Ethernet/IP Add-On Instruction (AOI) and User-defined … the Controller to RSLogix 5000. 2.2.1. Right-click the Ethernet network below the PL’s Ethernet Port, in the I/O Configuration

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Introduction Page 1

Ethernet/IP Add-On Instruction (AOI) and User-defined Data Type (UDT) installation for ACON-CA, PCON-CA, SCON-CA, MSEP-C, MSCON controllers, and ERC3 Gateways.

Introduction

The provided UDT’s and AOI’s are for the IAI controllers listed above with the Ethernet I/P option, operating in Full-Direct communication mode only. Some IAI documents also refer to this mode as Direct Indication or Direct Numerical Indication mode.

IAI Ethernet/IP devices support implicit messaging only and function as an adapter (slave device). The Allen-Bradley PLC functions as an implicit message scanner (master device).

The AOI’s and UDT’s are exported as .L5X files from RSLogix5000 version 17 and can be imported into any RSLogix5000 program that is version 17 or later (newer versions of RSLogix5000 are called Studio 5000 Logix Designer). The AOI’s and UDT’s are not locked; you can edit them to fit your needs.

This document is divided into major sections. Each section covers a type of controller or gateway device. A gateway handles communication between a PLC or other master device and multiple controllers, but it has no built-in axes.

Contents (these are links; click to jump to a topic) Introduction ............................................................................................................................................................................ 1

1. Requirements & Information .......................................................................................................................................... 2

1.1. Software and hardware .......................................................................................................................................... 2

1.2. Reference documents ............................................................................................................................................. 2

1.3. Feedback and revisions ........................................................................................................................................... 2

2. Single-Axis Positioning Controllers: ACON-CA, DCON-CA, PCON-CA, SCON-CA ............................................................. 3

2.1. Configure the Controller ......................................................................................................................................... 3

2.2. Add the Controller to RSLogix 5000. ....................................................................................................................... 4

2.3. Import the AOI’s and UDT’s .................................................................................................................................... 6

2.4. Create Tags to Use the UDT’s and AOI’s ................................................................................................................. 8

3. MSEP-C and MSCON Multiple-Axis Positioning Controllers ......................................................................................... 14

3.1. Configure the MSEP Gateway. .............................................................................................................................. 14

3.2. Add the controller to RSLogix 5000. ..................................................................................................................... 20

3.3. Import the Axis AOI’s ............................................................................................................................................ 22

3.4. Import the Gateway UDT’s ................................................................................................................................... 24

3.5. Create Tags to Use the UDT’s and AOI’s ............................................................................................................... 25

4. ERC3 Gateway (RCM-EGW) ........................................................................................................................................... 32

4.1. Configure the gateway. ......................................................................................................................................... 32

4.2. Add the controller to RSLogix 5000. ..................................................................................................................... 38

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Requirements & Information Page 2

4.3. Import the Axis AOI’s ............................................................................................................................................ 40

4.4. Import the Gateway UDT’s ................................................................................................................................... 42

4.5. Create Tags to Use the UDT’s and AOI’s ............................................................................................................... 43

5. Programming Information ............................................................................................................................................ 49

5.1. Communication Errors .......................................................................................................................................... 49

5.2. Using the AOI’s and UDT’s .................................................................................................................................... 49

1. Requirements & Information

1.1. Software and hardware

1.1.1. IAI PC Interface Software for RC and an IAI programming cable. The controllers cannot be set up using their Ethernet ports.

1.1.2. IAI Gateway Parameter Configuration Tool (for MSEP and gateway devices only). It can be downloaded from the IAI website.

1.1.3. Ethernet hub, router, or switch, and Cat-5 connection cables for PC, PLC, and the controller(s).

1.1.4. Rockwell Software RSLogix5000 programming software. This document uses graphics copied from version 20.01. Later versions may appear different.

1.2. Reference documents

1.2.1. IAI manual ME0278 Ethernet/IP Operation, for CON-type controllers.

1.2.2. IAI manual ME0299 MSEP-C/LC Instruction Manual. MSEP Ethernet/IP communication is covered in this manual.

1.2.3. IAI manual ME0302 ERC3 Gateway Unit Instruction Manual.

1.2.4. IAI manual ME0155 PC Interface Software for RC.

1.2.5. Allen-Bradley manual for your PLC model.

1.2.6. Allen-Bradley manual 1756-PM010E-EN-P, Logix5000 Controllers Add-On Instructions.

1.3. Feedback and revisions

1.3.1. Your feedback is greatly appreciated. If you find mistakes in the AOI’s, UDT’s, or this document, or you have suggestions for improvement, please contact John Stump at [email protected] or 888-354-9470.

