Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Emerson Industrial Automation Unidrive M200-M400 with SI-Ethernet RSLogixTM 5000 Add-On Instruction User Guide Introduction The Add-On Instruction (AOI) was created to expedite and simplify integration of Emerson Control Techniques Unidrive M products into Rockwell Automation PLC applications. The AOI enables easy integration of an Emerson Control Techniques drive into the RSLogixTM 5000 programming and configuration environment, as well as the Logix Architecture by incorporating the drives' controller tags and user-defined variables into one simple instruction. 1 Emerson Industrial Automation 7078 Shady Oak Road, Eden Prairie, MN 55344 Phone: 800-893-2321 Fax: 952-995-8020 Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Features and Functionality Speed Mode o Change speed reference in Hz o Command forward/reverse direction o Change acceleration and deceleration rates o Minimum and maximum speed clamps Jogging o Change jog reference in Hz o Command forward/reverse direction o Change jog acceleration and deceleration rates Status o Motor voltage o Actual speed in Hz o Motor current o Motor power (kW and hp) o Percentage load o Overload accumulator o Drive fault and error codes o Alarms o Motor rotation direction o Supply loss Diagnostics o Heatsink temperature o Inverter IGBT temperature o Drive error codes Current Limit Control – Motoring and Regenerative Auto/Manual Selection for Network or Terminal Strip Control and Reference Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Requirements One of the following Emerson Control Techniques drives: o Unidrive M200/M201, M300, M400 frame size 2 and above o SI-Ethernet option module with firmware V01.04.02.08 or greater Emerson Industrial Automation Unidrive M Connect software o Unidrive M Connect V02.05.01.0 or greater Emerson Control Techniques Add-On Instruction for the Unidrive M200-M400 Emerson Control Techniques Unidrive M Connect M200-M400 macro file Allen-Bradley ControlLogix or CompacLogix PLC with Ethernet interface Allen-Bradley RSLogixTM 5000 version 16 or higher Ethernet connections between Allen-Bradley PLC and Unidrive M200-M400 with SI-Ethernet OPTIONAL: CT-USB-CABLE and AI-485-ADAPTOR if needing to update firmware Unidrive M I/O Wiring DI/O 2 – Drive Enable STO 1 – Drive Safe Torque Off STO 2 – Drive Safe Torque Off M200/M201 – Terminal 11 M300, M400 – Terminals 31/34 (frames 1 to 4) M300, M400 – Terminals 31/35 (frames 5 to 9) Note: 0 V common on external 24 V dc power supply must be connected to drive 0 V common Setup Overview Set mode and region to Open-Loop and 60 Hz. NOTE: AOI will not function in RFC-A mode. Configure motor parameters for your particular motor Use the keypad (M200-M300 onboard, M400 needs CI-KEYPAD-LCD) to test motor operation Disable the drive and download the M200-M400 macro file to the Unidrive M drive Save the parameters in the drive Configure the Allen-Bradley PLC Ethernet/IP interface to the Emerson Control Techniques drive using RSLogixTM 5000. See below for more information. Import the Control Techniques Add-On Instruction into your PLC program using RSLogixTM 5000 Create a Tag with the Data Type Unidrive_M Insert the Add-On Instruction into your PLC program. There are only 3 required fields when inserting the instruction: Tag created for AOI Data Type in the previous step, Out_ToDrive (Ethernet Output Array Data), and Inp_FromDrive (Ethernet Input Array Data) Test the drive system using the Run/Jog command Write your application logic using the pre-defined data structures. See below for more information. Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Emerson Control Techniques Supplied Items Macro File .macro AOI File .L5X Example PLC Logic .ACD Unidrive_M200_M400_Macro Unidrive_M200_M400_AOI L61vxx_M200_M400_AOI_OpenLoop Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Setting up the Unidrive M200-M400 Checking Firmware Versions and Updating Firmware: Build a new project by scanning the Ethernet network. SI-Ethernet must be installed. Go Online with the drive and click Change Firmware. (Pop-up window will be grayed out with “This tool can only be used when connected to the comms ports on the front of the drive.”) o The current versions of firmware are displayed in the upper left of pop-up window o Need drive firmware V01.04.03.04 or greater and SI-Ethernet firmware V01.04.02.08 or greater o Update firmware if required If firmware update is required, close out of the current project and re-open Unidrive M Connect. Connect Unidrive M with an AI-485-ADAPTOR and CT-USB-CABLE to PC USB port. Build a Project by Scanning serial RTU network. (Cannot update the Unidrive M200-M400 or SI-Ethernet firmware over SI-Ethernet connection) Go Online with the drive and click Change Firmware o Browse to select the current Drive, Power board, and SI-Ethernet firmware. Click Next. The current versions of firmware can be downloaded from the Control Techniques website: (http://www.emersonindustrial.com/enUS/controltechniques/downloads/firmware/Pages/firmware.aspx) Save parameters in drive from the Unidrive M Connect Dashboard Repeat above steps for each drive Setting the Drive IP Address: Setup PC to obtain IP address automatically. Unidrive M has DHCP enabled by default. Using Unidrive M Connect Build a Project by scanning the Ethernet network Go Online with the drive Disable DHCP by setting SI-Ethernet parameter 1.02.005 to “Off” Set desired IP address in SI-Ethernet parameter 1.02.006 (default is 192.168.1.100) Click Save parameters in drive from the Dashboard Turn “On” drive parameter 15.007 to reset Ethernet and update to newly assigned IP address. This parameter will turn back “Off” when reset is complete. Verify that the drive has the newly assigned IP address by checking Active IP Address in parameter 15.011. Repeat above steps for each drive Close Unidrive M Connect project Change PC IP address to be on the same sub-network as the drive IP address Build a Project by scanning the Ethernet network Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Configure Drive Using Unidrive M Connect: Go Online with the drive Click Set mode and region and select Open-Loop and 60 Hz Use Unidrive M Connect Dashboard to Rename drive if desired Setup motor data in parameter Menu 5 or with Motor Setup in the Setup Wizards o Enter motor Rated Current o Enter motor Rated Voltage o Enter motor Rated Speed o Enter motor Rated Power Factor Click Send to drive if using the Motor Setup Wizard and Save parameters in drive Run Autotune (no load attached to motor): Go Online with the drive Set parameter 5.012 to “2” or use Autotune Wizard from the Dashboard Enable the drive Turn on parameter 6.034 “Run” to perform an Autotune. This will take several seconds. Turn off parameter 6.034 and disable the drive Save parameters in the drive Testing Drive and Motor Setup (no load attached to motor): Use Unidrive M Connect and go Online with the drive Set parameter 1.014 “Reference Selector” to Preset Enter 10.00 Hz in parameter 1.021 “Preset Reference 1” Enable the drive Turn on parameter 6.034 and motor should rotate at 10.00 Hz Download AOI Macro File: Load macro file into Unidrive M Connect software o Right click on Macro Files folder and select “Add Files…” o Navigate to the Unidrive_M200_M400_Macro macro file Right click on added Unidrive_M200_M400_Macro macro file and download file to drive o Ignore any warning messages Save parameters in drive Cycle power to the drive Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Setup the PLC Program using RSlogixTM 5000 Configuring the Ethernet Communication to the Unidrive M: Using RSLogixTM 5000, right click Ethernet in the Project Tree and click New Module Scroll down to ETHERNET-MODULE to add a Generic Ethernet Module to the Ethernet network. This will be your Unidrive M200-M400. Click Create. Using RSLogixTM 5000, setup the Ethernet module Name (use a descriptive name i.e Unidrive_M200_M400), IP address (default