Computer Numerical Control (CNC) Machining ... - Literature Library

Quick Start

Computer Numerical Control (CNC) Machining Accelerator Toolkit For FANUC Series 30i-B, 31i-B, 32i-B, and 35i-B CNC Systems

Important User Information 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://www.rockwellautomation.com/literature/) 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. WARNING: Identifies 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. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, CenterONE, CompactBlock, CompactLogix, ControlFLASH, ControlLogix, CrossWorks, Explorer, FactoryTalk, Guard I/O, GuardLogix, Integrated Architecture, Kinetix, MCS, PanelView, PowerFlex, ProposalWorks, RSLogix, RSLinx, TechConnect, RailBuilder, Rockwell Automation, Rockwell Software, and Ultra are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Follow this path to complete your CNC machining application. Chapter 1 Architecture and Hardware Selection Chapter 4 GuardLogix® Configuration

Chapter 2 System Layout and Wiring USER PROTECTED XXXVAC SUPPLY

MAINS DISCONNECT PROTECTION XXAMPS

Chapter 5 FactoryTalk® View ME Configuration

FILTERED POWER

DRIVE PROTECTION

POWERFLEX 4 AC DRIVE

FIELD SIDE

MOTOR

MOTOR_01

Chapter 6 System Commissioning

Chapter 7 Motion System Application Guide

Chapter 7 System Application Guide Chapter 3 FANUC CNC Configuration

The machine can go from any state in the shaded box to STOPPING.

RESETTING

IDLE (enabled)

START STARTING

RUNNING

STOP ABORT STOPPING

The machine can go from any state in the solid box to ABORTING.

ABORTING

RESET

STOPPED (disabled)

Rockwell Automation Publication IASIMP-QS034A-EN-P - October 2012

CLEARING

CLEAR

ABORTED

3

Where to Start

Notes:

4


Table of Contents Preface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Toolkits and FANUC Publications . . . . . . . . . . . . . . . . .

11 12 12 13 14

Chapter 1 Architecture and Hardware Selection Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Review System Selection and Configuration Tools . . . . . . . . . . . . . . . . . . FANUC CNC Express Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell Automation DMAT Wizard Software . . . . . . . . . . . . . . . . Rockwell Automation Safety Selection Tools . . . . . . . . . . . . . . . . . . . Rockwell Automation Product Selection Toolbox. . . . . . . . . . . . . . . Open FANUC CNC Express Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create CNC System Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create Supervisory Controller and Safety System Bill of Materials. . . .

17 18 19 19 19 20 21 22 23 28

Chapter 2 System Layout and Wiring

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select FANUC CNC Drawings from Drawing Library. . . . . . . . . . . . . . Edit FANUC CNC Drawing Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create a New Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit CNC Power Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit CNC Safety and Standard I/O Drawings . . . . . . . . . . . . . . . . . . Edit System Communication Drawings . . . . . . . . . . . . . . . . . . . . . . . . Edit CNC System Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble and Edit Your GuardLogix System Drawing Set . . . . . . . . . . .

30 30 31 31 34 34 35 38 41 43 44

Chapter 3 FANUC CNC Configuration

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial FANUC CNC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Powerup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter Write Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Speed Ethernet Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Ethernet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create a New Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Download FANUC LADDER III Software Project to the FANUC S35i-B CNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


47 47 48 48 48 49 51 53 56 60

5

Table of Contents

USB External Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EtherNet/IP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Logic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Editing Application Logic Modules and Adding Code . . . . . . . . . . . Device Logic Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verify and Save the Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Download FANUC LADDER III Software Project to the FANUC S35i-B CNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 64 68 70 73 75 77

Chapter 4 GuardLogix Configuration

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Create an Initial GuardLogix Project Using the DMAT Wizard. . . . . . 84 Order and Run the DMAT Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Import the Preconfigured RSLogix 5000 Project . . . . . . . . . . . . . . . . 84 GuardLogix Controller and Network Configuration . . . . . . . . . . . . . . . . 87 Create a New Project File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Configure Ethernet Module for your HMI Terminal and CNC Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Save the Project File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Import and Configure the Machine Logic Module . . . . . . . . . . . . . . . . . . 91 FANUC CNC AOP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Update FANUC CNC Add-On Profile (AOP) . . . . . . . . . . . . . . . . . 95 Add and Configure FANUC CNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Save the Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Import and Configure CNC Application Logic Module . . . . . . . . . . . . 100 Import and Configure FANUC CNC Device Logic Modules . . . . . . . 104 Set String Tag Names for Alarm History Faceplate . . . . . . . . . . . . . . . . . 108 Set Visible Rows for Equipment Status Faceplate. . . . . . . . . . . . . . . . . . . 111 Import and Configure Device and Application Status Logic. . . . . . . . . 113 Create Specific Application Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Application Code Logic Template Overview . . . . . . . . . . . . . . . . . . . 120 Application Logic Creation Steps That Use Application Logic Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Application Logic Creation Steps That Use a Template . . . . . . . . . 136 Safety Logic Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Safety I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 GuardLogix Safety Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Safety Faceplate Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Verify and Save the Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Chapter 5 FactoryTalk View ME Configuration

6

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Rockwell Automation Publication IASIMP-QS034A-EN-P - October 2012

Table of Contents

Design from a Preconfigured HMI Application File. . . . . . . . . . . . . . . . Restore and Open a Preconfigured HMI Application. . . . . . . . . . . Delete Unused Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Unused Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Parameter Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Unused Alarm Triggers and Tags . . . . . . . . . . . . . . . . . . . . . . Design from an Existing HMI Application File . . . . . . . . . . . . . . . . . . . . Open Your Existing HMI Application File and Add Displays . . . Add Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Parameter Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Import Alarm Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Unused Alarm Triggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Import and Edit Alarm Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Goto Display Buttons on Startup Display . . . . . . . . . . . . . . . Add FANUC CNC Goto Buttons to Your Application . . . . . . . . Associate Each Button to a Faceplate and Parameter File. . . . . . . . Configure Equipment Status Faceplate Display . . . . . . . . . . . . . . . . . . . . Add the Equipment Status Faceplate Display . . . . . . . . . . . . . . . . . . Add the ME_Equipment_Parameter File. . . . . . . . . . . . . . . . . . . . . . Configure Goto Buttons on the Equipment Status Faceplate . . . . Configure Additional Device Value Columns. . . . . . . . . . . . . . . . . . Configure Safety Faceplate Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151 151 154 155 156 160 162 162 165 167 171 173 174 177 177 179 185 186 187 189 191 193

Chapter 6 System Commissioning

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Download Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Download RSLogix 5000 Software Project File to the Logix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure and Download FactoryTalk Project to PanelView Plus Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning CIP Motion Drives . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning sercos Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning PowerFlex 7-class Drives. . . . . . . . . . . . . . . . . . . . . . Commissioning PowerFlex 4-class Drives. . . . . . . . . . . . . . . . . . . . . . Commissioning Kinetix 300 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning Supervisory and CNC System . . . . . . . . . . . . . . . . . . . . Verify Network Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator (manual) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program (automatic) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


195 195 196 197 197 198 205 205 205 205 205 205 206 206 212 212 213

7

Table of Contents

Chapter 7 System Application Guide

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Startup Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program/Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . State Diagram Faceplate Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Home View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC Status Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CNC Control Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Indication View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Diagnostic Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Online Help Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion Drive and/or PowerFlex Drive Faceplates. . . . . . . . . . . . . . . . . . Guard I/O Safety Faceplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Status Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm History Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 215 216 217 217 219 219 220 221 221 222 222 223 224 225 226 226 226 226 228

Appendix A Logic Program Overview

Machine/Application/Device Module Relationship . . . . . . . . . . . . . . . . Module Routine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Device Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 231 234 240 241

Appendix B Logic Module Customization

Machine State Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tag and Logic Modification Recommendations . . . . . . . . . . . . . . . . State Display Tag Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Idle State Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module Fault Customization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm History Faceplate Logic Modification . . . . . . . . . . . . . . . . . . . . . . Coordinated Reset Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

243 246 247 248 249 252 253

Appendix C Add Other Devices to the Equipment Status Faceplate

8

Add Devices to the Equipment Status Faceplate. . . . . . . . . . . . . . . . . . . . 255 Add Optional Faceplate Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258


Table of Contents

Appendix D Logix Communication and Controller Configure Personal Computer Communication Properties . . . . . . . . . 261 Configure the EtherNet/IP Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Configuration Configure the Logix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Index


9

Table of Contents

Notes:

10


Preface

Introduction

This quick start provides step by step instructions for using the CNC Machining Accelerator Toolkit to help you design, install, operate, and maintain a CNC work cell incorporating a GuardLogix Supervisory Controller and FANUC Series 30i-B, 31i-B, 32i-B, or 35i-B CNC System. Included are selection tools, layout and wiring drawings, and pre-configured logic and HMI files to assist you in creating an Integrated Architecture™ solution for your application requirements. All the supporting files are included on the CNC Machining Accelerator Toolkit DVD, publication IASIMP-SP018. The DVD provides PLC and CNC selection tools; CAD drawings for panel layout and wiring; basic status, control, and diagnostic logic files; FactoryTalk View ME faceplates, and more. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. With these tools and the built-in best-practices design, the system designer is free to focus on the design of their machine control and not on design overhead tasks. You can also download these same supporting files from the Rockwell Automation® Integrated Architecture Tools website, http://www.ab.com/go/iatools on the Beyond Getting Started tab. IMPORTANT

Before using this quick start and the contents of the CNC Machining Accelerator Toolkit DVD, read the Terms and Conditions READ ME PDF file on the DVD.

The beginning of each chapter contains the following information. Read these sections carefully before beginning work in each chapter: • Before You Begin - This section lists the steps that must be completed and decisions that must be made before starting that chapter. The chapters in this quick start do not have to be completed in the order in which they appear, but this section defines the minimum amount of preparation required before completing the current chapter. • What You Need - This section lists the tools that are required to

complete the steps in the current chapter. This includes, but is not limited to, hardware and software. • Follow These Steps - This illustrates the steps in the current chapter and identifies which steps are required to complete the examples by using specific networks.


11

Preface

Conventions

This manual uses the following conventions.

Convention

Meaning

Example

CNC

Used as an abbreviation for Computer Numeric Control. In this Toolkit, The GuardLogix PLC communicates to the FANUC CNC by using the EtherNet/IP communication protocol.

GuardLogix PLC to FANUC CNC EtherNet/IP configuration.

Click

Click the left mouse button once (assumes cursor is positioned on object or selection). Click button to initiate action.

Click Browse.

Double-click

Click the left mouse button twice in quick succession (assumes cursor is positioned on object or selection).

Double-click the H1 icon.

Right-click

Click the right mouse button once (assumes cursor is positioned on object or selection).

Right-click the Fieldbus Networks icon.

Drag and drop

Click and hold the left mouse button on an object, move the cursor to where you want to move the object, and release the mouse button.

Drag and drop the desired block into the Strategy dialog box.

Select

Click to highlight a menu item or list choice.

From the pull-down menu, choose H1-1.

Check/uncheck

Click to select a checkbox option.

Check Consider Case if you want to conduct a case-sensitive search.

>

Shows nested menu selections as menu name followed by menu selection.

Click File>Page Setup>Options.

Expand

Click the + to the left of a given item /folder to show its contents.

In the H1-1 dialog box, expand FFLD.

Enter

Used when you can type from the keyboard or choose from a list.

Enter the catalog number of the product.

Type

Used when the only option is to type from the keyboard.

Type the catalog number of the product.

Press

Press a specific button on the PanelView™ terminal or other component with touch-screen technology.

Press Axis Control.

Required Software

To complete this quick start, the following software is required.

Rockwell Automation Software

Cat. No.

Version

Required For

RSLogix™ 5000 • ControlFLASH™ • BOOTP/DHCP utility (EtherNet/IP network) • RSLinx® Classic

9324-RLD300RNE

20.00 or later

All ControlLogix®/GuardLogix PLC applications

FactoryTalk View Studio for Machine Edition • FactoryTalk Services • RSLinx Enterprise • RSLinx Classic

9701-VWSTMENE

6.00 or later

PanelView Plus terminals

FANUC III for PMC Development (Microsoft Windows)

A08B-9210-J505

6.80 or later

FANUC CNC applications

CNC Machining Accelerator Toolkit DVD

IASIMP-SP018

N/A

CAD files, wiring diagrams, application files, and other support information

12


Preface

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Table 1 - Additional Resources Resource

Description

Guard Logix and Compact Logix Controllers GuardLogix Controller Installation Instructions, publication 1756-IN045

Provides information on installing the GuardLogix controller

GuardLogix Controllers User Manual, publication 1756-UM020

Provides information on configuring and programming the 1756 GuardLogix system

CompactLogix Controllers Installation Instructions, publication 1768-IN004

Provides information on installing the CompactLogix™ controller

Compact GuardLogix Controllers User Manual, publication 1768-UM002

Provides information on configuring and programming the 1768 Compact GuardLogix system

GuardLogix Controller Systems Safety Reference Manual, publication 1756-RM093 Contains detailed requirements for achieving and maintaining SIL 3 with the GuardLogix controller system Logix Common Procedures Programming Manual, publication 1756-PM001

Provides information on programming Logix5000 controllers, including managing project files, organizing tags, programming and testing routines, and handling faults

Safety Modules and Products CompactBlock Guard I/O DeviceNet Safety Module Installation Instructions, publication 1791DS-IN002

Provides information on installing CompactBlock™ Guard I/O™ DeviceNet Safety modules

Guard I/O DeviceNet Safety Modules User Manual, publication 1791DS-UM001

Provides information on using Guard I/O DeviceNet Safety modules

Guard I/O EtherNet/IP Safety Modules Installation Instructions, publication 1791ES-IN001

Provides information on installing CompactBlock Guard I/O EtherNet/IP Safety modules

Guard I/O EtherNet/IP Safety Modules User Manual, publication 1791ES-UM001

Provides information on using Guard I/O EtherNet/IP Safety modules

POINT Guard I/O Safety Module User Manual, publication 1734-UM013

Provides information on installing, configuring and operating POINT Guard I/O Safety Modules

Safety Products Catalog S116, available at http://www.ab.com/catalogs/

Provides selection and specification information for Rockwell Automation safety products.

Kinetix Drives Kinetix 300 EtherNet/IP Indexing Drives User Manual, publication 2097-UM001 Kinetix 350 Single-axis EtherNet/IP Servo Drives, publication 2097-UM002 Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-UM002 Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001

Provides mounting, wiring, configuring, and troubleshooting instructions for the Kinetix® Motion Control servo drives

Kinetix 2000 Multi-axis Servo Drives User Manual, publication 2093-UM001 Kinetix 7000 Multi-axis Servo Drives User Manual, publication 2099-UM001 Kinetix Motion Control Selection Guide, publication GMC-SG001

Provides drive specifications, motor/servo-drive system combinations, and accessories for Kinetix motion control products


13

Preface

Table 1 - Additional Resources (Continued) Resource

Description

CIP Motion and sercos SERCOS and Analog Motion Configuration and Startup User Manual, publication MOTION-UM001

Information on configuring and troubleshooting your ControlLogix and CompactLogix sercos interface modules

CIP Motion Reference Manual, publication MOTION-RM003

Provides descriptions of the AXIS_CIP_DRIVE attributes and RSLogix 5000 software Control Modes and Methods

CIP Motion Configuration and Startup User Manual, publication MOTION-UM003

Information on configuring and troubleshooting your ControlLogix and CompactLogix EtherNet/IP network modules

Online Configuration and Selection Tools

Rockwell Automation Configuration and Selection Tools, available at http://www.rockwellautomation.com/en/e-tools/

These online tools install on your personal computer so that you can quickly access information on our products: • CrossWorks™ • Industrial Computer Selector • Operator Interface Selection Tool • Programmable Controller Family Selector

You can view or download publications at http://www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Additional Toolkits and FANUC Publications This table provides information for supporting toolkits and FANUC publications. Toolkits and FANUC Publications

Description

Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017

Toolkit for sercos interface or EtherNet/IP-based motion control

Safety Accelerator Toolkit DVD, publication SAFETY-CL002

Toolkit to provide a framework for developing safety applications.

FANUC Series 30i/31i/32i/35i -MODEL B, EtherNet/IP Adapter function, publication B-64014EN/04-2

Information on configuring and troubleshooting your FANUC CNC's EtherNet/IP network modules.

FANUC Series 30i/31i/32i/35i -MODEL B, FANUC Power Motion i -MODEL A, EtherNet/IP Scanner function, publication B-64014EN/04-3

Information on configuring and troubleshooting your FANUC CNC's EtherNet/IP network modules.

You can request the FANUC publications by contacting your local FANUC America distributor or sales representative. http://www.FANUCfa.com/us-en/Home

14


Chapter

1

Architecture and Hardware Selection

In this chapter you are introduced to the FANUC CNC Express software to create an EtherNet/IP bill of materials for your CNC system. The CNC Express software provides the means to select hardware and software from FANUC that are stocked locally in the United States. This is for reference only, and is not to be used for final product selection. Please contact your local FANUC representative prior to purchase. Use either the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, and/or Safety Accelerator Toolkit DVD, publication SAFETY-CL002, to configure the Rockwell Automation system, or to select the power distribution components for the CNC control system. Be sure that an 1756-EN2TR or 1756-EN3TR Ethernet module is selected for the Rockwell Automation system. To assist you with a possible architecture and hardware selection, reference the CNC Work Cell machine application. The CNC Work Cell machine application is an example only, with the focus of the toolkit being the integration between the Rockwell Automation GuardLogix controller and the FANUC CNC. See Figure 1 on page 16 for a CNC work cell application example.


15

Chapter 1


Figure 1 - CNC Work Cell Application Example

16



Chapter 1

Before You Begin Collect specific application data, for example: • System input voltage • System CNC model and display options • CNC required options • System I/O requirements • Motor and drive sizing • Other system sizing info

What You Need • The CNC Machining Accelerator Toolkit DVD, publication IASIMP-SP018. For a copy of the DVD,

contact your local Rockwell Automation distributor or sales representative. • FANUC CNC Express selection software. For a copy of the DVD, contact your local FANUC sales representative. • If Rockwell Automation Kinetix or PowerFlex® Drives are used in the system, the Drives and Motion Accelerator Toolkit DVD is required, publication IASIMP-SP017. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. • If Rockwell Automation GuardLogix safety controller and safety components are used in the system, the Safety Accelerator Toolkit DVD is required, publication SAFETY-CL002. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative.


17

Chapter 1


Follow These Steps Complete the following steps to create a bill of materials for your CNC system.

Start

Review System Selection and Configuration Tools page 19 Open FANUC CNC Express Software page 22 Create CNC System Bill of Materials page 23 Create Supervisory Controller and Safety System Bill of Materials page 28

18



Chapter 1

Review System Selection and Configuration Tools This section provides and overview of the FANUC and Rockwell Automation system selection and configuration tools that you may need for your FANUC configuration.

FANUC CNC Express Software The Excel workbook CNC Express Order Forms.xls contains the product information and the actual order forms. Each worksheet represents a certain product and contains the relevant order guide information for the product selections offered in that worksheet, and is followed by the order form. To order from this workbook, you make simple product selections by using check marks, and the workbook does the rest of the work.

Rockwell Automation DMAT Wizard Software The Drives and Motion Accelerator Toolkit (DMAT) Wizard software provides a streamlined way of creating a bill of material, assembling a system drawing set, and creating a RSLogix 5000 project file with a preconfigured controller, network, drives, and initial system program logic. This can be accomplished in minutes by inserting simple system and drive configuration entries, and running other system selection tools as needed. You can access this software tool on the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017.


19

Chapter 1


Rockwell Automation Safety Selection Tools The Safety Accelerator Toolkit provides a number of software selection tools to assist in hardware selection and performance estimation for your safety systems. You may access these software tools within the Safety Accelerator Toolkit DVD, publication SAFETY-CL002.

20



Chapter 1

Rockwell Automation Product Selection Toolbox Product Selection & System Design Tools

The Rockwell Automation Product Selection Toolbox (PST) offers a complete suite of user tools for product selection and configuration across product lines from project conception through final design. From push buttons to drives to motor control centers and fully networked control systems, you’ll find the product information and configuration assistance you need to help you and your customers succeed with Rockwell Automation.

• Provides access to information on a broad range of Allen-Bradley® products and services • Easy product selection interface to make it a snap to determine the exact catalog numbers for the item you need • Access to current list pricing, and a comprehensive supplemental product information list • Contains features, such as product selection wizards, agreement pricing, a spare parts generator, and the ability to separate part numbers to see what Rockwell Automation components comprise them • All of these features and more can help you select the correct product based on your requirements and give your customers the information they need fast

• Lets you quickly develop Logix/NetLinx control system configurations with BOM and reports • Integration with configurator allows configuration of PowerFlex drives and ArmorStart motor controllers • Motion control drive/motor combinations and accessories can be added through links to Motion Analyzer software • New Ethernet capabilities include Stratix™ switches and physical media with enhanced graphical views • IAB output can be easily exported to ProposalWorks to take advantage of extended proposal generation features, and supplementary data • Assists the user in selecting correct motor for application, proper drive, and gearbox (if required) • Effective optimization capabilities allow user to get the most out of the selected motor and drive combination • Intuitive software application designed specifically for configuring Motor Control Centers • User friendly interface helps reduce error and enables customers to get their MCCs quickly • Allows users to have the most up-to-date applications, product, price, and supplementary information • All programs are scheduled for update every three weeks

• Helps you configure Motor Control System starters for rated motor voltages from 230…690V • Program provides the correct catalog number, wiring diagram, and layout drawing for starters of your choice • Provides assistance in selecting and dimensioning all of required busbar rack components

• Assists in crossing competitive part numbers to Rockwell Automation equivalents • Gives users the ability to submit crosses directly to PST and they will provide a cross or users can go to: ab.com/e-tools and look up existing cross references in the database

• Simplifies the design of custom terminal block rails • Allows you to select and place terminal blocks on mounting rail along with specifying labeling of terminal blocks, locating jumper bars between blocks, automatically selecting end barriers, and partition plates

• Allows you select product 3D CAD drawings in AutoCAD software • Provides you with access to thousands of drawings for a wide range of Allen-Bradley products as well as assistance configuring catalog numbers


21

Chapter 1


Open FANUC CNC Express Software 1. Navigate to and choose the CNC Express application, CNC_Work_Cell_BOM.xlsx, on the CNC Machining Accelerator Toolkit DVD.

The initial CNC Express dialog box opens.

22



Chapter 1

2. Click continue to leave the links as they are. The multiplier pop up window will then be displayed. 3. Add the multiplier that has been approved by FANUC, and then click OK. You are now ready to begin creating the bill of materials (BOM).

Create CNC System Bill of Materials 1. Select the CNC model, and display options. a. Use the tabs near the bottom of the spreadsheet to navigate to and select the appropriate CNC model, based on your machining requirements. For the CNC Work Cell example, a 35i-B CNC is selected. The 35i-B tab is displayed.