1.3.2. The latest revision of this document is: January 5, 2016.

mailto:[email protected]

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Single-Axis Positioning Controllers: ACON-CA, DCON-CA, PCON-CA, SCON-CA Page 3

2. Single-Axis Positioning Controllers: ACON-CA, DCON-CA, PCON-CA, SCON-CA

2.1. Configure the Controller

The examples use a PCON controller but the same examples apply to the other controllers listed above.

2.1.1. Connect to the controller with a programming cable and run the PC Interface Software for RC application.

2.1.2. Select Parameter, then Edit from the menu bar. The parameter window will open. Note: the position window must be closed in order to open the parameter window, and vice-versa.

Figure 2-1

2.1.3. Scroll down to parameter #84, Fieldbus operation mode, and enter “3” in the Value field. This configures the controller for Full Direct Mode. The 3 will turn red.

Figure 2-2

2.1.4. Parameter #86, Fieldbus baud rate is the communication speed. The default is “0”, auto-negotiate the correct setting, but you can change it to match your network speed if you want. The settings are:

Value Baud Rate

0 Auto negotiation

1 10 Mbps, half-duplex

2 10 Mbps, full-duplex

3 100 Mbps, half-duplex

4 100 Mbps, full-duplex Table 2-1

2.1.5. Scroll down to parameter #140, IP address. Parameters 140 – 142 set the Ethernet/IP information.

Figure 2-3

2.1.6. Double-click the IP address in the value field of Parameter 140, IP Address. The Edit parameter window will pop up.

2.1.7. Enter an IP address that is compatible with your network and then click the OK button. This address will be used later in the PLC configuration.

Figure 2-4

2.1.8. Double-click the IP address in the value field of Parameter 141, Subnet mask. The Edit parameter window will pop up.

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Figure 2-5

2.1.9. Enter the appropriate subnet mask for your network and then click the OK button.

2.1.10. If a Gateway device is being used between the PLC and controller, such as a router that changes the IP address, double-click the IP address in the Parameter 142, Default gateway value field and enter its IP address using the same procedure as the previous steps.

2.1.11. Click the Load to CTL button in the upper left corner of the Parameter window. The Confirmation window will pop up.

Figure 2-6

2.1.12. Click the Yes button and wait for the parameters to be written to the controller. The Confirmation window will pop up again.

Figure 2-7

2.1.13. Click the Yes button. The controller will perform a software restart to make the parameters active.

2.1.14. The PLC has control of the controller when the Manu/Auto switch is in the Auto position. In manual mode the RC software may be used to operate the controller & actuator.

2.2. Add the Controller to RSLogix 5000.

2.2.1. Right-click the Ethernet network below the PLC’s Ethernet Port, in the I/O Configuration folder of the Controller Organizer, and then select New Module… (next figure).

Figure 2-8

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2.2.2. Select Communications in the Select Module pop-up window.

Figure 2-9

2.2.3. Navigate to Generic Ethernet Module and click the OK or Create button, depending on the version of RSLogix that you are using (next figure).

Figure 2-10

2.2.4. Fill in the parameters of the New Module window (next figure). Name can be any valid RSLogix name. IP Address should be an address that is appropriate for your network. Select Data – INT as the Comm Format; this and the Input, Output, and Configuration settings are critical.

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2.2.5. Uncheck the Open Module Properties checkbox; no additional parameters need to be set.

Figure 2-11

2.2.6. Click OK when done. The new module should be present in the Ethernet network, with the name that you entered, shown next.

Figure 2-12

2.2.7. RSLogix creates Controller Tag arrays for the module using the name that you entered. Tags for this example are shown in the next figure. Data from the controller is stored in the PCON:I array and data to the controller is in the PCON:O array.

Figure 2-13

2.3. Import the AOI’s and UDT’s

2.3.1. Download and extract the AOI files for the controller; the AOI files also contain the UDT’s.

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2.3.2. Right-click Add-On Instructions in the Controller Organizer and select Import Add-On Instruction…

Figure 2-14

2.3.3. Navigate to the folder that contains the AOI files and select the auto AOI file (.L5X) for this controller, and then click the Import button.

Figure 2-15

2.3.4. The Import Configuration window will open. Click the OK button to continue (next figure).

Figure 2-16

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2.3.5. The AOI will be added below the Add-On Instruction folder and the UDT’s will be added to the Data Types folder.

