Be more productive – Configuration – Part 1
1.) You may have heard or read about AutomationDirect’s newest programmable automation controller – the Productivity 3000. You might ask what is it, how does it work, will it work for my application, and how much easier is it to use than traditional programmable controllers? In this video, we’ll show you the "out of the box experience", how easy it is to power and connect up to the NEW Productivity 3000, configure the hardware, and be on your way to programming your new application.
2.) For this video we’re going to solve a hypothetical application. Our application will be… let’s say an assembly machine. For this machine, we need a controller that’ll do all of the following: Support AC and DC voltage inputs and outputs, isolated relay outputs, a few voltage and current analog input and output signals, communicate directly with a GS2 AC drive, interface to a C-more Touch Panel, and… the entire system needs to use Ethernet connectivity.
3.) OK, in order to accomplish all of this, we’re going to need the following hardware as shown here:
P3-08B – 8 slot base
P3-01AC – power supply, 100-240 VAC source
P3-550 – CPU
P3-16ND3 – 16-point, 12-24 VDC, sinking or sourcing input module
P3-08NAS – 8-point, 100-240 VAC input module
P3-16TD1 – 16-point, 6-27 VDC sinking output module
P3-08TAS – 8-point, 80-288 VAC output module
P3-08TRS – 8-point, 6-27 VDC, 6-240 VAC isolated relay output module
P3-04ADS – 4-channel voltage or current analog input module
P3-04DA – 4-channel voltage or current analog output module
P3-FILL – slot filler module
P3-RTB – removable terminal block, one for each of the above modules
GS2 AC Drive
C-more Touch Panel
24 VDC power supply
Stride Ethernet switches
4.) Let’s get started! Here we have all of the P3000 components in their shipping boxes. Watch as we assemble the hardware prior to connecting any wires. [Shane unpacks and assembles the components. On the first I/O module, install the module into the slot, show taking the module cover and snapping it to a terminal block, and then installing the terminal block with a screw driver to the I/O module. Also, we need to video tape a close up of installing the cover to the terminal block.] Let me make a quick statement about the terminal blocks on the I/O modules. On most of the I/O modules, you’ll need to purchase the removable terminal blocks. These are going to be part number P3-RTB. They’re not supplied with the modules. Well, we did this because a lot of customers prefer using our ZipLink cables and modules vs. the screw terminal blocks, so we give you the option of which route you’d prefer for your application. [Shows a ZipLink module and cable being connected to an I/O module.] And finally because we have all the I/O modules we require for our application in the first seven slots, I’ll install a filler module in the last slot, not just for esthetics, but to help eliminate dust and contaminants from getting into the base.
5.) If you noticed, I didn’t worry about which modules I selected, or which slot I placed them into. That’s because there are no power budget restrictions with the P3000. It was designed to accept worst case scenarios, so no more adding up the power consumptions of each I/O module.
6.) The P3000 doesn’t have any module location restrictions when it comes to placing the modules in a base. Now of course the power supply and the CPU both have dedicated slots, but all of the I/O modules can be inserted in any order. Now… here’s a tip: Typically you would lay out your system so that all of your Discrete input modules are together and come first – from L to R, then your Discrete output modules, then Analog input, your Analog output, and if you had any specialty modules like high speed or communications modules, they’d typically be at the end of the base. There’re no rules stating that your layout must follow this example, this just makes wiring, programming and troubleshooting easier in most applications.
7.) Also keep in mind that I/O modules can be HOT SWAPPED on the P3000 system and we go into more detail with this feature and other features in later videos.
8.) OK. As you watched me put the modules in the base, it was simple: just press them into place and lock the tabs on the top and the bottom. I’ll show you again real quick. Each I/O module has a tab on the bottom and one on the top. Slide the module into the base and lock the tabs. And if you noticed, the power supply, and the CPU, they only have locking tabs on the bottom. They are installed by inserting at a 45 degree angle into the notch at the top of the base and rotating down until they are seated. The tabs at the bottom are then locked.
9.) Our assembly machine control system will be using a GS Drive and C-more Touch Panel that have Ethernet connectivity. It is good practice to extend both the Ethernet and Remote I/O ports on the CPU to Ethernet switches to make it simpler to connect to these devices and future devices. Here we have added a couple of Stride Ethernet switches, and provided 24 VDC power to the switches. Please note that the Remote I/O port uses Ethernet connectivity. [Shows Stride Ethernet switches already wired to 24 VDC with Ethernet cables connected from ports to the switches. No power on at this point.]