23

Chapter 1


b. Use the cells in the spreadsheet to navigate to and select the appropriate CNC package, based on your specific application requirements. The 35i-B selections are displayed.

c. Use the cells in the spreadsheet to navigate to and select the appropriate EtherNet/IP options.

d. Use the cells in the spreadsheet to navigate to and select the appropriate displays and options. When all options are selected the cell at the bottom of the tab ( J347) will display either a TRUE OVERALL or FALSE OVERALL status. Make the appropriate corrections until the status reads TRUE OVERALL. TIP

The Status is FALSE until the I/O selection has been satisfied in the next step.

The 35i-B configuration is now complete.

24



Chapter 1

2. Select the System I/O. a. Use the tabs near the bottom of the spreadsheet to navigate to and select the IOetc tab, for I/O selection. The IOetc tab is displayed.

b. Use the cells in the spreadsheet to navigate to and select the appropriate I/O modules, based on your specific application requirements. The 35i-B selections are displayed.

c. Use the cells in the spreadsheet to navigate to and select the appropriate I/O and options. When all options are selected the cell at the bottom of the tab (U268) will display either a TRUE OVERALL or FALSE OVERALL status. Make the appropriate corrections until the status reads TRUE OVERALL. TIP

The Status is FALSE until the I/O selection has been satisfied in the next step.

The I/O configuration is now complete. Rockwell Automation Publication IASIMP-QS034A-EN-P - October 2012

25

Chapter 1


3. Select the drives and motors for the application a. Use the tabs near the bottom of the spreadsheet to navigate to and select the appropriate voltage for the drives, based on your system power voltage. For the CNC Work Cell example, 460V drives is selected. The 460V drives tab is displayed.

b. Use the cells in the spreadsheet to navigate to and select the appropriate motors and drives, based on your specific application requirements. The 460V drives selections are displayed.

c. Use the cells in the spreadsheet to navigate to and select the appropriate motor and drive options. When all options are selected the cell at the bottom of the tab (U801) will display either a TRUE OVERALL or FALSE OVERALL status. Make the appropriate corrections until the status reads, TRUE OVERALL. The 460V drives configuration is now complete.

26



Chapter 1

4. Review the complete CNC configuration. a. Use the tabs near the bottom of the spreadsheet to navigate to and click the Summary tab. The Summary tab is now displayed.

b. Use the cells in the spreadsheet to navigate to and select the appropriate CNC control, and drive system selection. When the system is configured properly, the pricing is shown. If the configured solution is not correct, fix conflicts are displayed in the value fields. The CNC BOM configuration is now complete.

5. Name and save the BOM project file. a. From the File menu, choose Save As.


27

Chapter 1


b. Type a new BOM project file name. By creating a new BOM project file specifically for your application, you preserve the initial toolkit file for future reference. In this example, the file was named CNC_Work_Cell_BOM. 6. Repeat step 1…step 5 for each CNC in your system. The BOMs can now be submitted to FANUC for purchase. We recommend that your local FANUC representative review and approve the configuration prior to purchase.

Create Supervisory Controller and Safety System Bill of Materials Refer to the Drives and Motion Accelerator Toolkit for creating a supervisory controller bill of materials that includes Rockwell Automation Kinetix or PowerFlex drives. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. • Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. Refer to the Safety Accelerator Toolkit for creating a safety system bill of materials that includes Rockwell Automation GuardLogix controller and Guard I/O. • Safety Accelerator Toolkit DVD, publication SAFETY-CL002.

28


Chapter

2

System Layout and Wiring In this chapter you select CNC layout and wiring drawings from a library of drawings in AutoCAD .dwg, .dxf, or .pdf formats to start your system drawing set. If you are using AutoCAD or AutoCAD Electrical software, you can also take advantage of the drawing editing steps included in this chapter. The library’s device wiring references and attributes move with the devices as you edit your power drawing set. You will use the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, and/or Safety Accelerator Toolkit DVD, publication SAFETY-CL002, to assemble your drawing set for the Rockwell Automation components in your system. Figure 2 - CNC Power, I/O, and Layout Drawing Examples CNC I/O Example

CNC Power Example

CNC System Layout Example


29

Chapter 2

System Layout and Wiring

This section uses the CNC Work Cell application example to help you understand how to use the drawing libraries. The CNC Work Cell includes the following main devices: • Two FANUC 35i-B CNC systems • Two Kinetix 6500 servo drives and motors • One GuardLogix safety controller and EtherNet/IP network module

Before You Begin Complete your system architecture and hardware selection (see Chapter 1).

What You Need • CNC Machining Accelerator Toolkit DVD, publication IASIMP-SP018. For a copy of the DVD, contact • • • • •

•

30

your local Rockwell Automation distributor or sales representative. AutoCAD Electrical software to open the DWG or DXF files. Adobe Reader software to open PDF files. System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001. System Design for Control of Electrical Noise Video, publication GMC-SP004. If Rockwell Automation Kinetix or PowerFlex Drives are used in the system, the Drives and Motion Accelerator Toolkit DVD is required, publication IASIMP-SP017. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. If Rockwell Automation GuardLogix safety controller and safety components are used in the system, the Safety Accelerator Toolkit DVD is required, publication SAFETY-CL002. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative.



Chapter 2

Follow These Steps Complete the following steps to create your system layout and wiring drawings. Start

Select FANUC CNC Drawings from Drawing Library page 31 Edit FANUC CNC Drawing Set page 34 Assemble and Edit Your GuardLogix System Drawing Set page 44

Select FANUC CNC Drawings from Drawing Library The CNC drawing library is organized by these drawing file types: • AutoCAD Electrical .dwg • AutoCAD .dxf • Adobe PDF The drawings are examples only, and may not reflect your application. There are many different models of FANUC CNCs and drive combinations available. This toolkit does not detail all possible combinations. This toolkit uses the 35i-B CNC as an example. TIP

If you do not have CAD software that is compatible with the .dwg/.dxf formats, the PDF files provide an excellent reference library for wiring all your system devices.


31

Chapter 2


1. Create a project folder. For the CNC Work Cell example, the CNC_Work_Cell folder was created. 2. Browse to the CNC CAD Drawing Library on the CNC toolkit DVD and select the DWG Format Drawings, DXF Format Drawings, or PDF Format Drawings directory.

Each drawings directory include these files in their respective files formats. All drawings are associated with the FANUC CNCs, with the exception of these three drawings: • The 07_PLC_1791DS_IB16 and 11_PLC_1791DS_IB4XOW4 drawings are examples of Rockwell Automation Guard I/O showing the safety I/O interface with the FANUC Dual Check I/O. • The 15_CNC_Ethernet_Communication drawing includes an example of EtherNet/IP communication with the Rockwell Automation GuardLogix controller, PanelView Plus, and Kinetix/PowerFlex drives.

32



Chapter 2

3. Copy the entire set of drawings in this folder.

4. Paste the drawing you copied into the Project Drawings folder.


33

Chapter 2


Edit FANUC CNC Drawing Set These steps provide general instructions for how to maximize the use of the toolkit’s drawing library in creating a complete CNC system layout and wiring drawing set. We recommend AutoCAD or AutoCAD Electrical software to take full advantage of the drawing editing steps and the library’s device wiring references and attributes that move with the devices as you edit your project drawing set. Some of the initial project creation steps are illustrated by using AutoCAD Electrical software, but most are generic and can be used with a variety of software drawing packages.

Create a New Project 1. Open your drawing software. 2. Create and name your new project.

3. Add and select the toolkit library drawings you copied in the previous section.

34



Chapter 2

Edit CNC Power Drawings 1. Open your initial CNC power drawing that includes the main power distribution components, 01_CNC_Drives_w_Dual Check IO.dwg. See Figure 3 on page 36. 2. Modify this drawing for your project. The 01_CNC_Drives_w_Dual Check IO includes the main power distribution components as well as the CNC power supply, one spindle module and motor, and one servo module and motor. Typically you would have at least these components in each of your CNC systems. Copy this drawing for every CNC you have in your system. For the CNC Work Cell application example, there are two FANUC CNC systems, so this drawing would be copied for the second CNC system. 3. Open the 02_CNC_Drives_w_Dual_Check_IO drawing and modify for your project. See Figure 4 on page 37. The 02_CNC_Drives_w_Dual_Check_IO drawing includes three additional servo modules and motors. You will most likely copy this drawing for every CNC you have in your system. Delete the servos and motors not required for you system. For the CNC Work Cell application example there are two FANUC CNC systems, so this drawing would be copied for the second CNC system, and one spindle module and motor would be deleted from each drawing. 4. Open the remaining CNC control power distribution drawings and edit power connections and devices as necessary. The drawings include: • 03_CNC_Control_Power_Distribution • 04_CNC_Control_Power_Distribution • 05_CNC_Monitored_Safety_Relay • 06_CNC_24VDC_Safety_Power • 17_CNC_Power_Connections • 18_CNC_Cable_Connections


35

Chapter 2


Figure 3 - 01_CNC_Drives_w_Dual Check IO Drawing

36



Chapter 2

Figure 4 - 02_CNC_Drives_w_Dual Check IO Drawing


37

Chapter 2


Edit CNC Safety and Standard I/O Drawings 1. If FANUC Dual Check Safety is incorporated into your project, open the following drawings for your project: • 07_CNC_AID16D_Dual_Check_IO_Module • 08_CNC_AID16D_Dual_Check_IO_Module • 09_CNC_AOR8G_Dual_Check_IO_Module 2. Modify your Dual Check safety input module drawings. The Dual Check safety input module drawings 07_CNC_AID16D_Dual_Check_IO_Module and 08_CNC_AID16D_Dual_Check_IO_Module include a variety of input device examples to include in your drawing set. a. Copy and paste input devices to match your application. See Figure 5 on page 39. In addition to safety devices, the 07_CNC_AID16D_Dual_Check_IO_Module drawing includes example dual channel connections from the GuardLogix Guard I/O outputs. 3. Modify your Dual Check safety output module drawing. The Dual Check safety output module drawing, 09_CNC_AOR8G_Dual_Check_IO_Module includes a few output device examples to include in your drawing set. a. Copy and paste output devices to match your application. See Figure 6 on page 40 In addition to safety devices the 09_CNC_AOR8G_Dual_Check_IO_Module drawing includes example dual channel connections to the GuardLogix Guard I/O inputs. 4. If using GuardLogix as a supervisory safety controller for your CNC cell in your project, then open and modify the following drawings for your project: • 07_PLC_1791DS_IB16 • 11_PLC_1791DS_IB4XOW4 These drawings show examples of the dual channel input and output connections from the FANUC Dual Check Safety I/O. You may copy these connections to other Guard I/O modules within the Safety Accelerator Toolkit drawings. 5. Open and modify the following standard CNC I/O drawings for your project: • 12_CNC_AOR16G_Output_Module • 13_CNC_Digital_Inputs • 14_CNC_Relay_Outputs These drawings include a variety of input and output device examples to include in your drawing set.

38



Chapter 2

Figure 5 - 07_CNC_AID16D_Dual_Check_IO_Module Drawing


39

Chapter 2


Figure 6 - 09_CNC_AOR8G_Dual_Check_IO_Module Drawing

40



Chapter 2

Edit System Communication Drawings 1. Open the following communication drawings to access your project's EtherNet/IP configuration drawings: • 15_CNC_Ethernet_Communication • 16_CNC_Ethernet_Switch • 18_CNC_Cable_Connections 2. Delete and or copy network devices to match your system requirements. The 15_CNC_Ethernet_Communication drawing is shown in Figure 7 on page 42. It includes both FANUC CNC system and Rockwell Automation GuardLogix, PanelView, and Kinetix/PowerFlex Drive EtherNet/IP connections. Simply delete and/or copy EtherNet/IP devices to match your project requirements. The 16_CNC_Ethernet_Switch and 18_CNC_Cable_Connections drawings include references to FANUC CNC system and Rockwell Automation EtherNet/IP devices, cables, and connections. Delete and or copy components to match your project requirements. 3. Access other Rockwell Automation device footprints required for your application. To access Rockwell Automation Kinetix or PowerFlex drive system footprints, including HMI and other power components, use the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. Navigate to the CAD drawing libraries layout section directories for a variety of device footprints.


41

Chapter 2


Figure 7 - 15_CNC_Ethernet_Communication Drawing.

42



Chapter 2

Edit CNC System Layout Drawing 1. Open the panel layout drawing for your application.

CNC Subpanel Layout Drawing

For the CNC Work Cell application example, the 19_CNC_Panel_Layout.dwg file is opened. The panel layout drawing includes sub-panel and enclosure drawings. The panel is designed to accommodate best-practice techniques used to minimize electrical noise. Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001.

2. Delete, replace, or add component footprints to your panel layout drawing. To access Rockwell Automation power components, use the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. Navigate to the CAD drawing libraries layout section directories for a variety of device footprints. 3. Delete, replace, or add components to your enclosure drawing.

CNC Enclosure Layout Drawing

To access Rockwell Automation HMI or power components, use the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017. Navigate to the CAD drawing libraries layout section directories for a variety of device footprints.


43

Chapter 2


Assemble and Edit Your GuardLogix System Drawing Set If Rockwell Automation Kinetix and PowerFlex drives are to be used in your system, use the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, to assemble and edit your GuardLogix system drawing set. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. Drive I/O Example

Drive Power Example

System Layout Example

AC Line Filter

LIM Module

44



Chapter 2

If Rockwell Automation GuardLogix safety controller and safety components are used in the system, use the Safety Accelerator Toolkit DVD, publication SAFETY-CL002, to assemble your safety wiring and layout drawing set. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative.

Title Drive Safety Wiring Safety Controller Power Other Safety Devices

Guard I/O Module Wiring

Drive I/O Safety Controller Network Drawings

Safety Controller I/O Ethernet Switch Wiring Panel Layout Drawings


45

Chapter 2


Notes:

46


Chapter

3

FANUC CNC Configuration

In this chapter you initially configure your FANUC 30i-B, 31i-B, 32i-B, or 35i-B CNC, set up the CNC communication, and create a new project file for your CNC application. The intent is to provide a quick setup for an EtherNet/IP connection between a Rockwell Automation ControlLogix/GuardLogix PLC and a FANUC 30i-B, 31i-B, 32i-B, or 35i-B CNC. The overall CNC configuration and parameterization is not being addressed by this quick start, and is the responsibility of the machine tool builder.

Before You Begin • Complete your system architecture and hardware selection (refer to Chapter 1). • Complete your system layout and wiring (refer to Chapter 2).


contact your local Rockwell Automation distributor or sales representative • FANUC LADDER III software, version 6.8 or later • USB flash drive • FANUC Series 30i/31i/32i/35i –MODEL B, EtherNet/IP Adapter function, publication [email protected] • FANUC Series 30i/31i/32i/35i -MODEL B, FANUC Power Motion i -MODEL A EtherNet/IP Scanner

function, publication [email protected]


47

Chapter 3


Follow These Steps Complete these steps to configure your FANUC 30i-B, 31i-B, 32i-B, or 35i-B CNC for your application.

Start

Initial FANUC CNC Configuration page 48 Logic Configuration page 68

Initial FANUC CNC Configuration In this example, you set up your FANUC 30i-B, 31i-B, 32i-B, or 35i-B CNC to allow configuration parameters to be modified, to receive configuration parameters from external sources, and to select the high speed Ethernet option.

System Powerup Locate the CNC systems power button, then press to apply power.

48



Chapter 3

Parameter Write Enable Set the parameter write enable (PWE, 8900#0) bit to allow the configuration parameter changes described in the following sections. 1. Press the OFS/SET button on the QWERTY MDI Panel to open the SETTING (HANDY) screen.

Either the OFFSET screen or the SETTING screen is displayed. On first powerup, the OFFSET screen is displayed.

2. Press the SETTING button to call the SETTING screen.


49

Chapter 3


3. Use the arrow keys on the MDI panel to move to the desired selections. 4. Prior to setting the parameter, be sure that MDI modes has been selected by pressing the

button on the CNC main panel.

5. Enter 1 from the numeric entry, then press INPUT to set the parameter write enable bit (PWE, 8900#0). This lets you set the parameters, and configure the CNC for use.

6. Setting this may cause an alarm to be triggered and displayed. Cancel the alarm by pressing RESET on the MDI Panel. You will then have to open the SETTING screen again as described above.

7. Turn the parameter write enable key switch to the on position. IMPORTANT

50

This will take affect after the initial program has been downloaded later in this chapter.



Chapter 3

High Speed Ethernet Option Select the high speed Ethernet option to be used. This enables the fast Ethernet board to be used, and is required for the CNC EtherNet/IP option. 1. Press the SYSTEM function key from the MDI panel.

The system PARAMETER screen is displayed.

2. Press either the + softkey or the right arrow function key to advance to the chapter selection for PMC configuration.


51

Chapter 3


The chapter selection screen to display the PMC configuration options is displayed. 3. Press the PMC CONFIG softkey. 4. Press either the + softkey or the right arrow function key to advance to the chapter selection for PMC online configuration, then press ONLINE.

The chapter selection screen to display the PMC online configuration options is displayed.

5. Use the arrow keys on the MDI panel to move to the HIGH SPEED field, then select USE. The fast ethernet board is now available to be configured for the EtherNet/IP application.

52



Chapter 3

Configure Ethernet Module In this example, you configure the fast Ethernet board for communicating to the Supervisory PLC, and an offline development personal computer. See CNC to Controller Communication on page 208 for location of the fast Ethernet board.

IP Address, Subnet Mask, and Port Number Configure the IP Address of the fast Ethernet board to allow network connectivity. 1. Press the SYSTEM function key from the MDI panel.


2. Press either the + softkey or the right arrow function key to advance to the chapter selection for Ethernet.


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The chapter selection screen to display the fast Ethernet options is displayed. 3. Press the ETHERNET softkey to view the settings and selections of the fast Ethernet board.

4. Press the COMMON softkey to view the common settings of the fast Ethernet board. It may be necessary to press either the + softkey or the right arrow function key to advance to the chapter selection for Ethernet common.

5. Use the arrow keys on the MDI panel to move to the IP ADDRESS field, then enter the IP address for your configuration by using the number keys on the MDI panel. The example uses the IP address 192.168. 30.80 6. Use the arrow keys on the MDI panel to move to the SUBNET MASK field, then enter the mask for your configuration by using the number keys on the MDI panel. The example is using the mask 255.255.255.0

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7. Press the FOCAS2 softkey to view the FOCAS2/ETHERNET settings of the fast Ethernet board. 8. Verify that PORT NUMBER (TCP) is 8193. This is the default port number, and also the default configuration for the offline development software packages. The Ethernet board is now configured for the connection to the offline development personal computer.


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Create a New Project File Throughout the rest of this chapter, the controller and network configuration procedures are written specifically for an S35i-B CNC. Steps for other FANUC CNC models are similar. It is assumed that FANUC LADDER III has been installed and is operational on the development personal computer being used for this task. The process of creating a new project is based on using an example file that has been pre-written. You must change the name of the file from the toolkit, to something that is relevant to the application and task being created. 1. From the Start menu, launch the FANUC LADDER III software.

2. From the File menu, choose Open Program.

The Open dialog box appears.

3. Locate the CMAT 35i-B.LAD file from the CNC Machining Accelerator toolkit DVD, and select OPEN.

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The sample program opens, and is ready for editing. Change the CNC model for your specific application.

4. From the File menu, choose PMC Type changed and save.


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5. Select the model.

6. Select the control configuration for the specific application.

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7. From the File menu, choose Save As.

8. Save as a different file name, in a different location.

9. Click OK and save with the default options. 10. Click OK. You are now ready to begin editing the file for your specific application.


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Download FANUC LADDER III Software Project to the FANUC S35i-B CNC 1. Open your FANUC LADDER III project file. 2. From the Tool menu, choose Communication. The Communication dialog box opens.

3. Click the Network Address tab and click Add Host. 4. Type in the IP address of the CNC that you are working on, then click OK. The host has now been entered into the address list.

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5. Click Connect to establish communication with the CNC.

6. After the successful connection has been established, click Close to close the dialog box.

7. From the Tool menu, choose Store to PMC.


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The Program transfer wizard dialog box opens.

8. Click Next, then Finish.

9. After the download is complete, the Program transfer wizard dialog box closes, and the Program RUN/STOP dialog box appears. Click Yes to run the program. The FANUC LADDER III PMC program is now downloaded and running within the s35i-B CNC.

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USB External Device Define the USB port as the punch/reader port. This lets you receive and save configuration files to an external portable USB device. 1. Use the arrow keys as previously described to move to the I/O CHANNEL setting and enter the value 17. You will see the value displayed on the entry line beneath the settings. 2. Press INPUT as previously described, to change the parameter. You will now see the value 17 displayed in the parameter.

The USB port has now been selected as the I/O channel for the punch/reader function.


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EtherNet/IP Settings Configure the EtherNet/IP settings of the fast Ethernet board to allow the communication to the supervisory PLC, and the connection to the Rockwell Automation AOP as detailed in Chapter 4. The EtherNet/IP settings used throughout this quick start are the following CNC data table tags: • PLC to FANUC tags - R1000 – R1255 • FANUC to PLC tags - R2000 – R2255 A detailed description of these addresses, and the specific mapping between the PLC and CNC can be found in the CMAT-IDS.xlsx file. The path to this file is C:\Program Files\ RA_Simplification\CMAT\A-Files\ 4-Controller Logic\02_CNC_Logic. Refer to the FANUC EtherNet/IP documentation listed in What You Need on page 47 of this chapter, if you would like to change these locations.

1. Use the CNC Machining Accelerator Toolkit to navigate to the CNC Logic folder and copy both EtherNet/IP configuration files onto an external USB device. • EIPADAPT.MEM • EIPSCANR.MEM

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2. Take the USB device and plug it into the CNC port next to the panel display.

3. Press the SYSTEM function key from the MDI panel.

The System PARAMETER screen is displayed.


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4. Press either the + softkey or the right arrow function key to advance to the chapter selection for Ethernet network.

The chapter selection screen to display the fast Ethernet options is displayed.

5. Press the ETHERNET softkey to view the settings and selections of the fast Ethernet board.

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6. Press either the + softkey or the right arrow function key to advance to the chapter selection for EtherNet/IP scanner settings, EIP S SET. 7. Press the (OPRT) softkey to display available operations for the EtherNet/IP scanner settings. 8. Press either the + softkey or the right arrow function key to advance to the operation selection for restore.

9. Press the RESTORE softkey to display available operations for the EtherNet/IP scanner restore operations.

10. Press the EXECUTE softkey to copy the parameters from the external USB device to the CNC parameter memory.

11. Power down the CNC to accept the changes to the EtherNet/IP settings. 12. Power up the CNC, then repeat step 2...step 11 for the Ethernet adaptor settings (at step 6 select EIP A SET). The Ethernet board is now configured for the connection to the supervisory PLC that uses the EtherNet/IP protocol.


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Logic Configuration In this chapter you use the preconfigured PMC logic files and edit them specifically for your application. The toolkit provides a preconfigured PMC file with application and device modules that significantly speed-up your application logic development. An initial I/O configuration is provided as well, as an example only. To assist you in understanding how to best use the preconfigured logic files, the CNC Work Cell application is used as an example in all of the logic configuration steps. IMPORTANT

The overall machine CNC functionality and configuration is not being detailed or explained here. The CNC Machining Accelerator Toolkit, and this quick start, provide the framework to communicate with the Rockwell Automation GuardLogix supervisory controller.