Figure 2-17

2.3.6. Repeat steps 2.3.2 through 2.3.5 but select the manual AOI file for the controller instead of the auto file.

2.3.7. The next figure shows the imported AOI’s and UDT’s for this example, a PCON controller.

Figure 2-18

2.4. Create Tags to Use the UDT’s and AOI’s

2.4.1. Create input and output tag names that uniquely identify this axis or its function on your machine. For the Data Type, select the new UDT’s that were imported with the AOI’s. The figure below shows input and output tag examples for a PCON controller. The Data Types are the imported PCON UDT files, shown in the next figure.

Figure 2-19

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2.4.2. Data from a controller needs to be transferred (mapped) from the controller input array to the newly-created input tag. This should be done with a Synchronous Copy File (CPS) instruction.

Figure 2-20

The Destination tag of an instruction determines its Length. PCON:I is a system defined tag that contains 16 integer words. It is being copied to a single tag, PCON1_Input, so Length = 1. Since tag PCON1_Input is a UDT that contains members that require 16 integers worth of data, all 16 words in the PCON:I tag get copied even though the length is 1.

2.4.3. The members of a UDT can be used individually or the entire contents of the tag can be used by an AOI. A period (.) is used as a delimiter to specify a member of a UDT. In the next figure, PCON1_Input member Actual_Position is copied to a tag that is read by a Human Machine Interface (HMI).

Figure 2-21

2.4.4. Command data being sent to the controller needs to be moved from the output UDT to the “real-world” output tags, also accomplished by a CPS instruction. In our example, the AOI’s manipulate the members of UDT PCON1_Output; that tag’s data needs to be moved to output tag PCON:O.

Figure 2-22

2.4.5. The AOI’s provide convenient methods to program the controller functions. They are inserted in ladder logic like any other instruction; they are located at the bottom of the list in the Add Ladder Element popup window. Click the + symbol to expand Add-On and select the AOI that you want.

Figure 2-23

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2.4.6. The Axis Manual AOI contains code to reset the controller, turn the servo on and off, home the actuator, and jog or inch forward and reverse.

The Axis Auto AOI commands the controller to move to a position and supplies the motion data for the move, such as speed and acceleration. It allows selecting absolute, incremental, or push moves.

Both AOI’s have tags for status conditions and data from the controller. The enable coil (EN) is true whenever the instruction is true.

The question marks in the next figure must be replaced with tag names or constants. You can enter 10 in the Accel field, for example, if you always want the actuator to accelerate at 0.10 G. Some tags supply data to the AOI and some are data from the AOI, available for use in the ladder logic. Constants cannot be used as outputs from the AOI.

For our example, the input & output UDT’s we created need to be entered at the bottom of the AOI’s, in the Map_Axis_Inputs and Map_Axis_Outputs fields.

Figure 2-24

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2.4.7. These tables show which tags are inputs to each AOI and which ones are outputs from it.

Manual AOI Tags

To the Controller Data Type From the Controller Data Type

Servo_On BOOL Homed BOOL

Home BOOL Alarm_Code INT

Jog_or _Inch BOOL

Jog_Inch_Forward BOOL

Jog_Inch_Reverse BOOL

Reset_Axis BOOL Table 2-2

Auto AOI Tags


Start_Move BOOL Actual_Position DINT

Target_Position DINT Axis_Moving BOOL

Target_Speed DINT Movement_Complete BOOL

Accel INT Last_Command_Current INT

Decel INT Axis_Pushing BOOL

Position_Band DINT Push_Failed BOOL

Pause_Motion BOOL

Increment_Mode BOOL

Push_Mode BOOL

Push_Forward BOOL

Push_Current INT Table 2-3

2.4.8. Tags must be created for the PCON_Axis_Manual and PCON_Axis_Auto fields in the AOI’s, as shown next. The black tag names on the left side of the AOI’s are members of these tags.

Figure 2-25

The next figure shows an example of a manual AOI being used with tags for a Human-Machine Interface (HMI). Data is exchanged via the HMI tags on the right side of the AOI. No additional ladder logic is needed to get data from the HMI or to send data to it.

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Figure 2-26

2.4.9. Some UDT members are not needed by the AOI’s but are available for use. All the members of the UDT’s are shown in the next tables.

Input UDT Members (from the controller)

Member Type Description & Mneumonics Restrictions

Actual_Position DINT The actual position of the actuator x 0.01 mm.

Command_Current DINT The current, in milliamps, that the current or last motion command required. This is not live data.

Actual _Speed INT The actual speed of the actuator x 0.01 mm/sec.

Alarm_Code INT The active alarm code, in decimal. Convert this number to hexadecimal to look it up in the controller manual.