IP Address for the drive i.e 192.168.1.100) and connection parameters. Click OK. Connection parameters must be identical to Figure 2. See example screens below. o Input: Assembly Instance = 100 and Size = 16 o Output: Assembly Instance = 101 and Size = 16 o Configuration: Assembly Instance =1 and Size = 0 Figure 1: Generic Ethernet Module (Unidrive M200-M400) Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Figure 2: Generic Ethernet Module Setup (Unidrive M200-M400) Import Add-On Instruction into PLC Program: Right Click on the Add-On-Instructions folder in the Project Tree Browse to and select Unidrive_M200_M400_AOI.L5X file. Click Import. Drag the Unidrive_M200_M400_AOI into your main program Create a Tag for AOI Data Type (i.e. Drive_1) Enter Inp_FromDrive data (Unidrive_M200_M400:I.Data) Enter Out_ToDrive data (Unidrive_M200_M400:O.Data) o For xxx:I.Data and xxx:O.Data, xxx = Generic Ethernet Module Name (i.e. Unidrive_M200_M400) Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Figure 3: Unidrive M200-M400 Add-On Instruction Creating the Application Logic: AOI Variable Nomenclature: Variables with “Cfg” prefix are read/write system configuration setup data Variables with “Sts” prefix are read only status information. Examples are: At Set Speed, Error Code, Drive Active, etc. Variables with “Set” prefix are read/write control word information. Examples are: Jog Speed, Jog Accel, Jog Decel, etc. Variables with “Cmd” prefix are read/write command bits. Examples are: JogRev, JogFwd, DriveEnable, etc. Notes: Most data words have implied decimal points 9 Emerson Industrial Automation 7078 Shady Oak Road, Eden Prairie, MN 55344 Phone: 800-893-2321 Fax: 952-995-8020 Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Figure 4: Example Project Figure 5: Example Jog Logic Figure 6: Example Network (Auto)/Terminal (Manual) Control Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Network/Terminal Control Drive control can be initiated either over a network (default) or via the drive terminals. o Cmd_AutoManual command In network control, run and speed commands initiated through RSLogix program In terminal control, run and speed commands initiated through drives digital and analog inputs Testing PLC Logic Connect the PLC, Unidrive M200-M400 with SI-Ethernet and PC via Ethernet Download the RSLogixTM 5000 program to the Allen-Bradley PLC Check status of the communications between PLC and Unidrive M (I/O and OK LEDs are solid green) Enable the Unidrive M (keypad should read rdy (Ready), if keypad reads inh (Inhibit) enable drive/STO input) In the Unidrive_M200_M400_AOI: o Enter Jog Speed (Hz). Set_JogSpeedHz = 10.0 o Enter Jog Acceleration (sec). Set_JogAccel = 2.0 o Enter Jog Deceleration (sec). Set_JogDecl = 2.0 o Turn on Jog Forward. Cmd_JogForward = 1 Motor should now rotate at 10.0 Hz For Network/Terminal Control, create an Auto/Manual rung similar to Figure 6 above o Toggle bit so that Cmd_AutoManual is closed (this enables terminal control). Network control is enabled by default (Cmd_AutoManual bit is open) o With default drive digital input mapping designations, enable DI 2/STO and DI3 Run Forward o Drive will now run via Analog Input 1 control (potentiometer) Create project rungs of code similar to figures above or reference sample projects (available for download from Control Techniques website: http://www.emersonindustrial.com/enUS/controltechniques/products/software/plc/Pages/plc.aspx) Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Troubleshooting Make sure drive is enabled. Keypad reads rdy, if keypad reads inh enable drive. Digital I/O 2, terminal 11 for M200/M201. STO input, terminals 31/34 or 31/35 for M300 and M400. Make sure drive is not tripped Motor data setup is correct Macro file has been downloaded and saved to drive Check Input assembly object size parameter 1.20.020 is 64 bytes Check Output assembly object size parameter 1.20.021 is 64 bytes Check that SI-Ethernet Menus 1.21 and 1.22 have values loaded into