IMPORTANT

In this example, there is a supervisory PLC that manages an entire work cell consisting of a gantry, and two machining centers. This PMC program is for one of the machining centers, but could be used interchangeably as a starting point.

In this example, the PLC is controlling the machining centers, sending commands over the EtherNet/IP network to the FANUC CNC devices.

PLC AOP

CNC/PMC Logic

PMC Device Module(s) Device Status

Device Commands

Application Commands

CNC Operator Panels

MDI Panels

Application Module(s)

Operator Commands

LCD Display CNC Machine Module

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The CNC architecture consists of two central processing units (CPUs), one specifically for the coordinated machine motion (CNC), and one for the machine I/O and peripheral functions (PMC). The CNC is the machine module in this example. It consists of proprietary software from FANUC, and is a layer that is not accessible for modifications. FANUC provides a means to interface with a CNC by using pre-defined system data table address registers. Refer to the FANUC documentation provided with your CNC for more information. Within the PMC, there are application modules and device modules. The modules are described below: • Application Modules – The application modules execute the machine commands and provide the more

specific application commands for the CNCs functions. These modules must be defined, edited, and completed for your specific application prior to final commissioning on a CNC machine. To complete the proper handshaking between the PLC and CNC for the example project, these application modules have been programmed with timers to simulate a response. Add the custom application code as necessary to complete the programming for the specific application in these areas. • Device Modules – The device modules translate the overall machine and application commands, and provide uniform status and diagnostics from/to the very specific EtherNet/IP device tags. This reduces much of the non-inventive code required to control and monitor the EtherNet/IP device. Table 2 - Preconfigured Logic Modules Used in CNC Work Cell Example Module Type

File Names LEVEL1 LEVEL2

Application

P0001 (OP Panel Path 1) P0005 (Machine Sequence) P0010 (Window Functions) P0023 (Alarm Routine)

Device

P0015 (PLC EIP Input Routine) P0016 (PLC EIP Output Routine)


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Editing Application Logic Modules and Adding Code 1. Open the FANUC LADDER III file that was saved previously. 2. Review the logic modules in the folder tree.

3. Double-click the files to open and edit the logic for your specific application

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P0001 (OP Panel Path 1) This application program manages the operator panel and MDI panel I/O interface. The Machine mode push buttons, indicator lights, and feed rate override signals are controlled from this program routine.

P0005 (Machine Sequence) This application program manages the sequencing involved in a machine tool application. This, along with other programs (provided by the OEM) specific to the machine application will control machine I/O, and/or control overall machine functionality. Edit this file as necessary to control the machine to meet the performance specifications required for the application. To maintain code modularity, add additional files on a function by function basis.


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P0010 (Window Functions) This application program manages the window functions provided by the CNC. The window functions allow the PMC program to access features of the CNC that are not part of the standard data table interface between the PMC and CNC (refer to the FANUC documentation for further details). This module is used to provide status and command to the EtherNet/IP device modules.

P0023 (Alarm Routine) This application program manages the alarming for the CNC, and also provides status to the EtherNet/IP device module. Add application program files as necessary for your specific application.

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Device Logic Modules IMPORTANT

These modules are mandatory for the EtherNet/IP communication between the CNC and the PLC.

These pre-defined modules require no modifications to interact with the supervisory PLC and ControlLogix AOP as described in the following chapters. If additional functionality is desired, FANUC and Rockwell Automation have provided an open architecture that can be used. Refer to the documents in What You Need on page 47 for the specific details of the EtherNet/IP feature. 1. Review the logic modules in the folder tree.

2. Double-click the files to open the logic for review.


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P00015 (PLC EIP Input Routine) This device program moves the 256 bytes from the data table area previously specified (R1000…R1255) for the EtherNet/IP option into a buffered data table that is used throughout the program by the application modules.

A detailed description of these addresses, and the specific mapping between the PLC and CNC, can be found in the CMAT-IDS.xlsx file.

P00016 (PLC EIP Output Routine) This device program manages the output data being sent to the supervisory PLC. The program uses status information from the application modules to set a buffered data table area specific for the functions detailed in the IDS previously mentioned. Refer to CMAT-IDS.xlsx for the mapping (as shown in the screen above). The buffered data table area will then be moved into the 256 bytes of the data table area previously specified (R2000…R2255) for the EtherNet/IP option.

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Verify and Save the Project File When you have finished programming your FANUC CNC application with the FANUC LADDER III software, verify and save your file. 1. From the Tool menu, choose Compile to check for errors.

2. Click Exec when the Compile dialog box opens.


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3. Click Close after the compile is complete. TIP

If the compile has completed with no errors, than it is OK to download to the CNC; otherwise, review the compile report and return and correct the errors.

4. Click to save your FANUC LADDER III application file.

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Download FANUC LADDER III Software Project to the FANUC S35i-B CNC 1. Open your FANUC LADDER III project file. 2. From the Tool menu, choose Communication. The Communication dialog box opens.

3. Click the Network Address tab and click Add Host. 4. Type in the IP address of the CNC that you are working on, then click OK. The host has now been entered into the address list.


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5. Click Connect to establish communication with the CNC.

6. After the successful connection has been established, click Close to close the dialog box.

7. From the Tool menu, choose Store to PMC.

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The Program transfer wizard dialog box opens.

8. Click Next, then Finish.

9. After the download is complete, the Program transfer wizard dialog box closes, and the Program RUN/STOP dialog box appears. Click Yes to run the program. The FANUC LADDER III PMC program is now downloaded and running within the s35i-B CNC.


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Notes:

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4

GuardLogix Configuration In this chapter you will use RSLogix5000 to configure your GuardLogix controller, add and configure the FANUC CNC AOP, import preconfigured logic modules, and edit them specifically for your application. In addition, the logic modules include control, status, and diagnostic code that provide information to preconfigured operator interface faceplates that you can run on personal computers or PanelView Plus terminals. Figure 8 - Logic Modules HMI Application Controller Logic PanelView Plus Terminal Machine Status

Machine Faceplate

Machine Module Device Faceplates

Machine Commands

Application Status Operator Commands

Application Modules

Device Commands

Device Status

Device Modules

The machine module provides a state machine model that coordinates multiple devices and application logic for coordinated CNC applications. It provides overall machine commands, for example start, stop, abort, clear, and reset to the application modules and the individual device modules based on the status of the applications and devices. The application modules execute the machine commands and provide the more specific application commands to the CNCs and devices. They also coordinate the machine and application status, and execute the application fault commands. In addition, the toolkit includes control logic examples to help you create your specific application logic. Rockwell Automation Publication IASIMP-QS034A-EN-P - October 2012

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GuardLogix Configuration

The device modules translate the uniform machine and application commands and provide uniform status and diagnostics from the very specific device tags and parameters. This reduces much of the non-inventive code required to control and monitor the many unique devices. For more information on the machine, application, and device logic modules, refer to Appendix A. To assist you in understanding how to best use the preconfigured logic files, the CNC Work Cell application is used as an example in all of the logic configuration steps. Table 3 - Preconfigured Logic Modules Used in CNC Work Cell Application Module Type Machine Logic

File Names Machine_Module Device&Application_Status Application_Module

Application Logic

App1_Gantry_Simulation App2_CNC_Machining

Device Modules

Fanuc_CNC_Module CIPMotion_Drive_Module

Before You Begin • Complete your system architecture and hardware selection (refer to Chapter 1). • Complete your system layout and wiring (refer to Chapter 2). • Complete your FANUC CNC configuration (refer to Chapter 3).


contact your local Rockwell Automation distributor or sales representative. • RSLogix 5000 software, version 20.0 or later • RSLinx Classic software, version 2.56 or later • If Rockwell Automation Kinetix or PowerFlex Drives are used in the system, the Drives and Motion

Accelerator Toolkit DVD, publication IASIMP-SP017, can be used to significantly streamline GuardLogix configuration and standard logic. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. • If Rockwell Automation GuardLogix safety controller and safety components are used in the system, the

Safety Accelerator Toolkit DVD, publication SAFETY-CL002, can be used to significantly streamline Guard I/O configuration and safety logic. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative.

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Follow These Steps Complete these steps to import and configure logic modules for your FANUC CNC application. Start

GuardLogix Controller and Network Configuration

Are you using the DMAT Wizard to configure the initial GuardLogix controller and Kinetix/PowerFlex drive configuration and logic?

No

page 87

Import and Configure the Machine Logic Module

Yes

Create an Initial GuardLogix Project Using the DMAT Wizard page 84

FANUC CNC AOP Configuration

page 91

page 95

Import and Configure CNC Application Logic Module

Set Visible Rows for Equipment Status Faceplate

page 100

page 111

Import and Configure FANUC CNC Device Logic Modules Optional Step Complete if Alarm History faceplate is used in application.

Import and Configure Device and Application Status Logic

page 104

page 113

Set String Tag Names for Alarm History Faceplate

Create Specific Application Logic page 120

page 108

Application Logic Creation Steps That Use Application Logic Examples page 126

No

Optional Step Complete if Equipment Status faceplate is used in application.

Are you familiar with the RSLogix 5000 software programming environment, motion instructions, and programming PowerFlex drives?

Yes

Application Logic Creation Steps That Use a Template page 136

Safety Logic Integration page 137 Verify and Save the Project File page 146


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Create an Initial GuardLogix Project Using the DMAT Wizard If Rockwell Automation Kinetix or PowerFlex drives are used in the system, the DMAT Wizard can be used to significantly streamline GuardLogix configuration and standard logic.

Order and Run the DMAT Wizard 1. Order a copy of the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, from your local Rockwell Automation distributor or sales representative. 2. Install the Drives and Motion Accelerator Toolkit onto your computer. 3. Run the DMAT Wizard following the instructions in Chapter 1 of the Drives and Motion Accelerator Toolkit Quick Start, publication IASIMP-QS019. a. When configuring project in the DMAT Wizard, be sure to select the GuardLogix controller within the machine configuration if you are incorporating safety logic into the supervisory controller. b. Configure all of the low voltage (PowerFlex) and servo (Kinetix) drives for your system. c. You will be adding the FANUC CNC AOP and associated logic modules per the instructions later in this chapter.

Import the Preconfigured RSLogix 5000 Project Follow these steps to open the preconfigured RSLogix 5000 project. 1. Launch RSLogix 5000 software.

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2. Click the Open icon on the toolbar. 3. From the Files of type pull-down menu choose All RSLogix 5000 files.

4. Navigate to the RSLogix 5000 XML file that was created by the DMAT Wizard and Click Open.

If the Drives and Motion Accelerator Toolkit was installed in the default directory, you will find the RSLogix 5000 XML file in: C:\Documents and Settings\PC Name\My Documents\DMAT\ProjectName\MachineName.


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For the CNC Work Cell example, the path is: C:\Documents and Settings\PCName\My Documents\DMAT\CNC_Work_Cell\CNC_Work_Cell.

5. From the Revision pull-down menu, choose the version of RSLogix 5000 software to import into.

IMPORTANT

Your RSLogix 5000 software must be version 20.0 or later to use the FANUC CNC AOP.

6. Click Import to save and open the project as an ACD file.

After the import process is complete, the project opens and the controller organizer displays all of the preconfigured project components including the controller, network, device configurations, the preconfigured logic program files and the faceplate and control AOI files. Because the DMAT Wizard created a project with a controller, network module, and Machine Module logic, go to FANUC CNC AOP Configuration on page 95.

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GuardLogix Controller and Network Configuration In this section you will create a new GuardLogix project file and configure the EtherNet/IP communications.

Create a New Project File Throughout this section the controller and network configuration procedures are written specifically for a 1756-L6x or 1756-L6xS ControlLogix controller. If you are integrating Kinetix motion into your project, we recommend that you select a 1756-L7xS for your system. Steps for other Logix controller and communication modules are similar. IMPORTANT

If you are creating a new project and have not configured your personal computer communication or controller hardware, see Appendix D.

1. From the Start menu, launch RSLogix 5000 software.

2. Click New Project. The New Controller dialog box opens.


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3. Configure the new controller. a. From the Type pull-down menu, choose the controller type. b. From the Revision pull-down menu, choose the revision. c. Type the file name in the Name field. d. From the Chassis Type pull-down menu, choose the chassis. e. Enter the Logix processor slot (leftmost slot = 0). 4. Click OK.

5. From the Edit menu, choose Controller Properties. The Controller Properties dialog box opens. 6. Click the Date/Time tab. 7. Check Enable Time Synchronization. This enables time synchronization for the controller. 8. Click OK.

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Configure Ethernet Module for your HMI Terminal and CNC Modules 1. Expand I/O Configuration in the Controller Organizer. 2. Right-click I/O Configuration and choose New Module. The Select Module Type dialog box opens.

3. Expand the Communications category and select your 1756-series Ethernet module. TIP

For systems communicating to a FANUC CNC over an EtherNet/IP network, a 1756-EN2x or 1756-EN3x module is required.

In this example, the 1756-EN2TR module is selected. 4. Click Create. The New Module dialog box opens. 5. Configure the new module. a. Enter the module Name. b. Enter the Logix EtherNet/IP module slot (leftmost slot = 0). c. Select an Ethernet Address option. In this example, the Private Network address is selected. d. Enter the address of your EtherNet/IP module. In this example, the last octet of the address is 10. 6. Click Change in the Module Definition area. The Module Definition dialog box opens.


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7. From the Time Sync Connection pull-down menu, choose Time Sync and Motion. IMPORTANT

Time Sync functionality is what enables motion control on an Ethernet network. While not specifically required for the CNC communication, without this setting, you won’t be able to run motion applications.

8. Click OK to close the Module Definition dialog box. 9. Click Yes when prompted to confirm your module definition changes. 10. Click OK to close the New Module dialog box.

Your new module appears under the I/O Configuration folder in the Controller Organizer. IMPORTANT

For the CNC Work Cell application example, the 1756-EN2TR Ethernet module is the only communication module that is needed. However, if your application requires other communication modules, such as sercos communication, for Kinetix drives, refer to the Drives and Motion Accelerator Toolkit, publication IASIMP-QS019.

Save the Project File When you configured the ControlLogix controller you named your (.acd) application file. In this example, the file name is CNC_Work_Cell. Before closing RSLogix 5000 software, save your file. Click file.

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Import and Configure the Machine Logic Module In this example, you add the preconfigured machine logic program file to your RSLogix5000 project and configure it to your specific application. 1. Open your RSLogix 5000 software project that you created in the previous section. For the CNC Work Cell application example, the CNC_Work_Cell project was opened. 2. Expand the Tasks folder in your Controller Organizer and drag-and-drop the MainProgram folder to the Unscheduled Programs / Phases folder.

3. Right-click the Main Task folder, and choose Import Program.

4. Navigate to the 01_GuardLogix_Logic folder within the toolkit’s files folder and open the 01_Machine_Logic folder. The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\ 4-Controller Logic\01_GuardLogix_Logic.


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5. Select the Machine_Module.L5x file and click Import.

The Import Configuration dialog box opens.

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6. Type the desired name for your machine in the Final Name field. For the CNC Work Cell application example, P01_CNC_Work_Cell is the Final Name. 7. Click Tags in the Import Content organizer.

The Configure Tag References dialog box opens.

8. Replace _MachineName with the desired tag name of your machine.


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For the CNC Work Cell application example, CNC_Work_Cell is the tag name.

9. Click OK. The new machine program appears in the Controller Organizer within the Main Task folder.

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FANUC CNC AOP Configuration To configure the FANUC AOP you update the CNC add-on profiles (AOP), and add and configure the FANUC CNC.

Update FANUC CNC Add-On Profile (AOP) IMPORTANT

The FANUC CNC add-on profiles are independent of RSLogix 5000 software releases. Update your CNC add-on profiles to make sure your application runs correctly.

Add-on profiles (AOP) are available for download at the RSLogix 5000 Add-On Profiles website: http://support.rockwellautomation.com/controlflash/LogixProfiler.asp. 1. Log in to the RSLogix 5000 Add-On Profiles website, http://support.rockwellautomation.com/controlflash/LogixProfiler.asp. The RSLogix 5000 Add-On Profiles dialog box opens. 2. Find the FANUC CNC profile. 3. Click the Add-On Profile icon and follow the download instructions. 4. Extract the AOP zip file and run setup.


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Add and Configure FANUC CNC For this CNC Work Cell application example, you will add the FANUC CNC to the EtherNet I/P network. 1. Open your RSLogix 5000 software project file. 2. Expand the I/O Configuration folder in the Controller Organizer and browse to the controller backplane. 3. Right-click the network communication module for your CNC and choose New Module. For the CNC Work Cell example, the 1756-EN2TR module is selected. The Select Module Type dialog box opens. 4. Click the FANUC Corporation vendor and select the appropriate CNC series module. For the CNC Work Cell example, the FANUC CNC module type is selected for the Drill CNC. 5. Click Create. The New Module dialog box opens.

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6. Configure the new module. a. Type the module Name. b. Select an Ethernet Address option. In this example, the Private Network address is selected. 7. In the Module Definition field click Change. The Module Definition dialog box opens.

8. Configure module definitions. The Module Definition dialog box lets you configure and access CNC data beyond standard I/O. a. Enter the series letter appropriate for your CNC hardware. b. Enter major and minor revisions appropriate for your CNC hardware. c. Enter number of allocations to use and allocation number, according to appropriate configuration of CNC.


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d. Set the IO Size for your CNC communication. For the CNC Work Cell application example, the IO Size (bytes) is set to 256 bytes.

e. Click OK to close the Module Definition dialog box.

f. Click Yes to accept the changes.

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9. Click OK to close the New Module dialog box. 10. Repeat the previous process for all other CNC modules needed for your application.

For the CNC Work Cell application example, two CNC modules are needed, one for drilling, and one for machining. The added modules appear in the I/O configuration tree, as shown here. IMPORTANT

The CNC Work Cell application example includes two CNC modules and two gantry drives, as shown here. However, if your application involves additional devices/modules, such as Kinetix drives, refer to the Drives and Motion Accelerator Toolkit, publication IASIMP-QS019.

Save the Project File When you have added and configured each of the CNC modules that are to be used in your application, save the project. Click file.

to save your RSLogix 5000 application


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Import and Configure CNC Application Logic Module In this example, you add preconfigured application logic to your RSLogix 5000 project and configure it for each of your CNC applications within your machine. 1. Expand the Tasks folder in your Controller Organizer, and right-click the Main Task folder. 2. Choose Import Program.

3. Navigate to the 01_GuardLogix_Logic folder within the toolkit’s files folder and open the 02_Application Logic folder. The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\ 4-Controller Logic\01_GuardLogix_Logic.

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4. Select the Application_Module.L5x file and click Import.



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5. Enter the name for your initial CNC application in the Final Name field. For the CNC Work Cell application example, the Final Name is P03_Machining. 6. Click Tags within the Import Content organizer.

The Configure Tag References dialog box opens. 7. Replace the _ApplicationName and _MachineName with the desired tag names of your application and machine.

For the CNC Work Cell application example, Machining was entered as the ApplicationName and CNC_Work_Cell was entered as the MachineName. 8. Click OK. The new application program appears in the Controller Organizer within the Main Task folder.

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9. Repeat step 1…step 8 for each application within your machine.


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Import and Configure FANUC CNC Device Logic Modules In this example, you add preconfigured FANUC CNC device logic to your RSLogix5000 project and configure it for each of your FANUC CNC systems within your machine. 1. Expand the Tasks folder in your Controller Organizer and right-click the Main Task folder. 2. Choose Import Program.

3. Navigate to the 01_GuardLogix_Logic folder within the toolkit’s files folder and open the 03_Device Modules folder. The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\ 4-Controller Logic\01_GuardLogix_Logic.

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4. Select the Fanuc_CNC_Module and click Import.



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5. Enter the name for your initial device in Final Name field. For the CNC Work Cell application example, P04_Drill_CNC is the Final Name. 6. Click Tags within the Import Content organizer.


7. Replace Final Tag Names with associated CNC and machine names that you have already configured in Chapter 4. a. Replace _CNCName of _CNCName:I, _CNCName:O, and _CNCName_FP tags with the name your FANUC CNC. b. Replace _MachineName of _MachineName tag with the machine name of your project. c. Replace _ModuleName of _ModuleName tag with the device name of your CNC.

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For the CNC Work Cell application example, the following tag names were entered.

8. Click OK. The new device module program appears in the Controller Organizer within the Main Task folder. For the CNC Work Cell application example the new program named P04_Drill_CNC appears in Controller Organizer. 9. Repeat step 1…step 8 for each FANUC CNC system in your machine.

For the CNC Work Cell application example, another program was added for the Machining CNC, named P05_Machine_CNC; it appears in Controller Organizer.


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For the CNC Work Cell application example, two additional programs (CIPMotion_Drive_Module) were added by the DMAT Wizard for gantry X and Y drives. Refer to the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, for information about importing and configuring additional drives and motion modules.

Set String Tag Names for Alarm History Faceplate If you plan to use the alarm history faceplate with your HMI application, follow these steps to set the application and device string tag names to match your application and device module names. These string names are used within the alarm messages indicating the device or application origin of the alarm. 1. Expand the Controller folder in your Controller Organizer and double-click Controller Tags. The controller tags open in the workspace.

2. Expand one of your application status tags (UDT_AppStatus) and/or module status tags (UDT_ModuleStatus) and select the value field of the string tag named XXX.Name. For the CNC Work Cell application example, the Gantry tag (UDT_AppStatus data type) is expanded and the Gantry.Name string tag value field is selected.

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.

The String Browser dialog box opens. 4. Enter the name of the associated application or device module. This string name is used within the alarm history messages providing the fault origin. 5. Click OK. The string tag value field updates with the name you typed in. For the CNC Work Cell application example, the value is Gantry.

6. Repeat step 1…step 5 for each application status (UDT_AppStatus) tag and device status (UDT_ModuleStatus) tag within the Controller Tags of your project. For the CNC Work Cell application example, these application and device string tag names were entered. Machining Example

Drill CNC Example


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Machine CNC Example

Gantry X Axis Drive Example

Gantry Y Axis Drive Example

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Set Visible Rows for Equipment Status Faceplate If you plan to use the equipment status faceplate with your HMI application, follow these steps to set the Inp_NumRowsVis tag value within the faceplate Add-On Instruction of the device you intend to place in the first row. 1. Determine how many of the nine available rows you will use in the Equipment Status faceplate. Refer to Chapter 5 beginning on page 147 for an overview of the faceplate so you can determine how many status rows you require and what device you would like to place in the first row. For the CNC Work Cell application example, four devices are included in the equipment status faceplate, with the first one being the Drill CNC, placed in the first row: • Drill CNC • Machining CNC • Gantry X Axis Drive • Gantry Y Axis Drive 2. Open the R04_Monitor routine for the device in the first row of the equipment status faceplate and navigate to the device specific faceplate Add-On Instruction.

For the CNC Work Cell application example, the R04_Monitor routine in the P04_Drill_CNC program was opened. 3. Click

(View Configuration dialog box) to open the Add-On Instruction properties.


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4. Navigate to the Inp_NumRowsVis tag and select the value. 5. Enter the number of devices you determined in step 1. For the CNC Work Cell application example, 4 was entered. 6. Click OK to close Add-On Instruction properties and complete the update.