Ready BOOL The controller is ready to execute moves. PWR

Alarm_Active BOOL ON when the alarm LED of the controller is on. ALM

E_Stop_Active BOOL When ON the controller is in an E-stopped condition. EMGS

Home_Complete BOOL The actuator has been homed. This bit stays on until the actuator needs to be homed, typically because power has been cycled, an encoder error occurred, etc. HEND

Homing Homing the actuator is in progress.

Load_Output_Reached BOOL Turns on during a push move when the push current threshold is reached in a specific zone. See LOAD in the controller manual.

PCON-CA, PCON-CFA

Manual_Mode BOOL When ON the controller is in manual mode. RMDS

Moving BOOL The actuator is in motion. MOVE

Servo_is_On BOOL The servo is turned on. SV

Position_Complete BOOL The last commanded position move was completed. This bit turns off when the controller is commanded to move or the servo is turned off. PEND

In_Zone_1 BOOL The actuator position is in ZONE1, set by parameters in the controller.

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In_PZone BOOL The actuator position is in the PZONE, set by the Zone_Minus and Zone_Plus members of the output UDT.

Push_Failed BOOL A push move was executed but a push was not detected. The motor current did not reach the push current setpoint. PSFL

Pushing BOOL A push move is in progress. The motor current has reached the push current setpoint. PUSH

Torque_Level_Reached BOOL Can be used with push moves. See TRQS in the Ethernet/IP manual.

PCON-CA, PCON-CFA

Total_Moving_Count DINT The total number of times that the actuator has moved, up to 1,048,575.

Total_Moving_Distance DINT The total number of meters that the actuator has moved, up to 1,048,575 meters.

Table 2-4

Output UDT Members (to the controller)

Member Type Description Restrictions

Target_Position DINT The position set point in 0.01 mm.

Positioning_Band DINT Determines how close the actuator must be before the position complete bit turns on, in 0.01 mm. The actuator does not stop inside this band.

Target_Speed DINT The speed set point in 0.01 mm/sec.

Acceleration INT The acceleration rate of the commanded move x 0.01 G (10 = 0.1 G)

Deceleration INT The deceleration rate of the commanded move x 0.01 G.

Servo_On BOOL ON = turn on the servo, OFF = turn off the servo. SON

Start_Move BOOL Execute the position, incremental, or push move.

Pause_Motion BOOL Temporarily stops the move in progress when on. The move continues when turned off. If Reset is turned on while Pause_Motion is on, the move in progress is aborted.

Increment_Select BOOL When ON an incremental move is commanded. The actuator will move the distance in Target_Position, relative to its actual position. In this case only, Target_Postion can be a negative value, to move the actuator towards its home position. INC

Load_Current_Threshold INT Set a threshold in this word if you want to know when the motor current exceeds a certain value. The range is 0 to 255, which represents 0 to 100% of the motor current. If threshold detection is not required, enter “0”. Load_Output_Reached will be ON when this threshold is reached.

PCON-CA, PCON-CFA

Jog_Forward BOOL Jog or inch in the direction away from home. JOG+

Jog_Reverse BOOL Jog or inch in the direction toward home. JOG-

Jog_Inch_Select BOOL OFF = jog, ON = inch. JISL

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MSEP-C and MSCON Multiple-Axis Positioning Controllers Page 14

Jog_Inch_Speed_Distance BOOL Selects between 2 pre-programmed jog or inch speeds. See JVEL in the Ethernet/IP manual.

Release_Brake BOOL Forces the brake to release, overriding the controller. Performs the same function as the RLS/NOM switch. BKRL

Stop_Mode BOOL When ON prevents the controller from using reduced current during a stop condition. See SMOD in the Ethernet/IP manual.

PCON-CA, PCON-CFA

Stop_Mode_Select_0 BOOL Selects the controller stop mode when it is idle for a time period. The default setting is “servo always on”, with both bits = 0. See ASO0 and ASO1 in the Ethernet/IP manual for more information.

Stop_Mode_Select_1 BOOL

Push BOOL When ON, the current command is a push move. PUSH

Push_Direction BOOL Push move direction; 1 = forward & 0 = reverse. DIR

Push_Current INT The set point for a push move, in percentage of motor current. Range is 20 – 70.

Zone_Minus DINT Lower limit to turn on the “In_Zone” bit from the controller.

Zone_Plus DINT Upper limit to turn on the “In_Pzone” bit from the controller.

