172.16.1xx.4. Select the correct Slot 6 from the drop-down.
Finally, select the correct version for these workstations v5.7 by selecting Change in the Module
Definition.

NOTE: the xx in the IP address is replaced with the 2 digit Workstation number.
i.e. Workbench #01 would be 172.16.101.4

13. Next, click Change in the Module Definition section. Use the drop-down to change the Time Sync
Connection setting to Time Sync and Motion.

14. Press OK to save the Module Definition settings and answer Yes to confirm.

15. Press OK again to choose all of the default values for the remaining module choices.

16. To use the I/O Modules need to be added in.

17. Right-click on the I/O Configuration folder and select New Module.

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18. Expand the Digital entry and scroll down until you can see the 1756-IB16D in the list. Double-click on
this module to select it.

19. Choose the Major Revision for your system (3 in our lab) and press OK.

20. Give the module the name Digital_Inputs, choose the correct chassis Slot (2 in our lab) and Disable
Keying. Press OK to accept.

21. Press OK again to accept the default configuration.

22. Add another module.

23. Expand the Digital entry and scroll down and select the 1756-OB16D in the list.

24. Choose the Major Revision for your system (3 in our lab) and press OK.

25. Give the module the name Digital_Outputs, choose the correct chassis Slot (4 in our lab) and Disable
Keying. Press OK to accept.

26. Press OK again to accept the default configuration.

27. AI0 (analog input pot 0) will be used to change the speed, so an analog module is needed.

28. Right-click on the I/O Configuration folder and select New Module.

29. Expand the Analog entry and scroll down until you can see the 1756-IF6I in the list. Double-click on this
module to select it.

30. Give the module the name Analog_In, choose the correct chassis Slot (8 in our lab) and Disable Keying.
Press OK to accept.

31. On the Configuration tab, Set channel 0 for, Input Range for 0 to 10 Volts, Low Signal to 0v, High Signal
to 10v, Low Engineering to 0 and High Engineering to 100. The remaining channels can be left at defaults
since they will not be used.

32. Press Apply and then OK accept the configuration.

33. Add a PF527 to the I/O Tree.

34. In the Motion section and choose the “PowerFlex 527 – STO CIP Safety” drive which includes the Safe
Torque Off capabilities. Press Create.

35. Name the drive ‘Drive2’ and enter the IP Address, 172.16.1xx.11

NOTE: the xx in the IP address is replaced with the 2 digit Workstation number.
i.e. Workbench #01 would be 172.16.101.11

36. Change in the Module Definition section.

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37. Use the drop-down to change the Power Structure setting to match the catalog number of the drive
being used, 25C-V-2P5.

38. Set the connection to Motion and Safety.

39. Click OK and save the changes.

40. Double Click on the PF755 drive in the I/O tree to reopen it.

41. Select the Associated Axes tab.

42. This is where you link your drive to the axis tag for a motion system. We haven’t created an axis of
motion, yet, so select the button next to the axis name space.

43. Name your axis ‘Motor1’ and use all of the default values. Press Create to close the dialog box.

44. When you return to the Module Properties screen of Drive2, Motor1 should now be associated with
Axis 1. If not, simply choose it from the drop-down selection next to the Axis 1.

45. Next, select the Motor/Master Feedback Device. We will use Port 4 Channel A. Our feedback is
connected to the 20-750-DENC-1. Simply choose it from the drop-down selection next to the
Motor/Master Feedback Device box.

46. Select Apply.

47. Click on the Ellipse next to Motor1 to begin configuring the axis properties.

Select the Axis configuration:

48. Select the first category, General. You can use the drop-down to set the Axis Configuration. We will
select Frequency Control.

Select the Motor:

We must reselect a motor because we changed the drive module.

49. Click on the Motor category and notice that one of the selections is now Nameplate Datasheet.

50. Leave the Data Source at Nameplate Datasheet.

51. Click on the Motor Type and notice that one of the selections is now Rotary Induction.

52. Enter the following Motor Name plate data:

• Voltage = 230
• Amps = 0.3
• Power Units = KW
• Power = 0.07 kw
• Hertz = 60
• RPM = 1600
• Poles = 4

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53. Next select the Scaling category and change Units to ‘Revs’ for our application if it was not Revs. This is
just a text label and the default calibration for each axis is motor revolutions.

54. Because of the small motors we are using, select the Planner and enter the following values. This will
help with tuning later.
• Maximum Speed = 30
• Maximum Acceleration = 30
• Maximum Deceleration = 30
• Maximum Acceleration Jerk = 30
• Maximum Deceleration Jerk = 30
55. Click the Apply button to save the changes we have made to this point.

56. On the Power Tab, set the Bus Regulator action to Adjustable Frequency from the drop down selection.
Also ensure the Shunt Regulator Resistor Type is set for Internal.

57. Close the Axis Properties box for your Motor1 axis by pressing OK.

58. When you return to the Module Properties screen of Drive2, Motor1 should now be associated with
Axis 1. If not, simply choose it from the drop-down selection next to the Axis 1.

59. Double Click on the Motion Group. Next Select the Attributes tab and at the upper right select the Axis
Schedule button.

60. Move the Axis to the Alternate 1 pane and set the update time to 4.0ms.

61. Click the Apply button to save the changes.

62. Close the Axis Schedule box for the axis by pressing OK.

63. Be sure to Save your work. We have completed the configuration for drive and motor in our system.

Download the Motion Project

64. Ensure that the Safety Jumper is removed from the drive! If the jumper is in, the drive will have a non-
resettable Fault after the download.