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Import and Configure Device and Application Status Logic In this example, you add the device and application status information rungs to the R02_Monitor routine of your machine program. 1. Expand the Tasks folder in the Controller Organizer. 2. Navigate to and open the R02_Monitor routine of your machine program. For the CNC Work Cell application example, the R02_Monitor routine within the P01_CNC_Work_Cell program was opened.

3. Right-click Rung 13 of the R02_Monitor routine and choose Import Rungs. IMPORTANT

If the DMAT wizard was used to create initial RSLogix project file for your system, select rung 13 and the remaining rungs up to the end rung. You will be replacing these rungs with the new Device & Application Status logic.


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4. Navigate to the 01_GuardLogix_Logic folder within the toolkit’s files folder and open the 01_Machine Logic folder. The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\ 4-Controller Logic\01_GuardLogix_Logic.

5. Select the Device&Application_Status.L5X file. 6. Check Overwrite Selected Rungs. 7. Click Import.

The Import Configuration dialog box opens. 8. Click Tags within the Import Content organizer.

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9. Replace Final Tag Names with the associated UDT_AppStatus tag names or UDT_ModuleStatus tag names for your specific application.

For the CNC Work Cell application example, both _ApplicationName UDT_AppStatus tags were assigned to Gantry and Machining UDT_AppStatus tags, and _ModuleName01…04 UDT_ModuleStatus tags were assigned to Drill_CNC, Machine_CNC, Gantry_X_Drive, and Gantry_Y_Drive UDT_ModuleStatus tags. IMPORTANT

If your machine requires more than two applications and/or more than ten modules (devices), then you also need additional instructions in the status rungs. Refer to step 13 on page 119 for more information.


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10. From the Operation pull-down menu, choose Discard for each unused _ApplicationNameXX and _ModuleNameXX tag.

For the CNC Work Cell application example, Discard was chosen for unused tags _ModuleName05…10.

11. Click OK to complete rung import.

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The imported module status rungs appear starting in rung 13 and the application status rungs appear starting in rung 19 of the R02_Monitor routine of your machine program.


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12. Delete all unused instructions within all of the module status and application status rungs. a. Right-click instruction to delete. b. From the pull-down menu, choose Delete Instruction. c. Repeat process for all unused instructions in rungs 13…24.

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Rungs 13…24 appear without edit rung indication and verify OK when all unused instructions have been deleted.

13. Add Instructions to Rungs 13…24 if more than two applications and/or more than ten modules (devices) are required for your machine. a. Copy existing status input instruction. b. Paste existing status input instruction. c. Rename pasted input instruction with additional module (device) status tag name. d. Repeat process for all additional devices in your machine.


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Create Specific Application Logic Now that you have imported and configured all the machine, application, and device modules, you can begin creating the specific application logic for your machine. You create your application logic within the R10_ApplicationCode routine of the application module. There are two methods for creating specific application logic for your machine. The two methods are described below: • Preprogrammed Logic Examples – The first method involves selecting and importing preprogrammed logic examples into the application code routine. These logic examples help familiarize less experienced users with the basics behind using instructions for controlling FANUC CNCs via their add-on profiles. These preprogrammed logic examples are designed to work seamlessly with the application module and can help further reduce programming time. • Write Logic from Scratch – The second method provides a blank template with placeholders if you choose to write your application-specific logic from scratch. This method is recommended for users who feel comfortable with the RSLogix 5000 software programming environment and who also have experience with instructions used for controlling FANUC CNCs via their add-on profiles.

Application Code Logic Template Overview To assist you in creating specific-application logic that interfaces with the preconfigured machine, application, and device modules, a logic template is included in the R10_ApplicationCode routine of the application module. It includes placeholders for both run and stop sequences. All of the application logic examples also follow this same template. IMPORTANT

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Figure 9 - Run Sequence Template ============================================ BY DEFAULT THE FOLLOWING RUNGS WILL BE ERRORED AND THEREFORE MUST BE ADDRESSED... MODIFY OR OVERWRITE THESE RUNGS WITH THE APPLICATION SPECIFIC LOGIC ***PLEASE NOTE THE STOP SEQUENCE IS DIRECTLY BELOW THE RUN SEQUENCE*** ============================================ NOP

0 ============================================ RUN SEQUENCE ============================================ 1

2

3

4

NOP e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e

SEQUENCE INITIATE This rung is a placeholder where Application specific logic can be inserted. By default, RunSEQ[0] is initially set to 1 following a Machine START command (that is, "MachineName".Cmd.START). Refer to the Machine Commands rungs in the R03_Control routine of the Application Module. EQU Equal Source A RunSEQ[0] 0 MOV Source B 1 Move Logic Placeholder Source 10 Dest

RunSEQ[0] 0

SEQUENCE PLACEHOLDER This rung is a placeholder where Application specific logic can be inserted. This rung can easily be duplicated if addtional sequence steps are needed. EQU Equal Source A RunSEQ[0] 0 Source B 10

MOV Move Source Dest

20 RunSEQ[0] 0

SEQUENCE PLACEHOLDER This rung is a placeholder where Application specific logic can be inserted. This rung can easily be duplicated if addtional sequence steps are needed. EQU Equal Source A RunSEQ[0] 0 Source B 20



30 RunSEQ[0] 0

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The run sequence is initiated by a machine START command via the start logic in the R03_Control routine of the application module. By default, the run sequence is initiated by placing a value of 1 in the RunSEQ[0] tag. When the RunSEQ[0] tag is set to 1, the first step in the run sequence is executed, starting the run sequence. Each of the rungs in the run sequence provides a placeholder where you can insert application-specific step logic. The Run-sequence logic may include, for example, CNC commands, and/or other conditional diagnostic logic. The move (MOV) instruction is a placeholder to advance the run sequence to the next step by incrementing the RunSEQ[0] tag. Each step in the run sequence requires a unique value assigned in ascending order. The steps typically increase by multiples of five or ten. By default, the run-sequence template steps 1…10…20…30, and so on. Before moving to the next step, a predetermined condition must normally be met to make sure the current step is complete. Figure 10 - First Run Sequential Step Example

This CNC Work Cell application code first-run step (RunSEQ[0] = 1) example includes a latch (L) instruction, as well as a MOV instruction for assigning a simulation number, used for this example. Also, the RunSeq MOV instruction indexes to the next sequence step (for example, value 3 into RunSEQ[0] tag). The next rung, that has EQU RunSeq = 3 as its condition, is then executed, and so forth.

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Figure 11 - Final Run Sequential Step Example

Much like the first run-step example rung, this CNC Work Cell final run step example also includes unlatch (U) instruction, as well as a MOV instruction for assigning a simulation number, used for this example. The RunSeq MOV instruction indexes to the next sequence step, a value of 1 this time, which will repeat the RunSeq steps. If continuous operation is not required, the final step could end the run sequence, or remain at this step indefinitely.


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Figure 12 - Stop Sequence Template ============================================ STOP SEQUENCE ============================================ NOP

5

6

7

8

e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e

SEQUENCE INITIATE This rung is a placeholder where Application specific logic can be inserted. By default, StopSEQ[0] is initially set to 1 following a Machine STOP command (that is, "MachineName".Cmd.STOP). Refer to the Machine Commands rungs in the R03_Control routine of the Application Module. EQU Equal Source A StopSEQ[0] 0 MOV Source B 1 Move Logic Placeholder Source 10 Dest

StopSEQ[0] 0

SEQUENCE PLACEHOLDER This rung is a placeholder where Application specific logic can be inserted. This rung can easily be dulpicated if addtional sequence steps are needed. EQU Equal Source A StopSEQ[0] 0 Source B 10


20 StopSEQ[0] 0

SEQUENCE COMPLETE By default, the Application is STOPPED when StopSEQ[0] reaches 999. Refer to the Application Status rungs in the R02_Monitor routine of the Application module to modify the conditions that detemine when the Application is STOPPED (that is, "ApplicationName".Stopped). EQU MOV Equal Move Source A StopSEQ[0] Source 999 0 Source B 20 Dest StopSEQ[0] 0

(End)

The stop sequence is initiated by a machine STOP command via the stop logic in the R03_Control routine of the application module. By default, the stop sequence is initiated by placing a value of 1 in the StopSEQ[0] tag. When the StopSEQ[0] tag is set to 1, the first step in the stop sequence is executed, starting the stop sequence. Each of the rungs in stop sequence provides a placeholder where application specific step logic can be inserted. The stop sequence logic may include, for example, CNC commands and/or other conditional diagnostic logic.

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The move (MOV) instruction is a placeholder to advance the stop sequence to the next step by incrementing the StopSEQ[0] tag. Each step in the stop sequence requires a unique value be assigned in ascending order. The steps typically increase by multiples of five or ten. By default, the stop sequence-template steps 1…10…20…30 …999. Before moving to the next step, a predetermined condition must normally be met to make sure the current step is complete. By default, the stop sequence ends when the StopSEQ[0] tag value reaches 999. The StopSEQ[0] tag is then monitored in the R02_Monitor routine of the application module for a value of 999 and then sets the ApplicationName.Stopped tag. The machine module monitors the ApplicationName.Stopped tag to determine when the application was properly stopped. Figure 13 - First Stop Sequential Step Example

This CNC Work Cell first stop step example includes a latch (L) instructions, and a MOV instruction, which indexes to the next sequence step (for example, value 10 into the StopSEQ[0] tag).


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Figure 14 - Final Stop Sequential Step and Sequence Complete Example

This CNC Work Cell final stop step and complete logic example includes logic to unlatch (U) the Stopped status, one the gantry has been confirmed to be stopped. Identical to the stop sequence template, the stop sequence complete rung sets the StopSEQ[0] tag value to 999, which indicates the stop sequence is complete.

Application Logic Creation Steps That Use Application Logic Examples If you are unfamiliar with the Rockwell Automation general Logix commands, Logix motion commands, FANUC CNC parameters, and/or are seeking common application methods for creating specific application logic, use these steps to create your specific application logic.

Toolkit Application Logic Example Overview The toolkit provides a variety of common application logic examples designed to help you create your specific application logic. The logic examples are organized by the device modules they support. The CNC Work Cell example supports a combination of a simulated gantry, and two FANUC CNCs for machining. Table 4 - CNC Work Cell Logic Examples Application Example

File Name

Description

Application Created From

CNC Work Cell gantry

App1_Gantry_Simulation

Simulate gantry motion

None

CNC Work Cell machine

App2_CNC_Machining

Simulate/run through CNC commands

None

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CNC Work Cell Logic Example Overview To assist you in understanding how to best use the logic examples, the CNC Work Cell application is used as an example. We recommend you study the CNC Work Cell gantry and machining applications to see the interaction of the machine, application, and device modules within the application logic. The CNC Work Cell examples are created by using basic CNC application examples included in the toolkit. After you’ve studied these examples, create your own applications by using the basic CNC examples. The CNC Work Cell application example is an excellent canvas to experiment with the other application examples. The example includes two CNCs, so it is possible for you to import and study all of the application examples. Figure 15 - CNC Work Cell Application Example


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The CNC Work Cell example has two applications (gantry and machining) and has the following run sequences. Table 5 - Gantry Application – Application1 Step

Simple X-Y Gantry Run Sequence Simulation

1

Verify/Ready

2

Pick – part in in-feed

3

Drop – drop in drilling center

4

Dwell – let drilling happen

5

Pick – when done, pick up part

6

Drop – drop in machining center

7

Dwell – let machining happen

8

Pick – when done, pick up part

9

Drop – drop into out-feed

10

Repeat

Table 6 - Machining Application – Application2 Step

Machining, Two CNCs Run Sequence Simulation

1

Verify/Ready

2

Get first gantry drop – begin drilling

3

Perform drilling execution

4

When done, let gantry pick part

5

On next gantry drop – begin machining

6

Perform machining execution

7

When done, let gantry pick part

8

Repeat

For the CNC Work Cell application example and in the following text, the Gantry Application is Application1, and the Machining Application is Application2. Application1 contains all logic for simulating motion of the gantry, and Application2 contains all logic and commands for both CNCs.

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Import Application Logic Examples In this example, you add logic examples to your R10_ApplicationCode routine within your application modules. 1. Expand the Tasks folder in the Controller Organizer. 2. Navigate to and open the R10_ApplicationCode routine within your first application program file.

For the CNC Work Cell application example, the R10_ApplicationCode routine within the P02_Gantry program was opened. 3. Select all rungs of the R10_ApplicationCode routine. 4. Right-click the selected rungs and choose Import Rungs.


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5. Navigate to the 02_Application Logic folder within the toolkit’s files folder. The file path is C:\Program Files\ RA_Simplification\CMAT\A-Files\ 4-ControllerLogic\ 01_GuardLogix_Logic\ 02_Application_Logic. 6. Double-click the CNC_Work_Cell_Logic_Examples folder.

7. Select the logic example file to start your application logic. For the CNC Work Cell application example, the App1_Gantry_Simulation.L5X file is selected. 8. Check Overwrite Selected Rungs. 9. Click Import.

The Import Configuration dialog box opens. 10. Click Tags within the Import Content organizer.

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11. Replace tag names in the Final Name column with the associated axis or drive names for your application.

For the CNC Work Cell application example, _CNC_1 was replaced with Drill_CNC, and _CNC_2 was replaced with Machine_CNC. 12. Click OK to complete rung import. 13. Repeat step 2…step 12 for each logic example you wish to import.


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For the CNC Work Cell gantry application example, the following rungs are imported. The rungs include a series of five incremental moves. Figure 16 - Gantry, Simulation Commands

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For the CNC Work Cell application example, the R10_ApplicationCode routine within the P03_Machining program was also opened and the CWC_Machine_App2.L5X file was imported.


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For the CNC Work Cell App2_CNC_Machining.L5X file, these files were replaced: • _CNC_1 was replaced with Drill_CNC • _CNC_1_FP was replaced with Drill_CNC_FP • _CNC_2 was replaced with Machine_CNC • _CNC_2_FP was replaced with Machine_CNC_FP

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For the CNC Work Cell Machining example, the following rungs are imported. The rungs include a series of commands for the FANUC CNCs, Drill_CNC and Machine_CNC. Figure 17 - Machining, FANUC CNC Commands


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Application Logic Creation Steps That Use a Template If you are familiar with Rockwell Automation’s general Logix commands, FANUC CNC parameters and commands, and have a good idea of your specific run/stop sequences, use these steps to guide you through your specific application logic creation. 1. Formulate and list your run sequence steps. 2. Add your initial run sequence step (RunSEQ[0] = 1) to the R10_ApplicationCode routine of your imported application module. 3. Add remaining run sequence steps (RunSEQ[0] > 1) and interlocks to remaining R10_ApplicationCode routine rungs and adding run sequence rungs as required. 4. Formulate and list your stop sequence steps. 5. Add your initial stop sequence step (StopSEQ[0] = 1) to the R10_ApplicationCode routine of your imported application module. 6. Add remaining stop sequence steps (1 < StopSEQ[0] < 999) and interlocks to remaining R10_ApplicationCode routine rungs and adding stop sequence rungs as required. 7. Add your final stop sequence step (StopSEQ[0] = 999) to the R10_ApplicationCode routine of your imported application module. 8. Determine any special reset logic requirements for your application and edit the R04_Reset routine in the application module. See Appendix B for more information on logic module customization. For other common application code requirements, not included in preprogrammed application modules or logic examples, see Appendix B.

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Safety Logic Integration There are different ways to provide a safety system for a CNC machining work cell. This toolkit provides an example of a supervisory GuardLogix safety controller that provides safety control for the two gantry drives, an EStop, a light curtain, and provides safety interlocking with the Dual Check Safety systems of the two CNC systems.

Safety I/O The safety interface between the GuardLogix controller and FANUC CNC Dual Check Safety systems is accomplished through the safety I/O of both systems. For safety category 3 and 4, two output channels and two input channels of GuardLogix I/O are connected to two input channels and two output channels of the Dual Check Safety I/O, as illustrated in Figure 18. Figure 18 - Safety I/O Example GuardLogix Safety Outputs

Dual Check Safety Inputs

GuardLogix Safety Inputs

Dual Check Safety Outputs

00

00

00

00

01

01

01

01

This wiring interface is included in the system layout and wiring library within this toolkit. Refer to the Dual Check I/O and 1791 Guard I/O drawings.


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GuardLogix Safety Logic The toolkit also provides example GuardLogix safety logic and associated FactoryTalk View ME safety faceplates. The example GuardLogix safety configuration and logic is in the CNC_Work_Cell_Logic_w_Safety.ACD file. The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\6-Project Examples\CNC-Work-Cell\. For this example, one SafetyPoint input module and one SafetyPoint output module is configured. The safety logic is located in the Zone1 safety routine within the Safety Task. The safety input and output logic is based on the example code provided in the Safety Accelerator Toolkit DVD, publication SAFETY-CL002. You may use this toolkit to streamline your safety wiring, logic, and HMI interface for your specific GuardLogix project.

The Zone1 routine includes safety input logic for an EStop push button, light curtain, and Dual Check Safety interlocks from the FANUC Drill and Machine CNC systems. The dual channel input stop instructions are used for all of the inputs, but are configured a bit differently. See the rung comments for configuration information for these examples: • Zone 1 Emergency Stop Example – Figure 19 on page 139 • Zone 1 Light Curtain Example – Figure 20 on page 140 • Zone 1 Dual Check Safety Drill CNC Example – Figure 21 on page 141 • Zone 1 Dual Check Safety Machine CNC Example – Figure 22 on page 142

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Figure 19 - Zone 1 Emergency Stop Example


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Figure 20 - Zone 1 Light Curtain Example

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Figure 21 - Zone 1 Dual Check Safety Drill CNC Example


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Figure 22 - Zone 1 Dual Check Safety Machine CNC Example

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The safety inputs are then interlocked with the safety outputs connected to Gantry_X and Gantry_Y drive safe-torque off inputs, and Drill_CNC and Machine_CNC Dual Check Safety inputs. The safety interlock, reset, output, and safety reset logic is also included. See Figure 23 on page 143 and Figure 24 on page 144 for an example of the safety outputs. Figure 23 - Safety Outputs Example


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Figure 24 - Safety Outputs Example (continued)

Safety Faceplate Logic In addition to the safety logic, the Safety Accelerator Toolkit DVD, publication SAFETY-CL002, includes safety I/O faceplates that allow you to view the status of the safety circuits and logic, and provides diagnostics for safety demands and faults. To communicate with these faceplates, preconfigured faceplate logic needs to be added to your project’s standard task. The example faceplate logic for the CNC Work Cell application example is found in the CNC_Work_Cell_Logic_w_Safety.ACD file. The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\6-Project Examples\CNC-Work-Cell\. The safety faceplate logic is based on the example code provided in the Safety Accelerator Toolkit DVD, publication SAFETY-CL002. Use this toolkit to streamline your safety wiring, logic, and HMI interface for your specific GuardLogix project. The faceplate logic was placed into a R03_Monitor routine of the P08_GuardIO_FP program. See Figure 25 on page 145 for an example of the logic. The faceplate logic includes a copy instruction rung, a Guard I/O AOI, safety reset rung, and fault reset rung for each Guard I/O module.

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Figure 25 - P08_GuardIO_FP Example

Refer to Configure Safety Faceplate Displays on page 193 to add Guard I/O faceplates to your project’s HMI.


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Verify and Save the Project File 1. On the RSLogix 5000 toolbar, click

to verify your controller.

This software function verifies your RSLogix 5000 controller programs and displays errors/warnings, if any. 2. Make corrections to programs as needed. 3. Click

to save your RSLogix 5000 project file.

After saving your application, you’ll want to download and test it. See Chapter 6 for downloading your application and system commissioning procedures.

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5

FactoryTalk View ME Configuration

In this chapter, you create the operator interface application file for your system by using FactoryTalk View Studio software. The toolkit includes preconfigured machine and device faceplate displays that provide status, control, and diagnostics for your supervisory PLC and CNC systems. Like the logic modules, the faceplate is designed to be used independently, or with other faceplates (from other toolkits) assembled together based on your specific application requirements.

Machine Startup Faceplate Display This display provides overall machine status and control. It may also be used as the main navigation display for access to the other device, Alarm History, and Equipment Status faceplate displays in your application.

Machine State Diagram Faceplate Display This display provides a graphical machine state status and is configured to fit within the middle section of the Startup display when launched from the State Diagram Goto display button. This display is sized for use with PanelView Plus 700, or larger, terminals.


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Figure 26 - Device Faceplate Display Example • The device faceplates are complex displays that provide status, control, and fault diagnostic views for a specific device. • The toolkit includes device faceplates for FANUC CNC devices. • This example shows specific views for the FANUC CNC faceplate.

CNC Control View

CNC Fault View

CNC Fault Help - Fault Action

148

CNC Configuration View

CNC Configuration Help


CNC Status View

CNC Status Help - Indicators


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Figure 27 - Device Faceplate Display Example (continued)

Alarm History Faceplate Display The Alarm History display provides time and date stamped machine and device faults and alarms. This display is sized for use in PanelView Plus 700 or larger terminals.

Equipment Status Faceplate Display This Equipment Status display provides a summary status of the devices in your system and a launch site for your individual device faceplate displays. This display is sized for use in PanelView Plus 700 or larger terminals.

Before You Begin • Complete your system architecture and hardware selection (refer to Chapter 1). • Complete your system layout and wiring (refer to Chapter 2). • Complete your FANUC CNC Configuration (refer to Chapter 3). • Complete your logic configuration (refer to Chapter 4).


contact your local Rockwell Automation distributor or sales representative. • FactoryTalk View Studio software, version 6.0 or later. • If Rockwell Automation Kinetix or PowerFlex Drives are used in the system, the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, can be used to significantly streamline FactoryTalk View ME configuration. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative.


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• If Rockwell Automation GuardLogix safety controller and safety components are used in the system, the

Safety Accelerator Toolkit DVD, publication SAFETY-CL002, can be used to significantly streamline FactoryTalk View ME configuration. For a copy of the DVD, contact your local Rockwell Automation distributor or sales representative. • The user manual for FactoryTalk View Studio, Volume 1. Refer to the FactoryTalk View Machine Edition User's Guide, publication VIEWME-UM004. • The user manual for FactoryTalk View Studio, Volume 2. Refer to the FactoryTalk View Machine Edition

User's Guide, publication VIEWME-UM005.

Follow These Steps This chapter provides two HMI application configuration options: • Designing from a preconfigured HMI application file • Designing from an existing HMI application file Complete these steps to create your Logix controller logic for your FANUC CNC application. Start

Design from a Preconfigured HMI Application File • Restore and Open a Preconfigured HMI Application • Delete Unused Displays • Delete Unused Parameter Files • Configure Parameter Files • Delete Unused Alarm Triggers and Tags

Yes

Are you creating a new HMI application file for your system?

No

page 162

page 151

Configure Goto Display Buttons on Startup Display page 177 Configure Equipment Status Faceplate Display page 185 Configure Safety Faceplate Displays page 193

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Design from an Existing HMI Application File • Open Your Existing HMI Application File and Add Displays • Add Parameter Files • Configure Parameter Files • Import Alarm Setup File • Delete Unused Alarm Triggers • Import and Edit Alarm Tags


Chapter 5

Design from a Preconfigured HMI Application File If you are creating a new HMI application file for your system, use this section to configure your application file. Using the preconfigured HMI application file is the most efficient way to create your application file. It includes all of the displays, parameter files, and Alarm Setup File tags and messages required for all faceplates and devices. If your existing HMI application file is not too extensive, it may still be more efficient to start from the preconfigured HMI application file and copy your existing application displays, parameter files, and alarm messages. Otherwise, follow the steps in Design from an Existing HMI Application File on page 162.