Table 2-5

3. MSEP-C and MSCON Multiple-Axis Positioning Controllers

These controllers have integral gateways that exchanges data between their built-in axes and the PLC. MSEP-C controllers have up to 8 axes and MSCON controllers have up to 6 axes. In addition to axis data, the controllers send and receive data and commands for the Gateway, so the PLC must have UDT’s for this data exchange.

AOI’s are provided for axis control but they are not needed for the Gateway because there is very little interaction needed with it in Full-Direct mode. The Gateway input UDT has status bits for each axis and for the controller in general. This data can be read from a UDT and used in the ladder logic directly. The Gateway output UDT has a bit that must be turned on in order for the PLC to control the axes.

The instructions are written for an MSEP controller but can also be used for an MSCON. The AOI’s and UDT’s are almost identical. The only difference is that the MSCON has a manual AOI tag named Jog_Parameters that allows switching to alternate jog speeds and inch distances. The MSEP doesn’t have this tag or feature.

The MSCON has Direct Indication Mode and Direct Indication Mode 2. The AOI’s and UDT’s are written for Direct Indication Mode.

3.1. Configure the MSEP Gateway.

3.1.1. Connect to the controller with a programming cable and run the Gateway Parameter Configuration Tool application.

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3.1.2. Select MSEP in the pop-up window and then click OK.

Figure 3-1

3.1.3. The Connection Check window will appear. Select the gateway unit number if different from 0 (the default) and then click OK.

Figure 3-2

3.1.4. The software will open. Click the Read button to read the existing parameters from the MSEP gateway.

3.1.5. Click Yes when the Confirmation window pops up. Ignore the text; it should say “Read the parameters from the Gateway unit?”

Figure 3-3

3.1.6. The tool will read the parameters and an Information window will pop up. Click OK.

Figure 3-4

The main window will populate with the values read from the MSEP (next figure).

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Figure 3-5

3.1.7. Select Setting and then EtherNet/IP Setting (I) from the menu:

Figure 3-6

3.1.8. Enter the IP address and Subnet mask for the controller. Enter a default gateway if the PLC is on a different network and is connecting to the controller through a router or some other device. Click OK when done.

Figure 3-7

3.1.9. Select Setting and then Specialty Parameter from the menu. In the GW-Param tab, set the unit velocity to 0.1 mm/s or 1.0 mm/s. This determines the format of the speed data to and from the controller.

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Figure 3-8

3.1.10. If you are connecting multiple controllers to this PLC select Setting and then Unit No. (U) from the menu. Since multiple controllers are rarely connected to a PLC this document will not explain the procedure. Please see the MSEP or MSCON manual for details.

Figure 3-9

3.1.11. For MSEP controllers:

Use the Axis Type dropdown box above the Full column to select the number of axes you are configuring on this controller. The axes must be selected in pairs because there can be two possible axes for each module of the controller. If a high-output MSEP module is used, it occupies the space of two axes.

In this example we will configure 3 axes so we select 4 in the dropdown. The Full fields for axes 0 through 3 should be populated with asterisks.

Figure 3-10

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We need to change the axis 3 status from active to inactive since we will not be using it. To do that we click once on the asterisk for axis 3 and it will change from * to (*). The parentheses indicate that it is not being used. The fields toggle each time they are clicked.

Figure 3-11

3.1.12. For MSCON controllers:

Click the Direct, Positioner radio button it isn’t already selected.

Check the boxes for the axes that you are using.

Select Direct Indication1 in the dropdown boxes for the axes/modules that you are using.

Figure 3-12

3.1.13. When you have the axes configured click the Write button. The tool will write the parameters to the controller and an Information window will pop up (next figure). Click OK to close it.

Figure 3-13

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3.1.14. A Confirmation window will pop up. Ignore the text; it is asking if it is ok to restart the controller. Click Yes.

Figure 3-14

3.1.15. Another Confirmation window will pop up. Ignore the text; it is asking if it is ok to read the parameters from the controller. Click Yes.

Figure 3-15

3.1.16. Yet another Information window will pop up. Click OK to close it.

Figure 3-16

3.1.17. The window below will pop up, telling you the operation modes available for this controller. This is information, not an error message. Click OK to close it.

Figure 3-17

3.1.18. The gateway for this example is now configured for 3 active and 1 reserved axes.

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Note that the Information section shows 80 bytes Out and 80 bytes In (next figure). The data length in the PLC must also be 80 bytes long or there will be a data size mismatch error.

Figure 3-18

3.1.19. Exit the Gateway Parameter Setting Tool application.

3.2. Add the controller to RSLogix 5000.

3.2.1. Right-click the Ethernet network below the PLC’s Ethernet Port, in the I/O Configuration folder of the Controller Organizer and then select New Module…

Figure 3-19


Figure 3-20

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3.2.3. Navigate to Generic Ethernet Module and click the OK or Create button, depending on the version of RSLogix that you are using.