mapping parameters o Menu 1.21 should have 16 input mapping parameters o Menu 1.22 should have 16 output mapping parameters Check the drive active IP address in parameter 15.010. This should be the same IP address as the Generic Ethernet Module in RSLogixTM 5000. Ethernet Connection Parameters are correct (Figure 2 above). I/O LED should be solid green. If blinking green, this is a good indicator that these are wrong. Try cycling power to the drive. Drive Control Word is Enabled (parameter 6.043) Monitor drive Control Word (parameter 6.042) Out_ToDrive Word 0 Monitor drive Status Word (parameter 10.040) In_FromDrive Word 0 Make sure there are no errors in the RSLogixTM 5000 program (tags have been created, data types, ect.) Check Sts_ErrorCode in Unidrive M Connect Check whether in terminal or network control Out_ToDrive Word 0 Bit 7 Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Appendix A - PLC AOI Parameters Name Usage Data Type Default Value Units Description Inp_FromDrive InOut DINT[16] Comms Data from Drive Out_ToDrive InOut DINT[16] Comms Data to Drive Cfg_DriveMinHZ Input REAL 0 Hz Minimum Reference Clamp Cfg_DriveMaxHZ Input REAL 60 Hz Maximum Reference Clamp Cfg_DriveMaxCurrentLimitPct Input REAL 150 % Symmetrical Current Limit Cfg_MotoringCurrLim Input REAL 150 % Motoring Current Limit Cfg_RegenCurrLim Input REAL 150 % Regen Current Limit Set_RunSpeedHZ Input REAL 40 Hz Preset Reference Set_RunAccel Input REAL 2 Sec Acceleration Rate Set_RunDecel Input REAL 2 Sec Deceleration Rate Set_JogSpeedHZ Input REAL 1.5 Hz Jog Reference Set_JogAccel Input REAL 2 Sec Jog Acceleration Rate Set_JogDecel Input REAL 2 Sec Jog Deceleration Rate Cfg_Ref_Select Input DINT Reference Selector Cmd_RunForward Input BOOL Command Run Forward Cmd_AutoManual Input BOOL Cmd_RunReverse Input BOOL Command Run Reverse Cmd_JogForward Input BOOL Command Jog Forward Cmd_JogReverse Input BOOL Command Jog Reverse Cmd_DriveEnable Input BOOL Command Drive Enable Cmd_FaultReset Auto Auto-Network Control, Manual-Terminal Control Input BOOL Sts_ActualSpeedHZ Output REAL Hz Command Fault Reset Post Ramp Reference Sts_ActualCurrent Output REAL A Current Magnitude Sts_PercentLoad Output REAL % Percentage Load Sts_OverloadAccum Output REAL % Motor Protection Accumulator Sts_ActualMotorVoltage Output DINT V Output Voltage Sts_ActualMotorkW Output REAL kW Output Power Sts_ActualMotorHP Output REAL hp Output Power Sts_DriveHeatsinkTemp Output DINT C Stack Temperature Sts_TempAccumulator Output DINT % Percentage of d.c. Link Thermal Trip Level Sts_DriveIGBTTemp Output DINT C Inverter Temperature Sts_DrivePwrCircuit2Temp Output DINT C Auxiliary Temperature Sts_DrivePwrCircuit3Temp Output DINT % Percentage of Drive Thermal Trip Level Sts_DriveStatus Output DINT Status Word Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Sts_DriveIOStatus Output DINT Digital I/O Read Word Sts_AtOrBelowMinSpd Output BOOL Running at or Below Min Frequency Sts_BelowSetSpd Output BOOL Below Set Frequency Sts_AboveSetSpd Output BOOL Above Set Frequency Sts_LoadReached Output BOOL Rated Load Reached Sts_Regening Output BOOL Regenerating Sts_DBActive Output BOOL Braking IGBT Active Sts_DBAlarm Output BOOL Braking Resistor Alarm Sts_CMDForward Output BOOL Forward Direction Commanded Sts_CMDReverse Output BOOL Reverse Direction Commanded Sts_RunningForward Output BOOL Forward Direction Running Sts_RunningReverse Output BOOL Reverse Direction Running Sts_DriveActive Output BOOL Drive Active Sts_AtZeroSpeed Output BOOL Zero Frequency Sts_AtSetSpd Output BOOL At Frequency Sts_InCurrentLimit Output BOOL Current Limit Active Sts_InputPowerLoss Output BOOL Supply Loss Sts_DriveOK Output BOOL Drive Healthy Sts_DriveFlt Output BOOL Drive Healthy Sts_ErrorCode Output DINT Trip 0 Sts_LastFault Output DINT Trip 0 Set_DriveInputWord1 Input DINT Application Menu 1 Read-write Integer 13 Set_DriveInputWord2 Input DINT Application Menu 1 Read-write Integer 14 Sts_DriveOutputWord1 Output DINT Application Menu 