Restore and Open a Preconfigured HMI Application 1. Navigate to the HMI application files within the file folder of the toolkit and open either the PanelView Plus 1000 or PanelView Plus 600 folder, based on the terminal size and faceplate requirements of your application. IMPORTANT

The machine state diagram, alarm history faceplate, and equipment status faceplate are compatible with PanelView Plus 700 or larger terminals. To take full advantage of all faceplates, choose the PanelView Plus 1000 folder.

The file path is C:\Program Files\RA_Simplification\CMAT\A-Files\5-HMI\ME\HMI Applications.

For the CNC Work Cell application example, the PanelView Plus 1000 folder was selected.


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Application Folder

PanelView Plus Terminals Supported

Faceplates Displays

PVP600

PanelView Plus 400, PanelView Plus 600

Machine Startup Display, All Device Displays

PVP1000

PanelView Plus 700, PanelView Plus 1000, PanelView Plus 1250, (1) PanelView Plus 1500 (1)

Machine Startup Display, Machine State Diagram Display, All Device Displays, Alarm History Display Equipment Status Display

(1) The PanelView Plus 1000 Machine, Alarm History, and Equipment Status faceplate displays are sized at 640x480 (VGA) resolution. If full-sized displays are desired, open display, select all (objects), group, and resize group. Some text editing for new display size may also be required.

2. Double-click the PVPxxxx_Application.apa archive file. For the CNC Work Cell application example, the PVP1000_Application.apa file was opened. The Application Manager dialog box opens. 3. Verify the application archive to restore and that Restore the FactoryTalk View Machine Edition application is selected. IMPORTANT

Selecting Restore the FactoryTalk View Machine Edition application and FactoryTalk Local Directory causes the local security settings on your personal computer to substitute for the security setting from the preconfigured application.

4. Click Next. 5. Rename the application to match your machine name. For the CNC Work Cell application example, the application name is CNC_Work_Cell. 6. Click Finish.

7. From the Start menu, choose Programs > FactoryTalk View > FactoryTalk View Studio. The New/Open Machine Edition Application dialog box opens.

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8. From the Existing tab, select the application file that you just restored. For the CNC Work Cell application example, CNC_Work_Cell is selected. 9. Click Open.

The application opens in FactoryTalk View Studio software.


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Delete Unused Displays 1. Determine the required faceplates for your application based on the table below. TIP

Only one faceplate display is required for devices/modules of the same type.

Faceplate Display Name

Parameter File

Supported Devices/Modules

CIPMotion_Faceplate

CIPMotion_Parameter

Kinetix 6500 drives and PowerFlex 755 drive configured as CIP Motion drive

Fanuc_CNC_Faceplate

Fanuc_CNC_Parameter

Fanuc 30i B-Series CNCs

K300_Faceplate

K300_Parameter

Kinetix 300 drives

PowerFlex_4_40_400_Faceplate

PowerFlex 4, PowerFlex 40,and PowerFlex 400 drives

PowerFlex_40P_Faceplate

PowerFlex 40P drives

PowerFlex_70_700_Faceplate

PF_Parameter

PowerFlex 700S2 drives


PowerFlex 753 and PowerFlex 755 drives Not Required

PVP1000_EquipmentStatus_Faceplate EquipmentStatus_Parameter

All

PowerFlex 70EC and PowerFlex 700VC drives

PowerFlex_700S_700S2_Faceplate

PVP1000_AlarmHistory_Faceplate

Supported PanelView Plus Terminals

All devices


PVP1000_Startup_Faceplate

Startup_Parameter

Machine logic module

PVP1000_StateDiagram_Faceplate

StateDiagram_Parameter

Machine logic module (states)


Startup_Parameter



SERCOS_Faceplate

SERCOS_Parameter

Kinetix 2000, Kinetix 6000, Kinetix 6200, Kinetix 7000, and Ultra™ 3000-SE drives

All


For the CNC Work Cell example, use these display names: • PVP1000_AlarmHistory_Faceplate • PVP1000_EquipmentStatus_Faceplate • PVP1000_Startup_Faceplate • PVP1000_StateDiagram_Faceplate • Fanuc_CNC_Faceplate • CIPMotion_Faceplate

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2. Expand the Displays component under the Graphics folder. 3. Right-click displays not needed in your application and choose Delete. Confirm deleting each un-needed display by clicking Yes.

Delete Unused Parameter Files 1. Determine required parameter files for your application based on the table on page 154. 2. Expand the Parameters component under the Graphics folder. 3. Right-click Parameter files not needed in your application and choose Delete. For the CNC Work Cell example, the CIPMotion_Parameter file is deleted. 4. Confirm deleting each un-needed file by clicking Yes.


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Configure Parameter Files 1. Right-click a parameter file for a device in your application and choose Rename.

2. Rename the parameter file with the name of the corresponding device in your RSLogix 5000 application. If more than one device uses the same faceplate then another parameter of the same type must be duplicated and renamed. Refer to step 4 and step 5 on page 157. For the CNC Work Cell example, these are the parameter files. Base Parameter File Name Fanuc_CNC_Parameter

CIPMotion_Parameter

CNC Work Cell Parameter File Name Drill_CNC Machine_CNC Gantry_X_Axis Gantry_Y_Axis

EquipmentStatus_Parameter

EquipmmentStatus

Startup_Parameter

Startup


StateDiagram

3. Click OK.

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4. To create another parameter file based on an existing one, right-click the parameter file and choose Duplicate. For the CNC Work Cell application example, Drill_CNC and Machine_CNC use the same Fanuc_CNC_Faceplate, but require individual parameter files. For example, Drill_CNC is duplicated and renamed to Machine_CNC in step 5.

5. Rename the parameter file as needed for your application. 6. Click OK. 7. Repeat step 1…step 6 for each device or logic module parameter file. This is the completed CNC Work Cell renamed parameter file listing. 8. Assign the parameters in each of the parameter files. In each parameter file, there are references to controller links (shortcuts) or specific tag names. The ! before any text indicates that line is a comment and each parameter file contains instructions on how to configure it. The # before a number indicates a parameterized tag.

Comments

Parameters


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For example, in the CNC Work Cell Drill_CNC parameter file, parameter #1 contains the shortcut name [CLX]. This shortcut name matches the name created in your RSLinx Enterprise communication setup. Parameter #2 represents the tag name for the specific faceplate Add-On Instruction, within your RSLogix 5000 project, from which the faceplate requests data. The CNC Work Cell Drill_CNC parameter #2 is assigned to the faceplate Add-On Instruction tag named Drill_CNC_FP found in the R02_Monitor routine of the P04_Drill_CNC program.

a. Double-click the parameter file to open it.

b. Enter your application controller’s shortcut name in all parameters. TIP

Less editing is required when assigning HMI alarm tags if you name your controller shortcut [CLX]. Refer to Chapter 6 for configuring your controller shortcuts in RSLinx Enterprise communication setup.

c. Enter the associated faceplate Add-On Instruction tag name of the device or module for this faceplate parameter. d. Close parameter file and acknowledge the Save Changes dialog box. 9. Repeat step 8 for each of your device or module faceplate parameters.

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For the CNC Work Cell example, the parameters are edited as follows. CNC Work Cell Parameter File Drill_CNC

Machine_CNC

Gantry_X_Axis

Gantry_Y_Axis

Parameter File Configuration #1=::[CLX] #2=::[CLX]Drill_CNC_FP #1=::[CLX] #2=::[CLX]Machine_CNC_FP #1=::[CLX] #2=::[CLX]Gantry_X_Axis_FP #1=::[CLX] #2=::[CLX]Gantry_Y_Axis_FP #1=::[CLX]Drill_CNC_FP #2=::[CLX]Machine_CNC_FP #3=::[CLX]Gantry_X_Axis_FP #4=::[CLX]Gantry_Y_Axis_FP

EquipmentStatus

#5=::[CLX]Gantry_Y_Axis_FP #6=::[CLX]Gantry_Y_Axis_FP #7=::[CLX]Gantry_Y_Axis_FP #8=::[CLX]Gantry_Y_Axis_FP

The machining status faceplate requires that parameters are set for all rows #1…#9 even if they are not visible. Typically, the last visible row parameter is entered in the remaining parameters. For example, Gantry_Y_Axis_FP parameter entered for #5...#9. Refer to Configure Equipment Status Faceplate Display on page 185 for more information.

#9=::[CLX]Gantry_Y_Axis_FP Startup StateDiagram

#1=::[CLX] #2=::[CLX]CNC_Work_Cell #1=::[CLX]CNC_Work_Cell


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Delete Unused Alarm Triggers and Tags TIP

IMPORTANT

Deleting the alarm triggers for hardware devices not used in your application may improve performance of your PanelView Plus terminal communication. These steps must be completed if a machine module is not used in your RSLogix 5000 project.

1. Expand the Alarms folder. 2. Double-click Alarm Setup. The Alarm Setup dialog box opens.

3. Click the Triggers tab. 4. Select any unused alarm trigger tags from the Select trigger organizer. Unused trigger tags are any associated devices not configured in your RSLogix 5000 project. For the CNC Work Cell application example, these alarm triggers are used: • SafeIOAlarmTrigger • ModuleAlarmTrigger • CNCAlarmTrigger • CIPMotionAlarmTrigger So, all other trigger tags are removed. 5. Click Remove. 6. Repeat step 4 and step 5 for all unused trigger tags. 7. Click OK in the Alarm Setup dialog box to save edits.

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8. Expand the HMI Tags folder and double-click Tags. The HMI Tags editor appears in the workspace.

9. Select each of the xxxAlarmHandshake, xxxAlarmName, and xxxAlarmTrigger tags associated with each of the alarm triggers that were deleted in the previous steps. For example, the circled tags are the three tags you would delete if the E3AlarmTrigger had been deleted previously. 10. Click

to delete the tags.

11. Repeat step 8…step 10 for all unused alarm tags associated with unused alarm triggers.

TIP


12. Click Close to complete tag editing. TIP

Because you used the pre-configured HMI file instructions, you can skip Design from an Existing HMI Application File, and go directly to Configure Goto Display Buttons on Startup Display on page 177.


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Design from an Existing HMI Application File If your existing HMI application file is not too extensive, it may still be more efficient to start from the preconfigured HMI application file and copy your existing application displays, parameter files, and alarm messages. Refer to Design from a Preconfigured HMI Application File on page 151. Otherwise, follow the steps in this example to add the HMI components to your existing FactoryTalk View Machine Edition application file.

Open Your Existing HMI Application File and Add Displays 1. Determine the required faceplates for your application based on the table below. TIP

Only one faceplate display is required for devices/modules of the same type.

Faceplate Display Name

Parameter File

Supported Devices/Modules

CIPMotion_Faceplate

CIPMotion_Parameter

Kinetix 6500 drives and PowerFlex 755 drive configured as CIP Motion drive

Fanuc_CNC_Faceplate

Fanuc_CNC_Parameter

Fanuc 30i B-Series CNCs

K300_Faceplate

K300_Parameter

Kinetix 300 drives

PowerFlex_4_40_400_Faceplate

PowerFlex 4, PowerFlex 40,and PowerFlex 400 drives

PowerFlex_40P_Faceplate

PowerFlex 40P drives


PF_Parameter

PowerFlex 700S2 drives


PowerFlex 753 and PowerFlex 755 drives Not Required

PVP1000_EquipmentStatus_Faceplate EquipmentStatus_Parameter

All

PowerFlex 70EC and PowerFlex 700VC drives

PowerFlex_700S_700S2_Faceplate


Supported PanelView Plus Terminals

All devices



Startup_Parameter


PVP1000_StateDiagram_Faceplate


Machine logic module (states)


Startup_Parameter



SERCOS_Faceplate

SERCOS_Parameter

Kinetix 2000, Kinetix 6000, Kinetix 6200, Kinetix 7000, and Ultra3000-SE drives

All


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2. Launch your FactoryTalk View Studio software and open your existing application file. For this example, the InstantFizz_ME application file is opened. 3. Right-click Displays within Graphics folder and choose Add Component Into Application.

4. Navigate to the HMI Modules folder within the toolkit’s files folder. The file path is C:\Program Files\ RA_Simplification\CMAT\A-Files\ 5-HMI\ME\HMI Modules\ 01_Machine. 5. Select the folder representing the type of the first faceplate you want to add. For this example, the 01_Machine folder was selected for the PVP1000_Startup_Faceplate file.


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6. Select the faceplate display file you want to add. For this example, the PVP1000_Startup_Faceplate.gfx was selected 7. Click Open.

The selected display is added to the Displays folder. 8. Repeat step 3…step 7 for each faceplate required for your application. TIP

IMPORTANT

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Only one faceplate is required for multiple device/modules of the same type. For example, if your application has two FANUC CNCs requiring a faceplate, only one Fanuc_CNC_Faceplate.gfx display is required.

The CNC Machining Accelerator Toolkit does not include the specific CIP_Motion, SERCOS, Kinetix, or PowerFlex faceplate displays. Refer to the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, for access to these faceplates.



Chapter 5

Add Parameter Files 1. Determine required parameter files for your application. Refer to the faceplate displays table on page 162 for the parameter file required for each faceplate. 2. Right-click Parameters within the Graphics folder and choose Add Component Into Application.

3. Navigate to the HMI Modules folder within the toolkit’s files folder. The file path is C:\Program Files\ RA_Simplification\CMAT\A-Files\ 5-HMI\ME\HMI Modules\01_Machine. 4. Select the folder representing the type of the first parameter you want to add. For this example, the 01_Machine folder was selected for the Startup_Parameter supporting the PVP1000_Startup_Faceplate.

5. Select the parameter file you desire to add. For this example, Startup_Parameter.par was selected to support the PVP1000_Startup_Faceplate added earlier. 6. Click Open.


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The selected parameter is added to the Parameters folder. 7. Repeat step 2…step 6 for each parameter file required for your application. IMPORTANT

166

The CNC Machining Accelerator Toolkit does not include the specific CIP_Motion, SERCOS, Kinetix, or PowerFlex faceplate parameters. Refer to the Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, for access to these faceplate parameters.



Chapter 5

Configure Parameter Files In this example, you configure a parameter file for each device or logic module in your application supported by a faceplate. 1. Right-click a parameter file for a device in your application and choose Rename.

2. Rename the parameter file with the name of the corresponding device in your RSLogix 5000 application. If more than one device uses the same faceplate then another parameter of the same type must be duplicated and renamed. Refer to step 4 and step 5 on page 157. For the CNC Work Cell example, these are the parameter files. Base Parameter File Name Fanuc_CNC_Parameter

CIPMotion_Parameter

CNC Work Cell Parameter File Name Drill_CNC Machine_CNC Gantry_X_Axis Gantry_Y_Axis


EquipmentStatus

Startup_Parameter

Startup


StateDiagram

3. Click OK.


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4. To create another parameter file based on an existing one, right-click the parameter file and choose Duplicate. For the CNC Work Cell application example, Drill_CNC and Machine_CNC use the same Fanuc_CNC_Faceplate, but require individual parameter files. For example, Drill_CNC is duplicated and renamed to Machine_CNC in step 5.

5. Rename the parameter file as needed for your application. 6. Click OK. 7. Repeat step 1…step 6 for each device or logic module parameter file. This is the completed CNC_Work_Cell renamed parameter file listing. 8. Assign the parameters in each of the parameter files. In each parameter file, there are references to controller links (shortcuts) or specific tag names. The ! before any text indicates that line is a comment and each parameter file contains instructions on how to configure it. The # before a number indicates a parameterized tag.

Comments

Parameters

For example, in the CNC Work Cell Drill_CNC parameter file parameter #1 contains the shortcut name [CLX]. This shortcut name matches the name created in your RSLinx Enterprise communication setup. Parameter #2 represents the tag name for the specific faceplate Add-On Instruction, within your RSLogix 5000 project, which the faceplate requests data from.

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The CNC Work Cell Drill_CNC parameter #2 is assigned to the faceplate Add-On Instruction tag named Drill_CNC_FP found in the R02_Monitor routine of the P04_Drill_CNC program.

a. Double-click the parameter file to open it.

b. Enter your application controller’s shortcut name in all parameters. TIP


c. Enter the associated faceplate Add-On Instruction tag name of the device or module for this faceplate parameter. d. Close parameter file and acknowledge the Save Changes dialog box. 9. Repeat step 8 for each of your device or module faceplate parameters.


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For the CNC Work Cell example, the parameters are edited as follows. CNC Work Cell Parameter File Drill_CNC

Machine_CNC

Gantry_X_Axis

Gantry_Y_Axis

Parameter File Configuration #1=::[CLX] #2=::[CLX]Drill_CNC_FP #1=::[CLX] #2=::[CLX]Machine_CNC_FP #1=::[CLX] #2=::[CLX]Gantry_X_Axis_FP #1=::[CLX] #2=::[CLX]Gantry_Y_Axis_FP #1=::[CLX]Drill_CNC_FP #2=::[CLX]Machine_CNC_FP #3=::[CLX]Gantry_X_Axis_FP #4=::[CLX]Gantry_Y_Axis_FP

MachingStatus

#5=::[CLX]Gantry_Y_Axis_FP #6=::[CLX]Gantry_Y_Axis_FP #7=::[CLX]Gantry_Y_Axis_FP #8=::[CLX]Gantry_Y_Axis_FP

The machining status faceplate requires that parameters are set for all rows #1…9 even if they are not visible. Typically, the last visible row parameter is entered in the remaining parameters. For example, Gantry_Y_Axis_FP parameter entered for #5...9. Refer to Configure Equipment Status Faceplate Display on page 185 for more information.

#9=::[CLX]Gantry_Y_Axis_FP Startup StateDiagram

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#1=::[CLX] #2=::[CLX]CNC_Work_Cell #1=::[CLX]CNC_Work_Cell



Chapter 5

Import Alarm Setup File Importing the Alarm Setup File is optional and required only if you are using the alarm history faceplate in your application. IMPORTANT

When importing the Alarm Setup File, your existing alarm configuration is lost. When prompted to back up your existing alarm configuration, you can choose to save it as an XML file.

1. Right-click Alarm Setup within Alarms folder and choose Import and Export. The Alarm Import Export Wizard opens.

2. Select Import alarm configuration into application. 3. Click Next.

4. Select Yes, if you have an existing alarm configuration. 5. Click Next.

6. In the backup file name field, type a backup file name. 7. Click

to browse for the backup file destination.

8. Click Next.


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9. Navigate to the 03_Alarm_History folder within the toolkit’s files folder. The file path is C:\Program Files\ RA_Simplification\CMAT\A-Files\5-HMI\ ME\HMI Modules\03_Alarm_History. 10. Select the Alarms.xml file. 11. Click Open.

The Alarm Import Export Wizard opens. 12. Click Finish.

13. Expand the Alarms folder and double-click Alarm Setup to verify import.

The triggers listed within the Triggers tab appear as shown. 14. Click OK to close the Alarm Setup dialog box. 172



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Delete Unused Alarm Triggers IMPORTANT TIP

IMPORTANT

Deleting unused alarm triggers is optional and applies only if you have imported the Alarm Setup File in the last section. Deleting the alarm triggers for hardware devices not used in your application may improve performance of your PanelView Plus terminal communication. These steps must be completed if a machine module is not used in your RSLogix 5000 project.

1. Expand the Alarms folder. 2. Double-click Alarm Setup. The Alarm Setup dialog box opens.

3. Click the Triggers tab. 4. Select any unused alarm trigger tags from the Select trigger organizer. Unused trigger tags are any associated devices not configured in your RSLogix 5000 project. For the CNC Work Cell application example, these alarm triggers are used: • SaveIOAlarmTrigger • ModuleAlarmTrigger • CNCAlarmTrigger • CIPMotionAlarmTrigger So, all other trigger tags are removed. 5. Click Remove. 6. Repeat step 4 and step 5 for all unused trigger tags. 7. Click OK in the Alarm Setup dialog box to save edits.


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Import and Edit Alarm Tags Importing and editing alarm tags is optional and required only if you intend to use the alarm history faceplate in your application. 1. From the Tools menu, choose Tag Import and Export Wizard.

The Tag Import and Export Wizard dialog box opens. 2. From the Operation pull-down menu, choose Import FactoryTalk View tag CSV files. 3. Click Next.

4. Click to browse for your existing FactoryTalk View.med project file. 5. Click Next.

6. Click to browse for the 03_Alarm_History folder within the toolkit’s files folder. The file path is C:\Program Files\RA_Simplification\ CMAT\A-Files\5-HMI\ME\HMI Modules\ 03_Alarm_History. The Select FactoryTalk View Export File dialog box opens.

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7. Select AlarmHistory_Tags. 8. Click Open.

9. Verify selected file and click Next.

10. Select Skip existing (fastest) and click Next.

11. Click Finish to execute import. 12. Close database confirmation dialog box.


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13. Expand the HMI tags folder in the project Explorer™ tool and double-click Tags. The HMI Tags editor appears in the workspace. 14. Verify a number of alarm tags have been added to the HMI tags listing.

15. Select each of the xxxAlarmHandshake, xxxAlarmName, and xxxAlarmTrigger tags associated with each of the alarm triggers that were deleted in the previous section. For example, the circled tags are three tags you would delete if the E3AlarmTrigger had been deleted previously. 16. Click

to delete the tags.

17. Repeat step 15 and step 16 for all unused alarm tags associated with unused alarm triggers. 18. Click Close to complete tag editing.

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Configure Goto Display Buttons on Startup Display The Goto buttons on the main startup screen that are used for launching the FANUC CNC faceplates use a special Goto button that is different than standard device Goto buttons that are included in the startup screen. The CNC Goto buttons includes a CNC status multi-state indicator directly on the button. For the CNCs in your application you must replace the default device Goto buttons with the CNC Goto buttons. First you add the Goto button graphics and objects to your application. Then you place and associate the individual Goto display buttons to the appropriate faceplate and specific parameter file.

Add FANUC CNC Goto Buttons to Your Application 1. Right-click Display and choose Add Component Into Application.

2. Browse to C:\Program Files\RA_Simplification\ CMAT\A-Files\5-HMI\ME\HMI Modules\ 01_Machine\ME_GoToButtons. 3. Select the Goto_FanucCNC.gfx file and click Open. The selected display appears under Displays in your application.


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4. Open your existing system display.

5. Delete existing Device Goto buttons for each CNC in your system. For the CNC Work Cell application example, Device 1 and Device 2 Goto buttons were deleted.

6. Open the Goto_FanucCNC display and copy the CNC Module GotoDisplay button. 7. Open your system display.

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8. Right-click Display and choose Paste. 9. Repeat step 1…step 8 for each CNC module in your application.

Associate Each Button to a Faceplate and Parameter File 1. Click the copied Goto display button and from the View menu, choose Object Explorer.

2. In the Object Explorer tool, double-click the Goto display button to open the Goto Display Button Properties dialog box.