Figure 3-21

3.2.4. Fill in the parameters of the New Module window. Name can be any valid RSLogix name. IP Address should be an address that is appropriate for your network. Select Data – INT as the Comm Format. The Assembly Instances are the same for all IAI products; Input = 100, Output = 150, Configuration = 1. The Input and Output sizes depend on how many axes are configured in the MSEP. The Configuration size is always 0.

Figure 3-22

3.2.5. The MSEP gateway uses 8 words of input and output data, and each axis also uses 8 words. If you are

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using all 8 axes then Sizes = 8 axes x 8 words + 8 gateway words = 72 words.

The table at right shows the Size value for the number of configured axes; input and output sizes are always equal.

Figure 3-22 shows the MSEP settings for the example used earlier. There are 3 active axes and 1 reserved axis, for a total of 4 axes. The gateway uses 8 words so 8 + (4 * 8) = 40 words. Recall that the Parameter Configuration Tool showed 80 bytes of input and output data. The INT words that we used are 2 bytes each, so 40 * 2 = 80. The PLC data sizes match the controller data sizes.

3.2.6. Uncheck the Open Module Properties checkbox if it is checked; no additional parameters need to be set.

3.2.7. Click OK when done. The new module should be present in the Ethernet network, with the name that you entered.

Figure 3-23

3.2.8. The RSLogix software creates Controller Tag arrays for the module using the name that you entered. Tags for this example are shown in the next figure. Data from the controller is stored in the MSEP:I array and data to the controller is in the MSEP:O array.

Figure 3-24

3.3. Import the Axis AOI’s

3.3.1. Download and extract the AOI files for the axes and the UDT files for the MSEP gateway. The axis AOI files also contain the axis UDT’s.


Figure 3-25

# of Axes Size

1 16

2 24

3 32

4 40

5 48

6 56

7 64

8 72

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3.3.3. Navigate to the folder that contains the AOI files and select the auto AOI file (.L5X) for this controller and then click the Import button.

Figure 3-26


Figure 3-27


Figure 3-28

3.3.6. Repeat steps 3.3.2 through 3.3.5 but select the manual AOI file for the controller instead of the auto

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AOI file.

3.3.7. The next figure shows the imported AOI’s and UDT’s for this example.

Figure 3-29

3.4. Import the Gateway UDT’s

3.4.1. Right click the User-Defined folder in the Controller Organizer and click Import Data Type…

Figure 3-30

3.4.2. Navigate to the folder that contains the UDT files and select the MSEP_Gateway_Input_UDT.L5X file and then click the Import button.

Figure 3-31

3.4.3. The Import Configuration window will open, like it did for the AOI’s. Click the OK button to continue.

3.4.4. The UDT will be added to the Data Types folder.

Figure 3-32

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3.4.5. Repeat steps 3.4.1 through 3.4.4 but select the MSEP_Gateway_Output_UDT.L5X file. The Data Types folder should show the gateway input and output UDT’s when you are done:

Figure 3-33

3.4.6. If you double-click the MSEP_Axis_Input UDT you can see the contents, or Members, that make up this data type. The members are internal tags of various data types, shown in the next figure.

Figure 3-34


3.5.1. Create input and output tags for the Gateway inputs and outputs. The data types will be MSEP_Gateway_Input and MSEP_Gateway_Output, respectively. These tags are used in Synchronous Copy File (CPS) instructions to transfer data from and to the controller. Examples are shown in the next figure.

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Figure 3-35

The Destination tag of an instruction determines its Length. UDT MSEP_Inputs_GW is a single tag so Length = 1 on the first CPS above. The processor copies data starting at MSEP:I:Data[0], until the tag is filled, which takes 8 integer words (0 – 7).

Destination MSEP_O:Data[0] is an array of integer words and source MSEP_Outputs_GW contains 8 integer words of data, so Length = 8 for the second CPS above.

3.5.2. Create input and output tags that uniquely identify each axis of the MSEP. For the Data Types, select the MSEP_Axis_Input and MSEP_Axis_Output UDT’s that were imported with the AOI’s. You can either create a tag for each axis or use an array of tags.

Each axis uses 8 integer words of the “raw” data arrays, from and to the controller. The example below shows instructions that copy data from the first 3 axes of the controller to 3 UDT’s. Each UDT requires 8 integer words from the raw data. The Gateway uses words 0 to 7, the first axis uses words 8 to 15, etc.