10.) Our assembly machine will be using an AC motor with a variable frequency drive, so let’s get a GS2 AC Drive connected to the Productivity 3000. The P3000 system has the ability to Auto-Detect GS drives that are connected to the P3000’s Remote I/O port by way of a GS Ethernet Drives Module, part number GS-EDRV100. Here’s the GS-EDRV100 module wired to our 24 VDC power source. The P3000 has built-in software instructions that will allow us to both configure and control the GS drive interfaced through the EDRV. Here we connect the supplied black cable from the GS drives RS-485 port to the EDRV module’s RJ-12 connector, and then use an Ethernet cable between the EDRV module’s RJ-45 connector and the Remote I/O port’s connected Ethernet switch. For your reference, there are switch settings and configurations that are required on the GS2 AC Drive and the GS-EDRV100 module that we will cover in a future video. [Shows GS Drive RS-485 port connected to GS-EDRV and EDRV Ethernet port connected to the Remote I/O Ethernet switch.]
11.) It is a simple matter of powering our C-more touch panel with 24 VDC and connecting an Ethernet cable between its Ethernet port and the Stride Ethernet switch that is connected to the CPU’s Ethernet port. Here’s a close up showing the connections. [Shows DC power connection and then Ethernet cable being plugged into the C-more and the other end plugged into the Stride Ethernet switch.]
12.) OK, our hardware’s configured, now we’ll apply power by wiring up 120 VAC to our P3000 power supply. [Shows wiring power to the CPU.]
13.) We’ll wire up a few I/O points now to show connectivity and how simple it is to use the programming software to identify the I/O and add them to our program. [Show wiring up devices to the input and output modules.] First I’ll wire up a limit switch to an input module. I’ve used the normally closed contact on the limit switch because I want a signal back to the P3000 when the switch is not being actuated. Next I’ll connect a Stacklight to one of our output modules. Again, our intention in this video is to show how easy you can get the P3000 out of the box, assembled, connected, and programmed.
14.) We apply power to the CPU and connect the communications cable. Now, if you’ve programmed PLCs in the past, you’re use to having a proprietary or special made cable for communications. In the past few years, what has been the most popular communications protocol? USB… I even have USB on my cheap car stereo. Most new PCs have several USB communication ports. Well, guess what this is?... USB! We can simply connect the P3000 with a standard USB cable. It doesn’t get any better!
15.) We’ll continue with the “out of the box experience” in part two of this video by showing how simple it is to use the software to configure the hardware, and then program a simple rung using tag names.
Thanks for watching! See you soon!
Be more productive – Configuration – Part 2
1.) OK, in Part 1, we powered up the system now we’ve connected the communication cable between our PC and the Productivity 3000 programmable automation controller. We’re now ready to use the programming software which we already downloaded and installed on this PC. Now in this video we’ll connect up to the CPU, auto discover the hardware, and create a couple simple programs.
2.) I should mention that all of our devices; the P3000, C-more and GS Drive EDRV module all require some minor Ethernet communication configuration that needs to be completed in order to get them all talking to each other. We will cover this in more detail in future videos.
3.) Here we’re connected to our P3000 system. [Shows software video capture.] You can see by opening the Hardware Configuration dialog, under the Setup Application Tools, and clicking on the Read Configuration, after a few seconds, all of the attached I/O modules and any other hardware is recognized. Now, keep in mind that the CPU needs to be in a Stop mode when reading the hardware configuration. Here we see the GS2 AC Drive that we’ve attached via the Ethernet Remote I/O connection is also recognized.
4.) In our real world connections, I’ve got a limit switch that detects if the assembly machine’s safety guard is opened. In most cases, we want to shut down the machine, and if this happens, we want to turn on an indicator light to alert the operator of the machine’s condition. We’ll call this limit switch our “Safety Guard Open” signal. I use the limit switches normally closed contact wired to the first input terminal on our DC input module. I’ve chosen the normally closed contact so that the circuit is complete when the switch is not being actuated by the guard. Think of it as what we want to happen if the switch were accidently removed from the machine. [Shows limit switch in enclosure.]
5.) I’ve also wired a Stacklight that will give a visual warning of a machine error. I wired the Stacklight to our DC output module. [Shows Stacklight attached to the top of the enclosure.]