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3. On the General tab, click the browse button next to the Display field. 4. Select the desired faceplate display and click OK.

5. Click the browse button next to the Parameter file field. 6. Select the associated parameter file and click OK.

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7. Click the Label tab to configure the desired button caption text.

8. Type the new name in the Caption field. For the first label within the CNC Work Cell application example, Drill CNC was entered.


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9. Use the Object Explorer tool to open the multistate indicator for the Goto button.

10. Assign the expression for multistate indicator object caption by clicking the Connections tab on the Multistate Indicator Properties dialog box.

11. Click Exprn.

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12. Create the expression as shown. Replace CNCName_FP with the actual name of the CNC as defined in your PLC program for the CNC that this Goto display button represents. For the CNC Work Cell application example, the first CNC is the Drilling CNC, so the CNCName_FP was replaced with Drill_CNC_FP. This expression gets the state of the CNC, and displays it directly on the Goto button, causing the caption to blink when a fault code is present on the module, for example. 13. Click OK to save the properties. The display updates with button changes. For the CNC Work Cell application example, Device 1 Goto Button displays as Drill CNC. 14. Repeat step 1…step 13 for each CNC Goto display button that you require.

For the CNC Work Cell application example, two of the special Goto buttons were used for the CNCs. For the two Gantry X and Y buttons, the default Goto buttons are used. The following table describes how the Goto buttons are configured. Device Goto Display Button

Display Setting

Parameter Setting

Drill CNC

Fanuc_CNC_Faceplate

Drill_CNC

Machine CNC

Fanuc_CNC_Faceplate

Machine_CNC

Gantry X

CIPMotion_Faceplate

Gantry_X_Axis

Gantry Y

CIPMotion_Faceplate

Gantry_Y_Axis


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After you have copied all the objects you need for your display, you can delete the Goto display file from your application. 15. Right-click the file and choose Delete.

16. Select all unused Goto display buttons and delete. For the CNC Work Cell application example, Device 5 through Device 10 Goto Display buttons were selected and deleted.

17. Select the State Diagram, Alarm History, and Equipment Status Goto display buttons and verify their display settings or delete them if not required.

184

System Goto Display Button

Default Display

Default Parameter

State Diagram

PVPxxx_StateDiagram_Faceplate


Alarm History


None required

Equipment Status

PVP1000_EquipmentStatus_Faceplate




Chapter 5

Configure Equipment Status Faceplate Display The equipment status faceplate display provides a summary status of the devices in your system and another launch site for your individual device faceplates. IMPORTANT

This section is optional and necessary only if you intend to use the equipment status faceplate.

The equipment status faceplate files let you quickly load and configure a summary display of preconfigured status and diagnostic displays or faceplates for FactoryTalk View Machine Edition. The equipment status faceplate works in conjunction with individual device faceplates and provides a single summary display of all the device faceplates that may be configured for an application. You can configure up to nine device faceplates to run with the equipment status faceplate, and you can launch each device faceplate directly from the equipment status faceplate. Figure 28 - Example of Equipment Status Display Configured with Four Device Faceplates

You can launch these faceplates from the Goto buttons. (Drill CNC shown)


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Add the Equipment Status Faceplate Display 1. Right-click Displays within the Graphics folder and choose Add Component Into Application.

2. Navigate to the 04_Equipment_Status folder within the toolkit’s files folder. The file path is C:\Program Files\ RA_Simplification\CMAT\A-Files\ 5-HMI\ME\HMI Modules\ 04_Equipment_Status. 3. Select the PVP1000_EquipmentStatus_Faceplate.gfx file. 4. Click Open.

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Add the ME_Equipment_Parameter File 1. Right-click Parameters within the Graphics folder and choose Add Component Into Application.

2. Navigate to the 04_Equipment_Status folder within the toolkit’s files folder. The file path is C:\Program Files\ RA_Simplification\CMAT\A-Files\ 5-HMI\ME\HMI Modules\ 04_Equipment_Status. 3. Select the EquipmentStatus_Parameter.par file. 4. Click Open.

5. Verify the MachiningStatus_Parameter file appears under Parameters. 6. Double-click MachiningStatus_Parameter to open the parameter editor.

The MachiningStatus_Parameter dialog box opens.


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7. Assign device faceplate Add-On Instruction tags to all nine parameters.

Each parameter #1…#9 corresponds to the device Add-On Instruction tag name of each machining status faceplate Row #1…#9. You must assign the #1 parameter to a device faceplate Add-On Instruction that includes the Inp_NumRowsVis assignment that was configured in Chapter 4. The remaining parameters #2…#9 must be assigned to valid device faceplate Add-On Instruction tag names for the machining status faceplate to operate without errors, even if corresponding machining status faceplate rows are not being used or assigned to non-preconfigured devices. It is recommended to fill in the unused parameters with the last valid Add-On Instruction tag name. In the CNC Work Cell example we are only using four rows; therefore, parameter #1…#4 are assigned to the corresponding device Add-On Instruction tags that we display in rows #1…#4. The remaining parameters, #5…#9, are assigned to the #4 row device Add-On Instruction tag name, [CLX]Gantry_Y_Axis_FP, as a place holder for those faceplate objects in the non-visible rows #5…#9.

8. Close the MachiningStatus_Parameter dialog box and acknowledge the Save Changes dialog box.

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Configure Goto Buttons on the Equipment Status Faceplate 1. Expand Displays within the Graphics folder and double-click PVP1000_EquipmentStatus_Faceplate.

Goto Display Buttons

2. Right-click the display and choose Object Explorer. The Object Explorer dialog box opens. 3. Expand Row_Group_1 and double-click GotoDisplayButton_1.

The Goto Display Button Properties dialog box opens.


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4. Click


to browse the display faceplates.

The Component Browser opens. 5. Select the faceplate display to launch from the first row Goto display button. For the CNC Work Cell application example, the Fanuc_CNC_Faceplate is selected. 6. Click OK to close the Component Browser dialog box.

7. Click files.

to browse the parameter

The Component Browser opens. 8. Select the parameter associated with the display to be launched from the first row Goto display button. For the CNC Work Cell application example, the Drill_CNC parameter is selected. 9. Click OK to close the Component Browser dialog box. 10. Click OK to save your edits to the Goto Display Button Properties dialog box.

11. Repeat step 3…step 10 for each Goto Display Button used in the machining status faceplate. Unused buttons can remain on the display, but won’t be visible based on the Inp_NumRowsVis tag value set in Chapter 4.

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Configure Additional Device Value Columns Not all device faceplates used with the equipment status faceplate are configured to display four value fields. If unused value fields are needed, then additional logic will need to be added to the existing device Add-On Instruction to move the additional Add-On Instruction tag values to the corresponding Sts_Valuexx tags. In this example, preconfigured logic within a FANUC CNC faceplate Add-On Instruction is used to write values to Values 1, 2, 3, and 4. Simply remove or change these values by using the MOV instructions to move other values to Values 1, 2, 3, or 4 if desired.


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The same is true for the units displayed for each additional value field desired. You can write logic to move a string value to the SetValueXUnits tag in the Add-On Instruction, or you can set the default string for this tag by locating it in the local tags section of the Add-On Instruction as shown below.

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Configure Safety Faceplate Displays Use the instructions in this section if your project includes a Rockwell Automation GuardLogix safety controller and safety components, and you want to use the safety I/O faceplates that allow you to view the status of the safety circuits and logic, and provide you with diagnostics for safety demands and faults. This example shows a pre-configured GuardIO Goto display button that can launch the on-top display or faceplate for the particular Guard I/O module. The faceplate includes status and diagnostic views controlled by its own toolbar buttons. CellGuard1

To configure your Safety faceplate displays, follow the instructions in the Configure Your Guard I/O or SmartGuard 600 I/O Faceplates section of the Safety Accelerator Toolkit Quick Start, publication IASIMP-QS005. The Safety System Application Guide chapter of the Safety Accelerator Toolkit Quick Start will assist you in how to use the faceplates. You can access this quick start and all the preconfigured safety faceplates within the Safety Accelerator Toolkit DVD, publication SAFETY-CL002.


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Notes:

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Chapter

6

System Commissioning

In this chapter you download your Logix and PanelView Plus applications, prepare and tune your drive hardware, verify network communication, and verify general operator/program control.

Before You Begin • Complete your system architecture and hardware selection (refer to Chapter 1). • Complete your system layout and wiring (refer to Chapter 2). • Complete your FANUC CNC Configuration (refer to Chapter 3). • Complete your logic configuration (refer to Chapter 4). • Complete your FactoryTalk View Machine Edition configuration (refer to Chapter 5).

What You Need • The CNC Machining Accelerator Toolkit DVD, publication IASIMP-SP018. For a copy of the DVD, • • • •

contact your local Rockwell Automation distributor or sales representative. RSLogix 5000 software, version 20.0 or later. RSLinx Classic software, version 2.56 or later. FactoryTalk View Studio software, version 6.0 or later. FANUC LADDER III software, version 6.8 or later, and the publications listed here: – FANUC Series 30i/31i/32i/35i –MODEL B, EtherNet/IP Adapter function, publication [email protected]. – FANUC Series 30i/31i/32i/35i -MODEL B, FANUC Power Motion i -MODEL A EtherNet/IP Scanner function, publication [email protected].


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Follow These Steps Complete these steps to complete the commissioning process for your Supervisory and CNC application.

Start

Download Applications page 197 Commissioning Devices page 205 Commissioning Supervisory and CNC System page 206

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Download Applications This section provides general steps for downloading the RSLogix 5000 project to the controller, and downloading the FactoryTalk View project to the PanelView Plus terminal.

Download RSLogix 5000 Software Project File to the Logix Controller IMPORTANT

The download steps assume controller power and communication wiring is connected, controller power is applied and RSLinx communication driver is configured. See Appendix D for more information on these topics.

1. Open your RSLogix 5000 project file. 2. From the Communications menu, choose Who Active. The Who Active dialog box opens.

3. Browse to and select your Logix controller and click Set Project Path. 4. Verify the key switch on your controller module is in the REM (remote) position. 5. Click Download. The Download dialog box opens.


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6. Click Download. 7. From the Communications menu, choose Run mode to switch the controller to Run mode.

Configure and Download FactoryTalk Project to PanelView Plus Terminal IMPORTANT

These download steps assume PanelView Plus power and communication wiring is connected, PanelView Plus terminal power is applied.

Create a New RSLinx Enterprise Configuration In this example, we use RSLinx Enterprise software to configure communication between your personal computer and/or PanelView Plus terminal and your system’s Logix controller. 1. Open your HMI project file in FactoryTalk View Studio software.

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2. Expand RSLinx Enterprise and double-click Communication Setup. The Communication Setup window opens.

Configure Design (Local) Communication The local tab in Communication Setup window reflects the view of the topology from the RSLinx Enterprise server on the development computer. In this example, the development computer is configured to communicate with a L62S GuardLogix controller via the Ethernet network. 1. Expand your system’s Ethernet network. 2. Expand your system’s Ethernet module. 3. Expand your controller bus or backplane. 4. Select your system’s controller. In this example, the controller is a ControlLogix 1769-L63 controller. 5. Click Add. Rockwell Automation Publication IASIMP-QS034A-EN-P - October 2012

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A new device shortcut appears. 6. Name the shortcut. For this example, the shortcut is named CLX.

7. Select the new device shortcut and the controller. For this example, CLX shortcut and 1756-L62S controller is selected. 8. Click Apply. A verification dialog box appears showing that the shortcut was assigned to the design path. 9. Close the verification dialog box. The Apply button dims indicating the shortcut is attached to the path.

Configure Runtime (Target) Communication The Runtime (Target) tab displays the offline configuration from the perspective of the device that is running the application and comprises the topology that is loaded into a PanelView Plus or PanelView Plus CE terminal. In this example you copy the configuration from the Design (Local) tab to the Runtime (Target) tab.

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1. Click Copy from Design to Runtime. This RSLinx Enterprise dialog box opens.

2. Click Yes. 3. Click Verify to make sure communication is setup correctly.

The Shortcut Verifier dialog box opens. 4. Verify that the path to the Design device and the Runtime device are assigned. 5. Click Close. 6. Click OK to save the configuration.

Create Your FactoryTalk View Runtime Application File In this example you create a runtime file for downloading to a PanelView Plus terminal. 1. From the Application menu, choose Create Runtime Application. The Create Runtime Application dialog box opens.


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2. From the Save as type pull-down menu, choose Runtime 6.0 Application (*.mer). 3. Enter a file name for the application. For the CNC Work Cell application example, the file name is CNC_Work_Cell.mer. 4. Click Save. The Runtime application (*.mer) file is created. This may take a few minutes.

Download Runtime File to PanelView Plus Terminal 1. Open FactoryTalk View Studio Machine Edition software. 2. From the Tools menu, choose Transfer Utility. The Transfer Utility window opens.

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3. Click and browse to the runtime file.

The Select File to Download dialog box opens. 4. Select the runtime file you created earlier. For the CNC Work Cell application example, CNC_Work_Cell is selected. 5. Click Open.


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6. Select the PanelView Plus terminal. 7. Click Download. The file transfers to the PanelView Plus terminal. 8. Click OK when transfer is complete and prompted to do so. 9. Click Exit, to close the Transfer Utility window. 10. From the File menu, choose Exit to close FactoryTalk View software.

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Commissioning Devices This section provides general procedures for preparing and verifying the function of the CIP Motion, sercos, PowerFlex drives, and FANUC CNCs. IMPORTANT

These commissioning procedures assume that CNC or drive power and communication wiring is connected and a personal computer with RSLogix 5000 software and internet browser is available.

Commissioning CIP Motion Drives Refer to Drive and Motion Accelerator Toolkit, publication IASIMP-QS019.

Commissioning sercos Drives Refer to Drive and Motion Accelerator Toolkit, publication IASIMP-QS019.

Commissioning PowerFlex 7-class Drives Refer to Drive and Motion Accelerator Toolkit, publication IASIMP-QS019.

Commissioning PowerFlex 4-class Drives Refer to Drive and Motion Accelerator Toolkit, publication IASIMP-QS019.

Commissioning Kinetix 300 Drives Refer to Drive and Motion Accelerator Toolkit, publication IASIMP-QS019.


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Commissioning Supervisory and CNC System This section provides general procedures for verifying the function of a completed CNC Machining Accelerator Toolkit system. IMPORTANT

These commissioning procedures assume all applications are downloaded, all system devices are commissioned, a personal computer with RSLogix 5000 software is available, and a PanelView Plus terminal is powered and connected to the system’s EtherNet/IP network.

Verify Network Communication Verify network communication between HMI terminal, Logix controller, and devices.

HMI Terminal to Logix Controller Communication To determine if communication is lost between the HMI terminal and Logix controller, look for the following: • Error messages on the diagnostic display • Wireframes on the display If there are communication problems with the controller, the diagnostic display lists messages (for example, CIP Connection Error). If the HMI terminal can communicate with the controller, but it cannot read/write specific tags, the diagnostic display lists similar messages (for example, Error Writing to xxxxx_Tag ). The HMI terminal displays wireframes and ????? on objects with tags it cannot read from the controller.

These are a few of the most common problems: • Hardware problem such as a Ethernet cable disconnected. • Communication path not properly configured in FactoryTalk View software, Communication Setup. • Tag names in the parameter files not matching the tag names in the controller.

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Controller to Device Communication Verify controller to device communication by observing the indicators on the controller’s communication module and the devices in the controller’s I/O tree. 1. Observe the controller’s communication module. Refer to the user manual for the specific module you are using. 1756-EN2TR EtherNet/IP Module

Status Indicator

Status

OK

Solid green

LNK1

Flashing green (indicates network activity)

LNK2

Off (flashing green if in a Device Level Ring configuration)

LNK1 LNK2 OK

2. Open your RSLogix 5000 project, go online with the controller, and observe the devices in the I/O tree. A device with a yellow exclamation mark (!) indicates a fault. The fault could be a configuration fault, a device fault, or a communication fault. View the quick pane in the Controller Organizer to determine fault.

3. From the HMI, open the faceplate for the individual CNC Device. Verify that the Comms. Ok status is green. The controller is monitoring a heart beat signal being produced by the CNC. As long as the controller detects a continuing transition, the status remains green; otherwise, the status is red.


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CNC to Controller Communication Verify CNC to controller communication by observing the indicators on the CNC’s EtherNet/IP communication module, and status from the CNC front panel display. Observe the CNC’s communication module. Refer to the user manual for the specific model, and module location for your application.

Typically the fast Ethernet board (that supports EtherNet/IP) resides in slot 2. The board is shown rotated 90 degrees counterclockwise, in order to expose the status indicators. This board is vertical in slot 2, and you will have to view the status indicators at an angle to determine their status. The board incorporates four status indicators.

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The locations and meanings of the status indicators are indicated below.

Table 7 - Ethernet Module Status Indicators Indicator

HER

LCOM

STATUS

COL

Status

Description

Off

Normal operation

Solid red

Error detected in the hardware

Flashing red

Error detected in the software

Off

Not connected

Solid yellow

Connected

Flashing yellow

Connected, and transmitting / receiving

Flashing green

Normal operation

Solid green

Power is on, board is stopped

Off

Power is off

Off

Normal operation

Solid red

Collision occurred, or noise

Flashing red

Collision occurred

For further validation of the Ethernet communication status, the fast Ethernet card can also be monitored by using the CNC front panel display. 1. From the MDI Panel of the CNC, press the

key.


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2. Press either the + softkey or the right arrow function key to advance to the Chapter selection for the Ethernet network. The Chapter Selection screen to display the fast Ethernet options is displayed.

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3. Press the ETHERNET softkey to monitor the communication state of the fast Ethernet board.

• If there is an active

connection to the board, the current Baudrate is displayed, as well as the packet status. • If there is no connection, the Baudrate is displayed as - - - - - - , and the packet information is zero.


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Clearing Faults After all the devices are connected and functioning on the network, clear faults to put the machine in a Stopped state.

HMI Clear Faults When the controller powers-up and the program goes into Run mode, the machine is faulted and in the Aborted state. See Appendix A for more information on the logic program modules. You can attempt to clear the machine faults by pressing the Clear Faults push button on the HMI terminal. If there are no faults, the machine state goes to Stopped. See Chapter 5 for more information on the HMI application programming.

HMI Test Faults Test the functionality of the state machine, device modules, and fault handling by simulating faults. By creating a fault, the machine state goes to an Aborted state and a fault is logged on the HMI Alarm History faceplate. Try creating a fault for each of the device modules in the system. You can create a fault by unplugging an encoder cable or communication cable on a drive or servo. Verify that the machine goes to the Aborted state. After each fault, correct the simulated fault and verify that you can clear the faults. The machine goes to the Stopped state after the faults are cleared. See Chapter 7 for more information on the faceplate fault diagnostic views.

Operator (manual) Control Before attempting to run the machine in automatic, manually trigger a cycle start on a CNC. With the faults cleared and the machine state in Stopped mode, put the machine in Operator mode. You can select each of the CNCs to manually send different commands. Test the Cycle Start/Stop mode, Feed Hold, and so on of each device. IMPORTANT

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Be sure the CNC machining cell selected for testing is safe, and ready to receive the specific commands (machine damage, or bodily injury could occur).



Chapter 6

Open one of the device faceplates. While in Operator mode, you are able to manually command the CNC. IMPORTANT

Triggering and entering Operator mode from a CNC faceplate will also command the machine to enter Operator mode.

See Chapter 7 for more information on how device control buttons function.

Program (automatic) Control With the faults cleared and the machine state in Stopped mode, you can put the machine in Program mode. By pressing the Start push button on the machine faceplate, the controller runs the machine according to the application program. IMPORTANT

Provide safety and protect against machine damage by stepping through a planned start-up procedure.

Machine Status

Machine Control


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Notes:

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7

System Application Guide

This chapter guides you through the pre-configured FactoryTalk View Machine Edition application faceplates providing you with an understanding of the status, control, and diagnostic operation of the faceplate displays.

Before You Begin • Complete your system architecture and hardware selection (refer to Chapter 1). • Complete your system layout and wiring (refer to Chapter 2). • Complete your FANUC CNC Configuration (refer to Chapter 3). • Complete your logic configuration (refer to Chapter 4). • Complete your FactoryTalk View Machine Edition configuration (refer to Chapter 5) • Complete your system commissioning (refer to Chapter 6).


contact your local Rockwell Automation distributor or sales representative. • Hardware installation and wiring complete with power applied. • Logix application file downloaded to the ControlLogix or CompactLogix controller. Controller set to run. • FactoryTalk View ME runtime application file downloaded to the PanelView Plus terminal. Run Application activated on terminal.


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Follow These Steps Complete these display overview steps to run the preconfigured application and gain an understanding of the FANUC CNC system operation. Start

Machine Startup Faceplate page 217

CNC Faceplate page 221

Motion Drive and/or PowerFlex Drive Faceplates page 226

Equipment Status Display Overview page 226

Alarm History Display Overview page 228

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Machine Startup Faceplate The machine startup faceplate display provides general machine status and control. It is also configured as the main navigation display for access to the other devices, the alarm history faceplate display, and the equipment status faceplate display.

Machine Status The Machine Status indicators (OK and FAULTED) provide general machine status (refer to the figure below). The specific indicator functions are included in the Machine Status Indicators table on page 218. In this example, there are five Goto display buttons configured. There is one Goto display button for each of the two CNCs, the State Diagram, the Equipment Status display, and the Alarm History display. Pressing any of the Goto display buttons launch the associated display. IMPORTANT

If the Machine Startup display is not visible or errors are reported on either the Logix controller or PanelView Plus terminal, refer to previous chapters to check system wiring and configuration settings.

Machine Status Indicators OK Status

Machine Status Indicators Faulted Status

Abort Status Indicator

Machine Control Buttons

Drive Goto Display Buttons

System Goto Display Buttons


Exit HMI Application Button

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Table 8 - Machine Status Indicators Status Indicator

Color/Value

Description

OK

Green

No machine faults detected.

Faulted

Red

Machine fault detected.

Power Up Module Not Ready Module Fault Abort Status

Failed to RESET

Displays additional diagnostic information for machine ABORT condition.

Failed to START Failed to STOP Failed to CLEAR Ready

Safe Speed

Green

Machine is ready to run. By default, the machine is in one of the following states: IDLE, STARTING or RUNNING

Gray

Machine is not ready to run.

Green

Safe speed condition is currently active in at least one device module.

Gray

Safe speed condition is not currently active.

ABORTING ABORTED CLEARING RESETTING State

IDLE

Displays the current machine state.

STARTING RUNNING STOPPING STOPPED

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Machine Control The Machine control buttons provide Operator Start, Stop, and Mode control. Machine Control Buttons

Program/Operator Mode In this example you start and stop the CNC/motion system in Program control mode. 1. Press the Operator control mode button so that Program is displayed. Program is now the active mode. 2. Press Start. The required axes and drives are enabled and homed. The machine state goes to IDLE. 3. Press Start (again). The required axes enable and begin operating according to the Logix program. When the system is running, Start appears dimmed. The machine state goes to RUNNING. 4. Press Stop. The system stops. IMPORTANT

The machine must be in a stopped state to switch modes.