Figure 3-36

Below are the corresponding output instructions for the 3 axes in Figure 3-36.

Figure 3-37

3.5.3. The next figure is an example that uses UDT arrays instead of individual UDT’s. The instructions copy data for 3 axes to and from arrays of UDT tags. The first axis is MSEP_Inputs_Axis[0], the second is MSEP_Inputs_Axis[1] and the third is MSEP_Inputs_Axis[2]. Each of these tags uses 8 words of the input and output data files. The output CPS destination is specified to the word level of the MSEP_O tag, so the length must be 24 (3 axes * 8 words).

Figure 3-38

The next figure shows the input and output UDT tag arrays of this example. Axis 2 is expanded to shows some of its members. Tags named unavailable are bits or words that not used by the gateway, but they must be configured to keep succeeding tags in the correct order.

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Figure 3-39

3.5.4. The members of a UDT can be used individually or the entire contents of the tag can be used by an AOI. A period (.) is used as a delimiter to specify a member of a UDT. In the next figure, MSEP_Inputs_Axis[0] member Actual_ Position is copied to a tag that is read by a Human Machine Interface (HMI).

Figure 3-40

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3.5.5. The provide convenient methods to program the controller functions. They are inserted in ladder logic like any other instruction; they are located at the bottom of the list in the Add Ladder Element popup window. Click the + symbol to expand Add-On and select the AOI that you want.

Figure 3-41


The Axis Auto AOI commands the controller to move to a position and supplies the motion data for the move, such as speed and acceleration. It allows selecting absolute, incremental, or push moves. Both AOI’s have tags for status conditions and data from the controller. The enable coil (EN) is true whenever the instruction is true.

The question marks in the next figure must be replaced with tag names or constants. You can enter 10 in the Accel_Decel field, for example, if you always want the actuator to accelerate and decelerate at 0.10 G. Some tags supply data to the AOI and some are data from the AOI, available for use in the ladder logic. Constants cannot be used as outputs from the AOI.


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Figure 3-42

3.5.7. These tables show which tags are inputs to each AOI and which ones are outputs from it. The MSCON manual AOI has a Jog_Parameters tag to select different jog & inch speeds, which the MSEP does not have.

Manual AOI Tags




Jog_or_Inch BOOL



Jog_Parameters (MSCON only)

BOOL


Auto AOI Tags





Accel_Decel INT Last_Command_Current DINT

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Pause_Motion BOOL

Increment_Mode BOOL

Push_Mode BOOL

Push_Forward BOOL


3.5.8. Tags must be created for the MSEP_Axis_Manual and MSEP_Axis_Auto fields in the AOI’s, as shown in the next figure. The black tag names on the left side of the AOI’s are members of these tags.

Figure 3-43

The next figure is an example of a manual AOI that is filled out.

Figure 3-44



Member Type Description

Actual_ Position DINT The actual position of the actuator x 0.01 mm

Command_Current DINT The current, in milliamps, that the last motion command required. This is not live data.


Actual_ Speed INT The actual speed of the actuator x 0.1 or 1 mm/sec, as set by the Parameter Configuration Tool.


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Alarm_Active BOOL ON when the axis has an active alarm condition



Alarm_Light BOOL ON when the alarm LED of this axis is on.

Movement_Complete BOOL The last commanded position move was completed. This bit turns off when the axis is commanded to move or the servo is turned off. PEND



Ready BOOL The axis is ready to execute moves.

E_Stop_Active BOOL When ON the controller is in an E-stopped condition. Table 3-3





Speed INT The speed set point in 0.1 or 1 mm/sec, as set by the Gateway Parameter Configuration Tool .

Accel_Decel INT The acceleration & deceleration rate of the commanded move x 0.01 G (10 = 0.1 G)



Home BOOL Home the axis.


Reset BOOL Resets low priority alarms. If turned on while Pause_Motion is on, it aborts the move in progress.

Servo_On BOOL Turns on the servo.

Jog_Inch_Select BOOL OFF = jog mode, ON = inch mode.

Jog_Reverse BOOL Jog towards the home position.

Jog_Forward BOOL Jog away from the home position.

Push_Mode BOOL Selects a push move. The actuator will push against an object like an air cylinder.

Push_Direction BOOL ON = push away from home, OFF = push toward home.

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ERC3 Gateway (RCM-EGW) Page 32

Increment_Select BOOL Selects an increment move. The actuator moves the distance specified in Target_Position, from its current position. If Target_Position is negative it moves toward home.