1 Read-write Integer 11 Sts_DriveOutputWord2 Output DINT Application Menu 1 Read-write Integer 12 Input BOOL Command Trip Cmd_ForceDriveTrip Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Appendix B – Ethernet IP Cyclic Data Interface Cyclic Data from Drive (Inp_FromDrive) Word (32-Bit) Direct AOI Tag Unidrive M Parameter Notes Word 0 Sts_DriveStatus 10.040 Status Word Word 0 Bit 0 Sts_DriveOK 10.001 Drive Healthy Word 0 Bit 1 Sts_DriveActive 10.002 Drive Active Word 0 Bit 2 Sts_AtZeroSpeed 10.003 Zero Frequency Word 0 Bit 3 Sts_AtOrBelowMinSpd 10.004 Running at or Below Min Frequency Word 0 Bit 4 Sts_BelowSetSpd 10.005 Below Set Frequency Word 0 Bit 5 Sts_AtSetSpd 10.006 At Frequency Word 0 Bit 6 Sts_AboveSetSpd 10.007 Above Set Frequency Word 0 Bit 7 Sts_LoadReached 10.008 Rated Load Reached Word 0 Bit 8 Sts_InCurrentLimit 10.009 Current Limit Active Word 0 Bit 9 Sts_Regening 10.010 Regenerating Word 0 Bit 10 Sts_DBActive 10.011 Braking IGBT Active Word 0 Bit 11 Sts_DBAlarm 10.012 Braking Resistor Alarm Word 0 Bit 12 Sts_CMDReverse 10.013 Reverse Direction Commanded Word 0 Bit 13 Sts_RunningReverse 10.014 Reverse Direction Running Word 0 Bit 14 Sts_InputPowerLoss 10.015 Supply Loss Word 1 Sts_ErrorCode 10.020 Trip 0 Word 2 Sts_ActualMotorVoltage 5.002 Output Voltage Word 3 Sts_ActualMotorHP 5.003 Output Power Word 4 Sts_ActualSpeedHZ 2.001 Post Ramp Reference Word 5 Sts_ActualCurrent 4.001 Current Magnitude Word 6 Sts_OverloadAccum 4.019 Motor Protection Accumulator Word 7 Sts_PercentLoad 4.020 Percentage Load Word 8 Sts_DriveHeatsinkTemp 7.004 Stack Temperature Word 9 Sts_DrivePwrCircuit2Temp 7.005 Auxiliary Temperature Word 10 Sts_DriveIGBTTemp 7.034 Inverter Temperature Word 11 Sts_TempAccumulator 7.035 Percentage of d.c. Link Thermal Trip Level Word 12 Sts_DrivePwrCircuit3Temp 7.036 Percentage of Drive Thermal Trip Level Word 13 Sts_DriveIOStatus 8.020 Digital I/O Read Word Word 13 Bit 0 8.001 DI/O 1 Word 13 Bit 1 8.002 DI/O 2 Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Word 13 Bit 2 8.003 DI 3 Word 13 Bit 3 8.004 DI 4 Word 13 Bit 4 8.005 DI 5 Word 13 Bit 5 8.006 DI 6 Word 13 Bit 6 8.007 DI 7 Word 13 Bit 7 8.039 STO 1 Word 13 Bit 8 8.040 STO 2 Word 13 Bit 9 8.008 RLY 1 Word 13 Bit 10 RLY 2 Word 14 Sts_DriveOutputWord1 18.011 Application Menu 1 Read-write Integer 11 Word 15 Sts_DriveOutputWord2 18.012 Application Menu 1 Read-write Integer 12 Application Tools CTOLAOIUG, rev 1, 12/1/2015 Applicable Products: Unidrive M200/M201, M300, M400 with SI-Ethernet Cyclic Data from Drive (Out_ToDrive) Word (32-Bit) Direct AOI Tag Word 0 Unidrive M Parameter Notes 6.042 Control Word Word 0 Bit 0 Cmd_DriveEnable 6.015 Drive Enable Word 0 Bit 1 Cmd_RunForward 6.030 Run Forward Word 0 Bit 2 Cmd_JogForward 6.031 Jog Forward Word 0 Bit 3 Cmd_RunReverse 6.032 Run Reverse Word 0 Bit 4 6.033 Forward/Reverse Word 0 Bit 5 6.034 Run Word 0 Bit 6 6.039 Not Stop Word 0 Bit 7 Cmd_AutoManual Auto/Manual Word 0 Bit 8 Cmd_AutoManual Analog/Preset Reference Word 0 Bit 9 Cmd_JogReverse Word 0 Bit 10 Unused Not Used Word 0 Bit 11 Unused Not Used Word 0 Bit 12 Cmd_ForceDriveTrip Trip Drive Word 0 Bit 13 Cmd_FaultReset Reset Drive Word 0 Bit 14 Unused Watchdog Word 1 6.037 Jog Reverse 6.043 Control Word Enable Word 2 Set_RunAccel 2.011 Acceleration Rate 1 Word 3 Set_RunDecel 2.021 Deceleration Rate 1 Word 4 Set_RunSpeedHZ 1.021 Preset Reference 1 Word 5 Cfg_Ref_Select 1.014 Reference Selector Word 6 Set_DriveInputWord2 18.014 Application Menu 1 Read-write Integer 14 Word 7 Set_JogSpeedHZ 1.005 Jog Reference Word 8 Set_JogAccel 2.019 Jog Acceleration Rate Word 9 Set_JogDecel 2.029 Jog Deceleration Rate Word 10 Set_DriveInputWord1 18.013 Application Menu 1 Read-write Integer 13 Word 11 Cfg_DriveMinHZ 1.007 Minimum Reference Clamp Word 12 Cfg_DriveMaxHZ 1.006 Maximum Reference Clamp Word 13 Cfg_DriveMaxCurrentLimitPct 4.007 Symmetrical Current Limit Word 14 Cfg_MotoringCurrLim 4.005 Motoring Current Limit Word 15 Cfg_RegenCurrLim 4.006 Regen Current Limit