6.) Now watch how simple it is to program the code for these I/O points and create a working ladder example. [Show software video capture.] I’ll start a new task and insert a normally open contact on my first rung. I need to assign an address, so I use the browse icon in the ‘NO Contact’ dialog box to scroll to input DI-0.1.1.1, the address for the first Input on the 16ND3 input module. Next I’ll drag and drop an output coil on the far right of the same rung. I’ll use the dialog’s browse icon to scroll down and locate output D0-0.1.3.1, the address for the first Output on the 16TD1 output module. From the Tag Database utility I’ll rename our input to read “Safety_Guard_Open”, and I’ll also rename our output to read “Guard_Open_Warning”. Using a tag name to describe our signals will make it so much easier to later understand and troubleshoot the program. Let’s see if it works! [Demonstrates both a screen capture of the software in monitor mode showing the elements changing color, and also showing the limit switch being operated with the Stacklight lighting by opening the door on the enclosure.] Success!
7.) Next we’ll program the P3000 to control the GS2 AC motor drive from our C-more touch panel. The P3000 software has a large number of built-in instructions. One group contains the communications instructions, and in this group are instructions that allow us to read and write data directly to an attached GS drive. In our situation we want to control the AC motor drive from our C-more touch panel, which requires the ability to write information to the drive.
8.) Here we insert a GS Drives Write instruction into our program from the Communications Instructions group. Next we select the GS Drive Node number that is setup on the GS-EDRV module’s dipswitches. Keep in mind that we were able to Auto-Discover the GS drive when we did our Hardware Configuration, so it should be available in the pull down list. Watch as I create tag names for the various parameters within the instruction box. [Uses software screen capture to show tag names being entered for all entries.] I can keep this as simple as creating Frequency Reference tag names for both the Run and Jog Commands within the Auto Write section and a few other tag names. I’ll use the tag names “RunFreq” and “JogFreq” for our drive running and jogging frequency. For our example we’ll keep the default polling times as shown. Although the status bits shown here are optional, we’ll go ahead and add them for our demonstration. [Enters status bit tag names based on the name of the status bit.] The status bits are very useful if troubleshooting is required.
9.) Shown here, we also have an entire section of parameters in the Manual Write section in the GS Drives Write instruction that we can control both when the drive is running and also when it is stopped. [Includes a software capture showing some of the various tabs for the Run Mode and Stop Mode parameters.] We will show uses of controlling these parameters in future videos. Now click OK to insert the GS Drives Write instruction. A Define Tags dialog box will appear showing the various tag names that we have just created. At this point we could change some of the data types, but for our example just click OK to accept them as is.
10.) Next we need to add contact signals in order to control the Auto Run and Auto Jog inputs to the GS Drives Write instruction. [Shows adding the contacts and typing in a tag name.] We’ll use the tag names “AutoRun” and “JogRun” to keep our example simple. Again, as we insert each contact we will see the Define Tags dialog box come up, so just click OK to accept. Since we won’t be changing any of the drives parameters, we won’t need to do anything with the RunModeData or StopModeData inputs to the instruction box. [Software capture used to show mouse pointer circling this area on the instruction.]
11.) Once we have completed our program, we will export the tag name database as a CSV file as shown here. Make sure to check the Include I/O Tags box in the dialog box so that our I/O tag name database is included. We are creating this file that will allow us to import all the tag names into the C-more programming software which will save us from having to re-type all of the tag names into our C-more program.
12.) We will now compile our project to check for errors and then transfer our completed project to the P3000 CPU. [Shows a software capture of project being compiled and transferred.]
13.) We now open the C-more programming software and start a new project. Make sure you select the AutomationDirect Productivity 3000 Ethernet PLC Protocol as shown. Import the tag name database file that was created, and create a numeric entry object that will allow us to change the GS2 drive’s frequency. We’ll select the imported tag name “RunFreq”. Next add a maintained push button that will allow us to start and stop the drive. Use the imported “AutoRun” tag name for the push button. We could have also added objects for the Auto Jog and Frequency functions at this time, but will try to keep our demonstration simple.
14.) We have now completed programming the P3000 so that we can control the GS2 AC Drive from our C-more Touch Panel. We first enter the frequency that we want the drive to run at using the C-more’s numeric entry object with the tag name “RunFreq”. Next we press the “AutoRun” push button that we have created on the C-more touch panel that will enable the GS2 drive to run in the auto mode. As you can see the AC motor connected to the drive ramps up to the frequency we have set. [Show C-more numeric entry and button being pressed, and GS2 frequency displayed, and motor rotating.] We will also cover how we did this simple example, with more detail, in later videos.
15.) This is the conclusion to the “out of the box experience”. We have our Productivity 3000 system assembled, wired to a few real world I/O points, configured in the software, and a simple program created, and finally we showed you how quick communications can be setup with a GS AC Motor Drive and our C more touch panel.
16.) More Productivity3000 videos at learn.automationdirect.com
Thanks for watching! See you soon!