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FlexLogix Controller System User Manual

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FlexLogix Controller System User Manual1794-L34 Firmware Revision 16User ManualImportant User InformationAllen-Bradley, FlexLogix, Logix5000, RSLogix, RSLogix 5000, Rockwell Automation, RSNetWorx, and RSLinx are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.Throughout this manual, when necessary, we use notes to make you aware of safety considerations.WARNINGIdentifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.IMPORTANTIdentifies information that is critical for successful application and understanding of the product.ATTENTIONIdentifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic 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, a drive or motor, to alert people that dangerous voltage may be present.BURN HAZARDLabels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may be dangerous temperatures.3Publication 1794-UM001G-EN-P - January 2007Table of ContentsImportant User Information. . . . . . . . . . . . . . . . . . . . . . . . . . 2Summary of ChangesIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7PrefaceDeveloping FlexLogix Controller SystemsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Related Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Chapter 1Where to StartUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Install Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Chapter 2Directly Connect to the Controller via the Serial PortUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Connect the Controller via the Serial Port. . . . . . . . . . . . . . . 15Configure the Serial Driver . . . . . . . . . . . . . . . . . . . . . . . . . 18Select the Controller Path . . . . . . . . . . . . . . . . . . . . . . . . . . 20Chapter 3Communicate over NetworksUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21EtherNet/IP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Connections over EtherNet/IP . . . . . . . . . . . . . . . . . . . . 24ControlNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Connections over ControlNet . . . . . . . . . . . . . . . . . . . . . 26DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Define Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Communicate with DF1 devices. . . . . . . . . . . . . . . . . . . 33Communicate with ASCII devices. . . . . . . . . . . . . . . . . . 35Modbus support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38DH-485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Third Party. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Communication Format . . . . . . . . . . . . . . . . . . . . . . . . . 42Connection Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 42Chapter 4Manage Controller CommunicationsUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Produce and Consume (Interlock) Data. . . . . . . . . . . . . . . . 45Send and Receive Messages. . . . . . . . . . . . . . . . . . . . . . . . . 47Determine whether to cache message connections . . . . . 47Connection Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Calculate Connection Use . . . . . . . . . . . . . . . . . . . . . . . . . . 50Connections Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Publication 1794-UM001G-EN-P - January 20074 Table of ContentsChapter 5Place, Configure, and Monitor I/OUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Select I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Place Local I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . 54Selecting a Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 54Configure I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55I/O connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Configure Distributed I/O onEtherNet/IP . . . . . . . . . . . . . . 59Configure Distributed I/O onControlNet. . . . . . . . . . . . . . . 60Configure Distributed I/O onDeviceNet . . . . . . . . . . . . . . . 61Address I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Determine When Data IsUpdated. . . . . . . . . . . . . . . . . . . . 63Monitor I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Displaying fault data . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Monitor a rack-optimized connection . . . . . . . . . . . . . . . 65Reconfigure an I/O Module. . . . . . . . . . . . . . . . . . . . . . . . . 66Reconfigure a module via RSLogix 5000 software . . . . . . 66Reconfigure a module via a MSG instruction. . . . . . . . . . 67Chapter 6Develop ApplicationsUse 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 device 80Determine if communication has timed out with a specific I/Omodule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Interrupt the execution of logic and execute the faulthandler 81Select a System OverheadPercentage . . . . . . . . . . . . . . . . . 82Use the Event Task. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Prioritizing Periodic and Event Tasks . . . . . . . . . . . . . . . 85Triggering the Event Task. . . . . . . . . . . . . . . . . . . . . . . . 86Programmatically Determine if an EVENT Instruction Triggered aTask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Checklist for an EVENT Instruction Task. . . . . . . . . . . . . 87Publication 1794-UM001G-EN-P - January 2007Table of Contents 5Chapter 7Configure PhaseManagerUse This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89PhaseManager Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . 89State Model Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91How equipment changes states . . . . . . . . . . . . . . . . . . . 92Manually change states . . . . . . . . . . . . . . . . . . . . . . . . . 94Compare PhaseManager to Other State Models. . . . . . . . . . . 94Minimum System Requirements. . . . . . . . . . . . . . . . . . . . . . 94Equipment Phase Instructions . . . . . . . . . . . . . . . . . . . . . . . 95Chapter 8Maintain the BatteryUsing this Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Storing Replacement Batteries . . . . . . . . . . . . . . . . . . . . . . . 97Estimating Battery Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Replacing a Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Appendix AFlexLogix System Status IndicatorsController LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Appendix BFlexLogix Back-Up on DeviceNetUsing This Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103How the Back-up Works. . . . . . . . . . . . . . . . . . . . . . . . . . 104Requirements of the Back-Up. . . . . . . . . . . . . . . . . . . . 105Power-Up and SystemStart-up . . . . . . . . . . . . . . . . . . . . . 106Developing the FlexLogix Back-Up Application . . . . . . . . . 108Back-up Heartbeat Configuration Rungs. . . . . . . . . . . . 108Reading Back-up State Rung. . . . . . . . . . . . . . . . . . . . . 112Reading Back-up Status . . . . . . . . . . . . . . . . . . . . . . . . 114Using Indicators to CheckStatus . . . . . . . . . . . . . . . . . . . . 115Development and Debugging Tips. . . . . . . . . . . . . . . . . . . 115Appendix CInstruction LocatorWhere to Find an Instruction. . . . . . . . . . . . . . . . . . . . . . . 117Index

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