5. Press the Control mode button until Operator is displayed in the Control field. In Operator control, you can use one of the faceplate displays to manually control one of the drives. Control Button

Button Function

Program/Operator

Toggles the control mode between Program and Operator. Operator mode permits manual control of the drives from the faceplate. Program mode operates the drive according to the Logix program. The active control mode is displayed on the button. If control mode is switched from Program to Operator while the machine is RUNNING, the machine is STOPPED.

Start

When in Program control mode, pressing Start will RESET the machine and place it into IDLE. The Start button is disabled when in Operator control mode. Pressing START when the machine is in IDLE places it into RUNNING.

Stop

When in Program control mode, pressing Stop brings the machine to a controlled stop. The machine must be stopped before you can switch to the other mode.

Clear Faults

The Clear Faults button attempts to clear faults on all axes. The condition that caused the fault must be corrected, otherwise the machine will remain in ABORTED.

IMPORTANT

Start and Stop buttons on your PanelView Plus terminal do not replace a hardwired start/stop control circuit for safety purposes. Your system must also include an emergency start/stop control circuit.


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State Diagram Faceplate Display This display provides a graphical machine state status and is configured to fit within the middle section of the Machine Startup display when launched from the State Diagram Goto display button.

White state indicator (oval) = Inactive machine state.

Green state indicator (oval) = Current machine state.

Gray state indicator (oval) = Previous machine state.

The State Diagram faceplate provides a quick reference for machine operators summarizing the relationship between machine states. Refer to Appendix A for more information on the individual states.

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CNC Faceplate The FANUC CNC faceplate is typically launched from the Machine Startup or Equipment Status faceplate’s corresponding Goto display buttons.

Home View Close Button

Title Bar Faceplate Toolbar

CNC Information

Table 9 - Faceplate Toolbar Buttons Function Button

Icons

Description

Function Button

Icons

Description

Alarm

The Alarm button indicates a drive fault condition and activates fault diagnostic views. A gray bell indicates normal status, with no faults. A yellow flashing bell indicates a fault condition.

CNC Control

From the CNC Control display you can home, start/stop cycle, disable, reset a CNC fault/alarm, unload the machine, change tools, gage parts, and more.

Configuration

The Configuration button lets you edit the faceplate name or name of the device.

Help

The Help button provides information for the existing view.

CNC Status

From the CNC Status display you can view general CNC status.

Close

Click the Close button to close the faceplate.


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CNC Status Views The CNC Status views let you display general CNC status: • Green = ON state • Gray = OFF state

TIP

The Comms. Ok indicator is red when inactive, instead of gray. Also, some other indicators also have a red state, such the Axis Fault.

CNC Control Views The Control Tab gives the general status of the CNC, and shows the available control buttons. The control buttons are unavailable when in Program mode, and available when in Operator mode.

Program Mode

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Table 10 - General Status/Control Buttons Conditions Required for Each Manual Control Button

Button/Indicator

Description

Program/Operator

Toggles the control mode between Program and Operator mode. Operator mode permits manual control of the drive from the faceplate. Program mode operates the drive according to the Logix program. The active control mode is displayed on the button.

Cycle Start/Cycle Stop

Toggles the drive between the start and stop states. The active state of the drive is displayed on the button.

CLR Alarms

Sends command to CNC to clear any active CNC alarms.

CLR Faults

Sends command to CNC to clear any active CNC faults.

Home

Commands the CNC to go to it's HOME position.

Block Delete

Sends the BLOCK DELETE command to the CNC.

Optional Stop

Sends the OPTIONAL STOP command to the CNC.

Feed Hold

Puts the CNC into FEED HOLD.

Unload Mch.

Sends the UNLOAD MACHINE command to the CNC, and sets commands the CNC back to it's RETURNED position.

Gage Part

Sends the GAGE PART command to the CNC.

E. Return

Sends the EMERGENCY RETURN command to the CNC, HOMING and RETURNING the axis.

Tool Change

Sends the TOOL CHANGE command to the CNC.

Machine cannot be in the STARTING or RUNNING state

Operator mode

Fault Indication View The Alarm button indicates a CNC fault condition and activates the fault diagnostic views.

Close Button Flashing Fault Indicator Alarm Indicator Current Fault Indicators

General Status Indicators

Table 11 - Fault Indication View Toolbar Button Alarm

Color Indicator

Description

Action

Gray

Normal state

None

Flashing yellow

Fault

Follow fault action screen

To access the detailed fault information and action displays, press the alarm button on the toolbar.


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Fault Diagnostic Views Figure 29 - Last Fault View

Help Button Press Help to go to Fault Description views. The Last Fault view is displayed when you press Alarm. The specific error being reported by the module is indicated.

Figure 30 - Fault Description View

Fault Actions View

Press arrows to toggle between display views.

This diagnostic information is triggered by the reported module error code. The input and output error code information provided is in accordance with the fault descriptions and actions found in the drive specific user manual.

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Configuration View The configuration button enabled.

Program Mode TIP

takes you to a display to edit the various CNC settings if Operator mode is

Operator Mode

In Program mode, the fields are not editable. However, in Operator mode, the values can be changed.

You can enter Part Program, Tool Number, and Toggle CNC Edit mode. Some of the fields here are also used on the Equipment Status faceplate. Pressing any of the name or device descriptions launches an numeric keypad for value entry. Press Enter on the keypad to complete the editing.


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Online Help Views Press the Help button on any view to access the online help information.

Online Help Example

Motion Drive and/or PowerFlex Drive Faceplates For motion drive and/or PowerFlex drive faceplates, refer to the System Application Guide chapter of the Drives and Motion Accelerator Toolkit Quick Start, publication IASIMP-QS019.

Guard I/O Safety Faceplates For Guard I/O safety faceplates, refer to Safety System Application Guide chapter of the Safety Accelerator Toolkit Quick Start, publication IASIMP-QS005.

Equipment Status Display Overview The Equipment Status faceplate files let you quickly load and configure a summary display of preconfigured status and diagnostic displays or faceplates for FactoryTalk View Machine Edition. The Equipment Status faceplate works in conjunction with individual device faceplates and provides a single summary display of all the faceplates that may be configured for an application. You can configure up to nine device faceplates to run with the Equipment Status faceplate and you can launch each device faceplate directly from it. In this example, the CNCs from the CNC Work Cell application example were added to the Equipment Status display. Click the device buttons to open the associated device faceplates.

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Figure 31 - Equipment Status Example - CNC Work Cell CNCs


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Alarm History Display Overview The Alarm History display provides time and date stamped machine and device faults, and alarms when launched from the Alarm History Goto display button on the Machine Startup faceplate display. Figure 32 - Alarm History Faceplate Display Example

In this example, a number of faults or alarms are displayed from a CNC named Drill CNC. Refer to FactoryTalk View Machine Edition User Manual Volume 1, publication VIEWME-UM004 for Alarm History alarm button operation and configuration.

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Appendix

A

Logic Program Overview

The CNC Machining Accelerator Toolkit DVD, publication IASIMP-SP018, was developed around a modular concept. Modularity lets you decide which components to incorporate into your machine, providing greater flexibility and a custom fit. The preconfigured logic is specifically designed around this modular concept and consists of three main logic modules. Table 12 - Logic Module Overview Logic Module Type

Function

Machine

The machine module contains the high level control for the entire machine. The machine module was built around a simple state machine that you can customize to fit most applications. The machine module broadcasts out commands and receives feedback information from each of the application and device modules. Based on the feedback information, the machine will react accordingly. In addition, the machine module provides a high level interface with the HMI, accepting commands like Start, Stop, and Clear Faults. It provides status info to the HMI terminal like current state of the machine (for example, RUNNING versus STOPPED).

Application

The application modules contain all of the application specific code. This is where a majority of the customizing is expected to occur and is essentially a programming space where you spend a significant portion of your efforts to develop proprietary logic specific to your application.

Device

Device modules contain all of the logic to control the essential functions required by the device. For example, an integrated motion servo drive like the Kinetix 6500 requires logic (MSO/MSF instructions) to enable and/or disable the servo drive. This logic reduces the programming effort required by most applications providing more time for the proprietary logic needed for the application. Typically, the device module consists of a physical drive, but could also consist of a virtual or feedback-only axis. Device modules can also consist of multiple devices (for example, a drive) and perhaps a feedback device (for example, a sensor).


229

Appendix A


Machine/Application/Device Module Relationship The machine module monitors the current state of the overall machine and based on the state and/or requests from the HMI terminal, broadcasts commands to both the application and device modules. The individual modules perform a predefined task based on the command. Some of the commands may be ignored depending on the module type. HMI Application Controller Logic PanelView Plus Terminal Machine Status

Machine Faceplate

Machine Module Device Faceplates

Machine Commands

Application Status Operator Commands

Application Modules

Device Commands

Device Status

Device Modules

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Each of the modules are defined as individual programs in the Logix Project. Each program contains all of the necessary logic to interact with the other configured modules. This interface between each of the modules is accomplished via the monitor and control routines in each of the programs. The machine commands and corresponding module status is routed through the monitor and control routines. This lets the modules operate independently in a modular structure.

Appendix A

Machine Module

Monitor and Control Routines

Application Module

Device Modules

Module Routine Overview Each module is broken down into routines that contain logic for a specific function. Each module contains a monitor and control routine that provides a common interface between the machine and the application/device modules. Each of the routines main functions are listed below. Figure 33 - Module Routine Listing Examples


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Appendix A


Table 13 - Module Routine Overview Logic Module Type

Machine

Application

Routine

Function

R00_Main

Dispatch routine, calls all of the other routines in the program.

R01_PowerUp

Initializes parameters following powerup or controller first scan.

R02_Monitor

• Summarizes the status from all of the dependent modules (for example, application and device modules). • Detects Abort and/or Stop conditions. • Provides machine status information to HMI terminal.

R03_Control

• Provides main interface with HMI terminal requests (for example, Start/Stop/Clear Faults pushbuttons). • Contains the state machine logic.

R00_Main


R01_PowerUp


R02_Monitor

• Summarizes the status for the application module (for example, OK, Ready, Running, Stopped). • Detects module faults (for example, Failed to RESET, Failed to RUN).

R03_Control

Receives machine commands and initiates the corresponding sequences (for example, RESET, RUN and STOP sequences).

R04_Reset

Contains the RESET sequence logic, used to prepare the application to run.

R10_ApplicationCode

• Typical location for the application specific logic. • Contains the RUN and STOP sequences.

R00_Main


R01_PowerUP


R02_Monitor

• Summarizes the status for the device module (for example, OK, Ready, Reset). • Detects module faults (for example, Failed to RESET, Failed to CLEAR, Module Not Ready). • Contains the faceplate add-on instruction (Add-On Instruction) for the HMI terminal faceplate.

R03_Control

Receives machine commands and initiates the corresponding sequences (for example, RESET and ABORT sequences).

R04_Reset_Abort

• Contains place holder for application specific reset logic if required. • Contains the ABORT sequence, which makes sure that the drives contained within the module are stopped and disabled. The ABORT sequence also makes sure that other devices are placed into a desired state.

R00_Main


R01_PowerUP


R02_Monitor


R03_Control

Receives machine commands and initiates the corresponding sequences (for example, RESET and ABORT sequences).

R04_Reset_Abort

• Contains place holder for application specific reset logic if required. • Contains the ABORT sequence that makes sure that the drives contained within the module are stopped and disabled. The ABORT sequence also makes sure that other devices are placed into a desired state.

FANUC CNC

PowerFlex

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Appendix A

Table 13 - Module Routine Overview (Continued) Logic Module Type

Routine

Function

R00_Main


R01_PowerUP


R02_Monitor


R03_Control

Receives machine commands and initiates the corresponding sequences (for example, RESET and ABORT sequences)

R04_Reset_Abort

• Contains the RESET sequence logic, used to prepare the application to run. • Contains the ABORT sequence that makes sure that the drives contained within the module are stopped and disabled. The ABORT sequence also makes sure that other devices are placed into a desired state.

R06_Messaging

Contains all of the explicit messaging logic required for the Kinetix 300 drive.

R10_EnableDisable

Contains the enable, disable, clear faults logic for the Kinetix 300 drive.

R11_OperatorMode

Contains the Operator or Manual mode logic for the Kinetix 300 drive. This logic is initiated via requests made from drive faceplate on the HMI terminal.

R00_Main


R01_PowerUP


R02_Monitor


R03_Control

Receives machine commands and initiates the corresponding sequences (for example, RESET and ABORT sequences)

R04_Reset_Abort

• Contains the RESET sequence logic, used to prepare the application to run. • Contains the ABORT sequence that makes sure that the drives contained within the module are stopped and disabled. The ABORT sequence can also make sure that other devices are placed into a desired state.

R10_EnableDisable

Contains the enable, disable, clear faults logic for the drives.

R11_OperatorMode

Contains the Operator or Manual mode logic for the drive. This logic is initiated via requests made from drive faceplate on the HMI terminal.

Kinetix 300

sercos or CIP Motion


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Appendix A


Machine Module The machine module contains the high level control for the entire machine. The machine module was built around a simple state machine that you can customize to fit most applications. The machine module broadcasts out commands and receives feedback information from each of the application and device modules. Based on the feedback information, the machine will react accordingly. In addition, the machine module provides a high level interface with the HMI, accepting commands like Start, Stop, and Clear Faults. It provides status info to the HMI terminal like current state of the machine (for example, RUNNING versus STOPPED).

Machine States By default, the machine program module operates based on this overall state diagram. Figure 34 - Machine State Diagram

The machine can go from any state in the shaded box to STOPPING.

RESETTING

IDLE (enabled)

START

STARTING

RUNNING

STOP ABORT STOPPING

The machine can go from any state in the solid box to Aborting.

ABORTING

RESET

STOPPED (disabled)

Transitional State

Permanent State

CLEARING

CLEAR

ABORTED

Machine Command

The machine module uses the transitional states to move between permanent states. Typically, the machine only remains on a transitional state for brief period of time. If the machine module detects an error during a transitional state or if the application or device modules fail to transition within an allotted time (10 seconds by default), the machine module issues an ABORT command. The fail safe transition timer makes sure the overall machine does not become stuck in a transitional state. It also helps to provide diagnostic information to determine which module is not transitioning properly. 234



Appendix A

You can fully customize the state machine, letting you change the relationship between states and the state names, and add or remove states if needed. Refer to Appendix B for information on how to customize the state machine. Table 14 - Default Machine States Machine State

State Type

Description

ABORTING

Transitional

Broadcasts the ABORT command until confirmation that all of the application and device modules are aborted. The ABORTING state is triggered based on feedback from the modules. Default ABORT conditions that place the machine in the ABORTTING state includes the following: • Powerup detected (for example, controller first scan) • Modules not ready while the machine is in STARTING and/or RUNNING states • Modules detected a fault condition • Modules failed to RESET • Modules failed to START • Modules failed to STOP • Modules failed to CLEAR

ABORTED

Permanent

All application and device modules are aborted (for example, stopped and disabled). Typically, this state indicates a fault condition.

CLEARING

Transitional

Broadcasts the CLEAR command until confirmation that all of the application and device modules are ok (for example, all active drive and/or modules have been cleared) within the allotted time. Otherwise, an ABORT condition is generated. Once all of the modules are ok, the machine is placed into the STOPPED state.

RESETTING

Transitional

Broadcasts the RESET command until confirmation that all of the application and device modules are reset within the allotted time. Otherwise, an ABORT condition is generated.

IDLE

Permanent

All application and device modules are reset or ready to run (for example, enabled or homed). Typically, this state that the machine is ready to run and awaits a START command.

STARTING

Transitional

Broadcasts the RESET command until confirmation that all of the application modules are running within the allotted time. Otherwise, an ABORT condition is generated.

RUNNING

Permanent

All application modules are running.

STOPPING

Transitional

Broadcasts the STOP command until confirmation that all of the application modules are stopped within the allotted time. Otherwise, an ABORT condition is generated.

STOPPED

Permanent

All application modules are stopped and all modules (application and/or device) are ready.

Table 15 - Default Machine Commands Machine Command

Application Module Response

Device Module Response

ABORT

Halts the application RUN sequence (if active) and initiates the STOP sequence. The STOP sequence attempts to stop and disable all active drives.

Halts the device module RESET sequence (if active) and initiates the device module ABORT sequence. The ABORT sequence makes sure the drives contained within the module are stopped and disabled. The ABORT sequence can also be used to make sure other devices are placed into a desired state.

CLEAR

Attempts to clear any active faults that exist in the modules.

Attempts to clear any active faults that exist in either the module and/or drive.

RESET

Initiates the application RESET sequence, which prepares the application and/or devices to run. Use this for the coordinated reset of multiple modules.

Initiates the device module RESET sequence, which prepares the device module to run.

START

Initiates the application RUN sequence. Customize the RUN sequence to fit the needs of your application.

Ignored (1)

STOP

Halts the application RUN sequence (if active) and initiates the STOP sequence. The STOP sequence attempts to stop and disable all active drives.

Halts the device module RESET sequence.

(1) By default, these commands are ignored by the module. However, you can change the relationship of each module to best fit the needs of the application.


235

Appendix A


Machine Control Module Tags The machine control data type, UDT_MachCtrl, comprises the overall machine control and status, including the state machine. The user-defined data type consists of these components.

Machine Mode

Machine Commands

Current Machine State

Previous Machine State Machine State Display Machine Status

Table 16 - Machine Tags Tag Group

Function

Machine mode

Additional modes can be added to the machine. By default, these are the included modes: • OPERATOR or Manual mode • PROGRAM or Auto mode

Machine commands

Broadcast machine commands that direct all of the dependent modules (for example, application and device modules).

Current machine state

Indicates the current state of the overall machine. Only one state can set at even given time.

Previous machine state

Indicates the previous machine state. Used primarily by the application and device modules to determine Transitional State faults.

Machine state display

String tag that can be used to indicate the current machine state.

Machine status

Indicates miscellaneous machine status information.

236



Appendix A

Device and Application Status Rung Tags and Logic The device and application status rungs provide feedback information to the machine module and consists of these components. Figure 35 - Device Module Status

Figure 36 - Application Module Status

The status bits are set in the monitor routine of the corresponding modules. These status bits are vital to the machine module, as they are used to determine the overall status of the machine. They help the machine transition between states or detect a fault and respond accordingly. All of the module status information is summarized in the monitor routine of the machine module.


237

Appendix A


For the CNC Work Cell application example, the rungs are found in the R02_Monitor routine of the P01_CNC_Work_Cell machine program. Table 17 - CNC_Work_Cell Device and Application Status Rung Example

238



Appendix A

Figure 37 - CNC_Work_Cell Device and Application Status Rung Example (continued)


239

Appendix A


Application Modules The application modules contain all of the application specific code. This is where a majority of the customizing occurs and is essentially a programming space where you spend a significant portion of your efforts to develop proprietary logic specific to your application. In this example, application code is shown for the CNC Work Cell Machining application.

240



Appendix A

Device Modules Device modules contain all of the logic to control the essential functions required by the device. For example, an integrated motion servo drive like the Kinetix 6500 requires logic (MSO/MSF instructions) to enable and/or disable the servo drive. This logic reduces the programming effort required by most applications providing more time for the proprietary logic needed for the application. Typically, the device module consists of a physical drive, but could also consist of a virtual or feedback-only axis. Device modules can also consist of multiple devices (for example, a drive or CNC) and perhaps a feedback device (for example, a sensor).

Device Module Tags The application and individual device modules interact with each other via device specific control tags that include both command and status information. The control tags consist of these data types. Table 18 - Device Tags Device Classifications

Covered Products

Data Type

FANUC CNCs

• FANUC 30i B-Series CNC • FANUC 35i B-Series CNC

Product specific add-on defined (Add-On Instruction) data type: Fanuc_XXi_CNC_Add-On Instruction (where XX refers to the specific Fanuc CNC).

PowerFlex drives

PowerFlex 4-class drives, for example 4, 40, 40P PowerFlex 7-class drives, for example 70EC, 700VC PowerFlex 750-Series drives for example 753, 755

Product specific add-on defined (Add-On Instruction) data type: PFlex_XXX_Add-On Instruction Where XXX refers to the specific PowerFlex drive.

Kinetix 300 drives

Kinetix 300

User-defined type: UDT_K300_Ctrl

A sercos physical axis

Kinetix 2000 Kinetix 6000 Kinetix 6200 Kinetix 7000

User-defined type: UDT_ServoCtrl

A sercos feedback-only axis

Applicable sercos drives


CIP Motion physical axis

Kinetix 6500 PowerFlex 755


CIP Motion feedback-only axis

Applicable CIP Motion drives


Virtual axis

N/A


All of the data types listed above can be modified to fit specific needs of your application. However, modifications to the data types could have an impact on the device module and/or other preprogrammed logic, especially during import of additional device modules. For example, the UDT_ServoCtrl data type that is used by the integrated motion drives (CIP Motion and sercos interface-based drives) consists of these tags.


241

Appendix A


Device Module Control Logic Example In this example, the R03_Control routine for a FANUC CNC device module initiates and/or clears the reset and abort sequences. The routine also attempts to clear any active faults.

Refer to the toolkit directory C:\Program Files\RA_Simplification\CMAT\A-Files\6-Project Examples\CNC-Work-Cell folder for a complete example of a logic program.

242


Appendix

B

Logic Module Customization

The toolkit logic modules are designed with a basic set of machine states, faults, alarms, and reset logic common to most applications. Knowing that specific application requirements dictate exceptions and additions, the ability to customize is also included in the logic module design. This appendix includes common modification recommendations for the customization of machine states, faults, alarms, and reset logic.

Machine State Customization You may wish to modify state names, add or remove states, or even change the relationship between states to fit your application. The state machine logic resides in the R02_Monitor and R03_Control routines in the machine module.


243

Appendix B


The application and device modules interact with the state machine via their R02_Monitor and R03_Control routines.

For example, the device modules accept commands and react accordingly. Therefore, changes to the state machine can impact the individual application and device modules. Refer to Appendix A for more information on the state machine and how it interacts with the application and device modules. The core for the state machine is built around the UDT_MachCtrl data type. The UDT_MachCtrl data type consists of three sub data-types that directly impact the state machine: • Mode = UDT_MachMode • Command = UDT_MachCmd • State = UDT_MachState

244



Appendix B

Modifications to the state, command, or mode need to be made to the corresponding data types. For example, to modify the state names, open and edit the UDT_MachState data type.


245

Appendix B


Tag and Logic Modification Recommendations This table contains some of the common modifications to consider for the state machine. The modifications and corresponding recommended actions are meant to highlight the more significant updates that are needed. Additional updates may also be necessary. Modification

Description

Recommended Actions

State Names

Simple change to the state name. The number of states and relationship between states remain unaltered. Example: Change RUNNING state to PRODUCING.

• Modify the UDT_MachState data type. • Update the corresponding MachineSTATE_Add-On Instruction embedded state name. (1) • Update the HMI file as needed. (2)

Command Names

Simple change to the command name. Their intended function remains unaltered. Example: Change RESET command to INITIALIZE.

• Modify the UDT_MachCmd data type. • Update the HMI file as needed. (2)

Mode Names

Simple change to the mode name. The number of modes and their intended function remain unaltered. Example: Change OPERATOR mode to MANUAL.