If the safety jumper is left in, power down the drive, remove the jumper and restore the
power.

65. From the top menus, select Communications > Who Active.

66. Browse through RSLinx to the controller in Slot 0, highlight it and select Download.

67. Select Download again.

68. If you are prompted to change the controller to Remote Run mode, answer Yes. You can also perform
the required motion setup and tuning in the Program mode.

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69. Open the controller organizer and select the PowerFlex drive. In the Quick Pane (the window below)
wait until the status says Running for the drive. There should not be Yellow warning triangles on the
drives. Contact an instructor if there is.

Programming Motion Commands

70. Create the following Controller scoped Tags for use in the program:
Tag Name Data Type Alias to I/O point
Run_Stop BOOL / Alias Local:2:I.Data.12
ClearFault BOOL / Alias Local:2:I.Data.11
Faulted BOOL / Alias Local:4:O.Data.11
System_Not_Synched BOOL / Alias Local:4:O.Data.8
MAFR_Drive MOTION_INSTRUCTION
MDS_Drive MOTION_INSTRUCTION
MSF_Drive MOTION_INSTRUCTION

71. Right Click on the MainProgram and Create a new routine and name it RunRoutine.

72. Open the Main routine and create the following rung. This rung ensures that the motion system is
synchronized before allowing the code within the RunRoutine to execute and the indicator illuminates if
the system is not ready.

73. Close the MainRoutine and open the RunRoutine.

74. In the RunRoutine, Create the following logic to detect and clear faults.

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75. The following Logic will allow the drive to run strictly as a velocity drive. Add the logic shown here.

76. Close the RunRoutine.

77. Within the Safety Task, Safety Program, open the MainRoutine.

78. Create 2 tags (since there isn’t any safety I/O we need to add some safety based tags to use in our
demonstration).
Tag Name Data Type
SafeOff BOOL
Output_Enabled BOOL

79. Next program the following logic.

Download the Motion Project

80. From the top menus, select Communications > Who Active.

81. Browse through RSLinx to the controller, highlight it and select Download.

82. Select Download again.

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83. If you are prompted to change the controller to Remote Run mode, answer Yes. You can typically
perform the required motion setup and tuning in the Program mode.

84. Open the controller organizer and select the PowerFlex drive. In the Quick Pane (the window below)
wait until the status says Running for the drive. There should not be Yellow warning triangles on the
drives. Contact an instructor if there is.

Tuning and Commanding Motion

85. Within the Safety Task, Safety Program, open the MainRoutine.

86. Next, Select the SafeOff tag in the Routine, Right Click and Toggle the tag (that will change the Tags
value to 1). The Safe Off Should clear and the drive should now display “Stopped”.

87. Right-click on your Motor1 axis and choose Properties.

88. Select the Motor/Analyzer Category and then the Static Motor test. Click Start. The drive will run the
static motor test.

89. When the test completes, click OK and Accept the test results.

90. Select the Hookup Tests Category and then the Motor and Feedback tab. Watch the Induction motor
pulley and click the Start button. The motor will rotate.

Because of the small motors used in the Demo Case, the PF527 will not be able to do a
rotate Tune or run Flux Vector!

91. Once the test completes the popup will change announcing the status of the test. Click OK. Another
popup will appear. Selecting yes will set the direction for positive commands as the direction that the
motor rotated. Selecting no will set the direction for positive commands as the opposite of the direction
the motor ran. Select Yes.

92. Click the Accept Test Results Button. This will set the all of the drive polarities correctly.

93. Now that the polarity is set, the Rotate Motor test could now be run in Motor/Analyzer Category if it
desired.

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94. Select Apply and then OK and the Axis Properties Dialog closes.

95. Save the project.

96. This time, we will need the processor in the Rem Run mode. Use the drop-down menu to select Run
Mode.

97. Clear the drive Fault if it is faulted.

98. Turn on DI12 (Run_Stop) and verify that the motor runs. Change the speed using AI0 to verify the
project is working.

99. Within the Safety Task, Safety Program, open the MainRoutine.

100. Next, Select the SafeOff tag in the Routine, Right Click and Toggle the tag (that will change the Tags
value to 0). The drive should Stop and display “inhibited Safe Off FLT”.

101. Next, Select the SafeOff tag in the Routine, Right Click and Toggle the tag (that will change the Tags
value to 1).

102. The Safe Off should clear and the drive should now display “Standby”.

103. Toggle DI12 (Run_Stop) Off and then On again. The drive should start. Verify that the motor runs.

104. Once you are done with the lab, the drive will need to reset to hardware (Non-CIP Safety) mode. To
accomplish this, follow the following steps.
a) Ensure that the drive is able to run – Safe Off is reset.
b) In the I/O tree, Double click on the PF527 to open the drive properties window.
c) Select the Connection Tab.
d) Check the Inhibit Module Box.
e) Select Apply.
f) Place the Logix Controller in Remote Program
g) Select the Safety Tab in the drive configuration window
h) Under Configuration Ownership, click on the Reset Ownership
i) Select Yes on the next Dialog box to continue with the reset.
j) The drive will reboot.
k) Power OFF the Drive.
l) Install the Safe Torque Off Jumper
m) Power Down the Logix Chassis, wiat 30 seconds and then power it back on.
n) Apply Power to the drive
o) At this time the drive is back to the “out of the box” state.

LAB END

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