• Modify the UDT_MachMode data type. • Update the HMI file as needed. (2)

Adding additional states or removing states. The operation of the state machine will change to accommodate an increase or decrease in states. Example: Add a new state called PAUSED.

• Modify the UDT_MachState data type. • Modify the machine module monitor and control routines as needed. • If necessary, add/remove commands to support the changes in the states. Refer to Add/Remove Commands modification. • If new states were added, then update the corresponding MachineSTATE_Add-On Instruction embedded state name. • Update the HMI file as needed. (2)

Adding additional commands or removing commands. Typically, increases or decreases in commands are required to support corresponding changes (+/-) with states. Example: Add a new command called PAUSE to support a new state called PAUSED.

• Modify the UDT_MachCmd data type. • Modify the machine module monitor and control routines as needed. • Modify the application and device modules monitor and control routines as needed. Typically, changes in commands require changes in the module status (UDT_AppStatus and UDT_ModuleStatus). For example, if you add a new command called PAUSE, then you must add a new status response from the modules called Paused. • Update the HMI file as needed. (2)

Add/Remove Modes

Adding additional modes or removing modes. Example: Add a new mode called THREAD.

• Modify the UDT_MachMode data type. • Modify the machine module monitor and control routines as needed. • Modify the application and device modules monitor and control routines as needed. • Update the HMI file as needed. (2)

State-to-State Relationships

Changing the conditions that enable transitions between states. Example: Update logic to transition from STOPPED directly to STARTING, bypassing IDLE.

• Modify the machine module monitor and control routines as needed. • Modify the application and device modules monitor and control routines as needed. • Update the HMI file as needed. (2)

Add/Remove States

Add/Remove Commands

(1) Refer to State Display Tag Modifications, on page 247, for more information. (2) Refer to Chapter 5, on page 147, for more information on the HMI terminal layout and function.

246



Appendix B

State Display Tag Modifications Each instance of any MachineSTATE_Add-On Instruction instruction contains an embedded string tag that sets the Machine.StateDisplay tag following a state change. The Machine.StateDisplay tag is referenced by the HMI to display the current or active machine state. In this example, you modify the embedded string tag. 1. Right-click the Add-On Instruction tag name and choose Open Instruction Logic.

2. Navigate to rung 5, right-click State_Name, and choose Monitor “State_Name”.


247

Appendix B


3. Use the String Browser to modify or set the State_Name. The new state name must match the updated state set by the MachineSTATE_Add-On Instruction instruction. For example, if the MachineSTATE_Add-On Instruction instruction places the machine into the Machine.State.PRODUCING state, then the corresponding State_Name tag must be set to PRODUCING. Each instance of any MachineSTATE_Add-On Instruction needs to be set or updated based on changes to the machine states.

Bypass Idle State Modifications By default, the state machine transitions from STOPPED to IDLE when start is pressed on the HMI terminal. While in IDLE, typically all of the modules are reset and ready to run. A sercos or CIP Motion axis, for example, are enabled and holding position at this point. When start is pressed a second time, the machine transitions from IDLE to RUNNING and motion begins. If your machine is not required to dwell on the IDLE state, but instead transitions to the RUNNING state, then make this edit. 1. Navigate to rung 5 in the R03_Control routine for the machine module.

2. Delete the XIC and ONS instructions. The IDLE state was not removed. Instead, the state machine transitions instantly from IDLE into STARTING without requiring a second start request. To the operator it appears as if the IDLE state was removed or bypassed altogether.

248



Appendix B

Module Fault Customization The application and device module R02_Monitor routines contain module fault logic.

Module faults are intended to act as a diagnostic tool to cover not only a drive or device fault, but also module specific faults. You can add custom module fault logic to provide additional diagnostic information based on your application. The default module specific faults are listed below. Table 19 - Module Faults Fault Description

Module Usage

Alarm History Fault Code

Drive Fault

Device Module

1

Not Ready

• Application Module • Device Module

2

Failed to Clear


3

Failed to Reset


4

Failed to Start

Application Module

5

Failed to Stop

Application Module

6

Safety Fault

Device Module

7

User Alarm

Reserved

8…19 (1)

Instruction Error


20

(1) Alarm History fault codes 8…19 are placeholders. You can use them to quickly add custom user-defined module faults. Refer to Chapter 5, FactoryTalk View ME Configuration, on page 147, for more information on the Alarm History faceplate and its function.


249

Appendix B


All of the device modules also contain a general drive fault. The drive fault is in addition to the drive specific faults. For example, when a CIP Motion drive faults for an Excessive Position Error, both the drive specific fault (Excessive Position Error) and general fault (Drive Fault) are displayed on the HMI alarm history faceplate. This general drive fault is also triggered when a drive faults, but does not provide specific fault information, for example, PowerFlex 4-class drives. To add new module faults to the alarm history faceplate, navigate to the fault trigger rungs and add the logic for your new fault with the appropriate fault code number.

250



Appendix B

In addition to adding the logic for the new module faults, the alarm message within the HMI application needs to be entered for the associated trigger value.


251

Appendix B


Alarm History Faceplate Logic Modification The alarm history rungs in the application and device module R02_Monitor routines support the HMI alarm history faceplate.

If your HMI application does not include the alarm history faceplate, then you can remove this logic from the monitor routine for each module. You can locate the alarm history faceplate logic rungs just below the alarm history header, in the rung comments. To remove logic, select alarm history rungs in each R02_Monitor routine of each application and device module and press the delete key or menu item.

252



Appendix B

Coordinated Reset Customization By default, each device module is pre-programmed with reset logic that is designed to prepare the module and the devices it contains (drives, for example) to run. For a sercos or CIP Motion axis, this might mean the reset logic will home the axis. This approach is well suited for applications where the individual device modules reset independently. However, some applications require multiple device modules to reset in a coordinated manner. For example, when two or more sercos and/or CIP Motion axes are homed in sequential order to avoid mechanical interference. To achieve a coordinated reset, we recommend that you remove the reset-sequence logic from each of corresponding device module R04_Reset_Abort routines and insert it into the application R04_Reset routine.

The reset logic from each device module can be blended together into a single reset sequence in the application module. Also, your application may contain device modules that can be reset independently while others may need a coordinated reset. In these cases, you only need to relocate the reset logic for the device modules that require the coordinated reset.


253

Appendix B


Notes:

254


Appendix

C

Add Other Devices to the Equipment Status Faceplate

In this appendix you add devices that do not have pre-configured faceplates, such as a discrete device (solenoid or valve).

Add Devices to the Equipment Status Faceplate 1. Go to the Object Explorer dialog box and select which Row_Group you wish to display the Non-preconfigured Device in. 2. Find the DeviceName_String_x object for that row.

3. Double-click DeviceName_String_x object to open the String Display Properties and click the Connections tab.


255

Appendix C


4. Assign a new controller tag by clicking the Tag browser and search for a controller tag containing the string name you want to display or you can type a static name in the tag field by enclosing in quotes; for example, “Furnace 1”. 5. Go to the State_MSI object and double-click to open its properties.

6. Click the States tab. This Multistate Indicator Properties is pre-configured with 18 device states. When the tag assigned to the MSI becomes a certain value, the MSI displays the appropriate caption. 7. Use the pre-existing captions and create logic in your controller to move the appropriate value to your device tag or edit the captions and values to meet your needs. 8. Click the Connections tab and assign a device tag to the MSI by clicking the Tag browser. 9. Consider deleting any states you are not using, to avoid any unwanted captions being displayed. Lastly, there are four value groups for each row that contain a numeric display and a string object to display units that you can configure.

256



Appendix C

10. Expand the Value1_Grp group. 11. Double-click the Value1_Str object to open its Numeric DIsplay Properties.

12. Click the Connections tab and assign a tag to the numeric display object. 13. Double-click the Units1_Str object to open its String Display Properties. 14. Click the Connections tab and assign a tag in the controller that contains a string for the units, or simply type in a static string by enclosing in quotes. In this example, “degrees” is the tag name. 15. Repeat step 11 and step 13 for each Valuex_Grp group in your row.


257

Appendix C


Add Optional Faceplate Views This example shows two additional faceplate toolbar buttons added to the equipment status faceplate that toggle between the existing main Equipment_Status_Faceplate Group (home button) and a new help object group (help button).

1. Create a new object group, for example HelpManual_Group, to be launched and add the objects within that group you wish to display when help toolbar button is pressed. 2. Right-click the new group and choose Animation>Visibility. 3. Set the Visibility animation to be true when the Set_EquipFaceplateAnimation tag in the Add-On Instruction becomes a certain value, for example 1.

4. Create an interlocked pushbutton on toolbar (see example) that will activate visibility of the new object group. 258



Appendix C

5. Set the connection or tag tied to this button to {#1.Set_EquipFaceplateAnimation}.

6. Set the button value to the number assigned in the group animation in step 3. 7. Create another interlocked pushbutton on the toolbar (home button in this example) that will activate visibility of the existing Equipment_Status_Faceplate Group. The pre-configured visibility value for this group is 0. 8. Repeat step 1…step 7 for additional faceplate object groups you wish to visually activate by faceplate toolbar buttons.


259

Appendix C


Notes:

260


Appendix

D

Logix Communication and Controller Configuration

In this appendix, you configure your personal computer and controller communication, configure your controller, and create a new project by using RSLogix 5000 software.

Configure Personal Computer Communication Properties In this example, you set and verify the IP address of the personal computer running your program.

Set the IP Address 1. On your desktop, right-click My Network Places and choose Properties.

2. Double-click Local Area Connection.

3. On the General tab, select Properties. 4. Verify Internet Protocol (TCP/IP) is checked and selected. 5. Click Properties.

6. Select Use the following IP address. 7. Enter the IP address and Subnet mask as shown, or enter your address. 8. Click OK. 9. Close all network windows. Rockwell Automation Publication IASIMP-QS034A-EN-P - October 2012

261

Appendix D


Verify Your IP Address 1. From the Start menu, choose Run. The Run dialog box opens. 2. Enter cmd. 3. Click OK. The Windows IP Configuration dialog box opens.

4. Enter ipconfig at the prompt. 5. Press Enter. 6. Verify that the IP address and Subnet Mask match what you entered. If these numbers do not match what you entered, contact your network administrator. 7. Close the cmd.exe window.

262



Appendix D

Configure the EtherNet/IP Driver 1. Click the RSLinx icon in the system tool tray to start the RSLinx Classic software. 2. From the Communications menu, choose Configure Drivers.

The Configure Drivers dialog box opens. 3. From the Available Driver Types pull-down menu, choose EtherNet/IP Driver. 4. Click Add New. 5. Click OK to accept the default name.

The Configure Driver dialog box opens. 6. Select Browse Local Subnet and associated personal computer EtherNet/IP port. 7. Click OK. The EtherNet/IP driver is added to the Configured Drivers list. 8. Verify that the status of the driver indicates Running. 9. Click Close.


263

Appendix D


Configure the Logix Controller To configure the Logix controller, you will check the Web for firmware updates, load the controller firmware, assign the IP addresses, and browse the EtherNet/IP network devices.

Check the Web for ControlFLASH Firmware Updates 1. From the Start menu, launch RSLogix 5000 software.

The RSLogix 5000 Start Page opens. 2. Click the Resource Center icon on the Start Page. 3. From the Downloads menu, choose Logix Firmware.

The Get Support Now webpage opens. 4. Click Control Hardware to access the controller firmware.

5. Follow the webpage instructions to download firmware.

264



Appendix D

Load the Controller Firmware TIP

This procedure shows how to load firmware in the controller by using a serial connection. It is faster to load the firmware by using an EtherNet/IP connection. For details, see the controller installation instructions.

1. Apply input power to the CompactLogix controller power supply. 2. From the Tools menu, select ControlFLASH.

The Welcome to ControlFLASH dialog box opens. 3. Click Next. 4. Select your controller catalog number. In this example, 1768-L43 is the controller catalog number. The steps to download other Logix controller firmware are similar. 5. Click Next.


265

Appendix D


6. Under AB_DF1-1, select the 1768-L43 controller. 7. Click OK.

8. Move the controller keyswitch to Program. 9. Compare the current drive firmware revision to the latest revision listed. If the Current Revision matches the newest Revision listed, then your controller already has the latest firmware and a firmware update is not needed. a. Click Cancel to abort the firmware upgrade. b. Go to Assign IP Addresses on page 267. If the Current Revision does not match the latest revision listed, click Next.

TIP

If you are unsure which revision to use, select the latest.

10. Click Finish, then click Yes to start the firmware update. When the controller is updated, the status box displays Update Complete. 11. Click Ok. 12. Click Cancel to close the ControlFLASH software. 13. Click Yes.

266



Appendix D

Assign IP Addresses The BOOTP/DHCP Server utility is used to assign IP addresses to most devices in this quick start, except the PanelView Plus terminal. The BOOTP/DHCP utility is installed during the RSLogix 5000 software installation. 1. From the Start menu, launch the BOOTP/DHCP Server utility.

If you are running this utility for the first time, the Network Setup Error dialog box opens. a. Click OK. b. Enter the subnet mask from step 7 on page 261.

If you are not running this utility for the first time, from the Tools menu, choose Request History. 2. Click OK.


267

Appendix D


The Request History field displays all of the devices in your network that need IP addresses. The EtherNet/IP (MAC) addresses correspond to the pre-loaded addresses and typically are marked on the device labels. 3. Double-click a request from one of the devices. 4. Enter a unique IP address for each device. 5. Click OK. If you are not on an isolated network, obtain the IP addresses from your network administrator. 6. Repeat step 3…step 5 for each device, except the PanelView Plus terminal. IMPORTANT

If you cycle power, the device will not retain its IP address unless you disable BOOTP/DHCP.

7. Select the first device in the Relation List field. 8. Click Disable BOOTP/DHCP. 9. Repeat step 7 and step 8 for all devices except the PanelView Plus terminal. 10. Close the BOOTP/DHCP utility. If prompted to save changes, click No.

268



Appendix D

Browse the EtherNet/IP Network Devices In this example, you verify that all your network devices are present in RSLinx Classic software. 1. Click the RSWho icon to view the EtherNet/IP driver and devices on the network. 2. Verify that all your network devices are detected. In this example, there are five network devices. The network configuration for your specific application will be different.


269

Appendix D


Notes:

270


Index Numerics 1756-EN2TR Ethernet module 15 1756-EN3TR Ethernet module 15

A add or remove states 243 alarm history faceplate display 149 import/edit alarm tags 174 logic modification 252 set tag name 108 alarm messages string names 108 alarm setup file 171 alarm tags editing 174 importing 174 alarm triggers 173 AOI properties 111 application data collect 17 application logic add preconfigured 100 development 68 examples 126 import preprogrammed logic 120 P0001 (OP panel path 1) 71 P0005 (machine sequence) 71 P0010 (window functions) 72 P0023 (alarm routine) 72 write logic from scratch 120 application modules 69, 81, 240 status 237 application programs manages CNC alarms and device status (P0023) 72 manages window functions of the CNC ( P0010) 72 operator panel and MDI panel I/O interface (P0001) 71 sequencing for machine tool application (P0005) 71 assign IP addresses 267

B bill of materials 15 create 23 BOM project file 27 BOOTP/DHCP utility 267, 268 buffered data table 74 bypass idle state modifications 248

C CNC architecture 69 communication 47 Goto buttons 177 logic examples 127 work cell application 15 CNC Express order forms 19 CNC faceplate 221 CNC control views 222 CNC status views 222 configuration view 225 fault diagnostic views 224 fault indication view 223 home view 221 online help views 226 CNC faceplate toolbar buttons alarm 221 close 221 CNC control 221 CNC status 221 configuration 221 help 221 collect application data 17 commissioning CIP motion drives 205 Kinetix 300 drives 205 PowerFlex 4-class drives 205 PowerFlex 7-class drives 205 procedures 206 sercos drives 205 common modifications to state machine add/remove commands 246 add/remove modes 246 add/remove states 246 command names 246 mode names 246 state names 246 state-to-state relationships 246 communication CNC to controller 208 controller to device 207 HMI terminal to Logix controller 206 status indicators 208 configure controller 56, 261 controller communication 261 Ethernet module 89 network 56 personal computer 261 control buttons machine 219 control drawings edit 38 control of electrical noise 30 ControlFLASH firmware updates 264 controller firmware load 265 coordinated reset customization 253 create a new project 261


271

Index

create a new project file 56 custom module fault logic add 249 customization coordinated reset 253 machine state 243 mode fault 249 customizing applications 240

D default machine commands 235 default machine states 235 design (local) 200 device logic P00015 (PLC EIP input routine) 74 P00016 (PLC EIP output routine) 74 device modules 69, 82 status 237 device program EtherNet/IP option (P00015) 74 manages output data sent to supervisory PLC (P00016) 74 diagnostic tool 249 download FactoryTalk View project to the PanelView Plus terminal 197 RSLogix 5000 project to the controller 197 drawings edit control drawings 38 edit power drawings 35 edit safety drawings 38 edit system communication 41 edit system I/O drawings 38 edit system layout drawings 43 FANUC CNC 31 FANUC CNC project 34 layout 29 wiring 29

E equipment status faceplate add devices 255 display 149, 185 set visible rows 111 error writing to xxxxx_tag 206 Ethernet board, enabling 51 Ethernet module configure 89 status indicators 209 EtherNet/IP bill of materials 15 driver, configure 263 network devices, browse 269 options 24, 51 settings, configuring 64

272

F faceplates adding devices to equipment status 255 display name 162 parameter file 162 alarm history 108, 174 CNC 221 deleting display names 154 parameter files 154 display alarm history 149 equipment status 149 machine startup 147 machine state diagram 147 equipment status 111, 185 machine startup 147, 217 machine state diagram 147 required for application 154 state diagram 217, 220 toolbar buttons 221 views, optional 258 FANUC bill of materials 23 CNC Express software 15 distributor/sales rep 14 order forms 19 publications 14 system selection and configuration tools 19 Web site 14 workbook 19 FANUC CNC drawings 31 project drawings 34 FANUC III for PMC development 12 FANUC LADDER III 56 fast Ethernet board 51 communicating to supervisory PLC 53 configuring 53 faults HMI clear faults 212 HMI test faults 212 firmware load controller 265 updates 264 functionality test device modules 212 fault handling 212 state machine 212

H high-speed Ethernet option 51 HMI application file configuration 150 design from existing file 162 design from preconfigured file 151 existing 150 preconfigured 150


Index

I I/O channel configure USB port 63 instruction latch (L) 122 move (MOV) 122 unlatch (U) 123 Integrated Architecture tools website 11 IP address assign 267 assign to devices 267 setting 261 setting for personal computer 261 verify 262 isolated network 268

L latch (L) instruction 122 logic add preconfigured application logic 100 add preconfigured machine logic 91 application examples 126 CNC examples 127 logic module routines application R00_Main 232 R01_PowerUp 232 R02_Monitor 232 R03_Control 232 R04_Reset 232 R10_ApplicationCode 232 FANUC CNC R00_Main 232 R01_PowerUP 232 R02_Monitor 232 R03_Control 232 R04_Reset_Abort 232 Kinetix 300 R00_Main 233 R01_PowerUP 233 R02_Monitor 233 R03_Control 233 R04_Reset_Abort 233 R06_Messaging 233 R10_EnableDisable 233 R11_OperatorMode 233 machine R00_Main 232 R01_PowerUp 232 R02_Monitor 232 R03_Control 232 PowerFlex R00_Main 232 R01_PowerUP 232 R02_Monitor 232 R03_Control 232 R04_Reset_Abort 232 sercos or CIP motion R00_Main 233 R01_PowerUP 233 R02_Monitor 233 R03_Control 233

R04_Reset_Abort 233 R10_EnableDisable 233 R11_OperatorMode 233 logic module types application 229 device 229 machine 229 logic modules preconfigured 82 logic modules, preconfigured 82 logic template 120 Logix processor slot 88

M machine commands abort 81, 235 clear 81, 235 default 235 reset 81, 235 start 81, 235 stop 81, 235 machine control buttons 219 machine logic program file add preconfigured 91 machine module 234 machine startup faceplate 217 machine control 219 machine status 217 program/operator mode 219 machine state aborted 235 aborting 235 clearing 235 default 235 idle 235 permanent state 234 resetting 235 running 235 starting 235 stopped 235 stopping 235 transitional state 234 machine state customization 243 machine state diagram 234 machine STOP command 124 machine tags 236 current machine state 236 machine commands 236 machine mode 236 machine state display 236 machine status 236 previous machine state 236 mapping between the PLC and CNC 64 modification alarm history faceplate logic 252 bypass idle state 248 modify state names 243 module fault customization 249


273

Index

module faults drive fault 249 failed to clear 249 failed to reset 249 failed to start 249 failed to stop 249 instruction error 249 not ready 249 safety fault 249 user alarm 249 module routines 231 module status application 237 device 237 modules application 81 device 82 move (MOV) instruction 122 MSO/MSF instructions 241

N network communication verify 206 network devices verify devices are detected 269 verify devices present in RSLinx Classic software 269 noise electrical 30

O offline development personal computer 53 operator interface application file 147 optional faceplate views 258 order forms CNC Express 19

P P0001 (OP panel path 1) 71 P00015 (PLC EIP input routine) 74 P00016 (PLC EIP output routine) 74 P0005 (machine sequence) 71 P0010 (window functions) 72 P0023 (alarm routine) 72 PanelView Plus terminals improving communication 173 supported 152 parameter write enable 49, 50 PWE, 8900#0 49 parameterized tag 168 PMC logic files preconfigured 68 PMC modules application modules 69 device modules 69 power drawings, edit 35

274

preconfigured logic add application logic 100 add machine logic program file 91 preconfigured logic modules application logic 82 device module 82 machine logic 82 project new creating 56 PWE 8900#0 50

R R02_Monitor routine 113, 169 R03_Control routine 122, 124 R04_Monitor routine 111 R10_ApplicationCode routine 120 required software 12 Rockwell Automation Integrated Architecture tools website 11 RSLinx Classic software 263 RSLogix 5000 add-on profiles website AOP website 95 RSLogix 5000 software launch 87 run sequence 122 run sequence template 121 RunSeq MOV instruction 122 runtime application (*.mer) file 202 file 201 target 200

S safety drawings edit 38 security settings on your personal computer 152 sercos communication modules 90 software required 12 state diagram faceplate 217, 220 state machine common modifications 246 model 81 state names modify 243 states add or remove 243 status bits 237 status indicators Ethernet module 209 status rungs 237 STOP command machine 124 stop sequence 124


Index

stop sequence template 124 supervisory PLC 53 synchronization, time 88 system communication drawings edit 41 system I/O drawings edit 38 system layout drawings edit 43

T tags UDT_AppStatus 108 UDT_ModuleStatus 108 time sync functionality 90 time synchronization 88 toolbar buttons faceplate 221

U UDT_AppStatus tag 108 UDT_ModuleStatus tag 108 unlatch (U) instruction 123 updates firmware 264 USB port define 63


275

Index

276


Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums, software updates, and to sign up for product notification updates. For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnectSM support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/.

Installation Assistance If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running. United States or Canada

1.440.646.3434

Outside United States or Canada

Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact your local Rockwell Automation representative.

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Publication IASIMP-QS034A-EN-P - October 2012 Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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