Table 3-4

3.5.10. The Gateway output UDT has a bit that places the controller in remote mode (.Remote_Control). The PLC must turn this bit on or the controller will ignore all commands that it receives. The rung can be conditioned with safety circuit inputs or other conditions if you want; an E-stop contact is shown in the rung below.

Figure 3-45

3.5.11. There is a bit that can be used to reset a communication error (.Reset_ERR_T_or_C). Most communication errors reset automatically after communication is restored so this is optional.

4. ERC3 Gateway (RCM-EGW)

An ERC3 gateway does not have built-in axes; it exchanges data between a PLC and a maximum of four ERC3 actuators.

4.1. Configure the gateway.

4.1.1. Set the MANU / AUTO switch on the gateway to the MANU position.

4.1.2. Connect to the gateway with a programming cable and run the Gateway Parameter Setting Tool software.

4.1.3. Select ERC3 GW from the pop-up window and click OK.

Figure 4-1

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4.1.4. The main window will open. Click the Read button to read the existing parameters from the gateway.

Figure 4-2

4.1.5. Click Yes when the Confirmation window pops up. Ignore the text; it should say “Read the parameters from the Gateway unit?”

Figure 4-3

4.1.6. The tool will read the parameters and an Information window will pop up. Click OK.

Figure 4-4

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The main window will populate with the values read from the gateway.

Figure 4-5

4.1.7. Select Setting and then EtherNet/IP Setting (I) from the menu:

Figure 4-6

4.1.8. Enter the IP address and Subnet mask for the controller. Enter a default gateway if the PLC is on a different network and is connecting to the controller through a router or some other device. Click OK when done.

Figure 4-7

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4.1.9. Select Setting and then Specialty Parameter from the menu. In the GW-Param tab, set the unit velocity to 0.1 mm/s or 1.0 mm/s. This determines the format of the speed data to and from the controller.

Figure 4-8

4.1.10. The gateway in this example is configured to control 4 axes. We will configure it for 2 axes. Use the dropdown box above the Full column to select 2.

Figure 4-9

4.1.11. Axes 0 and 1 will have asterisks (*) in the Full column and axes 2 & 3 will have hyphens (-).

Figure 4-10

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4.1.12. Click the Write button. A Confirmation window will pop up; click Yes.

Figure 4-11

4.1.13. The tool will write the parameters to the controller and an Information window will pop up (next figure). Click OK to close it.

Figure 4-12

4.1.14. A Confirmation window will pop up. Ignore the text; it is asking if it is ok to restart the controller. Click Yes.

Figure 4-13

4.1.15. Another Confirmation window will pop up. Ignore the text; it is asking if it is ok to read the parameters from the controller. Click Yes.

Figure 4-14

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4.1.16. Yet another Information window will pop up. Click OK to close it.

Figure 4-15

4.1.17. The window below will pop up, telling you the operation modes available for this controller. This is information, not an error message. Click OK to close it.

Figure 4-16

4.1.18. The gateway for this example is now configured for 3 active axes and 1 reserved axis.

Note that the Information section shows 48 bytes Out and 48 bytes In. The data length in the PLC must also be 48 bytes long or there will be a data size mismatch error.

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Figure 4-17

4.1.19. Exit the Gateway Parameter Setting Tool application.

4.2. Add the controller to RSLogix 5000.

4.2.1. Right-click the Ethernet network below the PLC’s Ethernet Port, in the I/O Configuration folder of the Controller Organizer and then select New Module…

Figure 4-18


Figure 4-19

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4.2.3. Navigate to Generic Ethernet Module and click the OK or Create button, depending on the version of RSLogix that you are using.

Figure 4-20

4.2.4. Fill in the parameters of the New Module window. Name can be any valid RSLogix name. IP Address should be an address that is appropriate for your network. Select Data – INT as the Comm Format. The Assembly Instances are the same for all IAI products; Input = 100, Output = 150, Configuration = 1. The Input and Output sizes depend on how many axes are configured in the gateway. The Configuration size is always 0.

In the preceding gateway configuration example we used 2 axes and the data size was 48 bytes. This is equivalent to 24 INT words so the Input and Output sizes for this example are 24. Of these words, the ERC3 gateway uses 8 and each axis uses 8.

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Figure 4-21

4.2.5. Click OK when done. The new module should be present in the Ethernet network, with the name that you entered.

Figure 4-22

4.2.6. The RSLogix software creates Controller Tag arrays for the module using the name that you entered. Tags for this example are shown in the next figure. Data from the controller is stored in the ERC3_GW:I array and data to the controller is in the ERC3_GW:O array.

Figure 4-23

4.3. Import the Axis AOI’s

4.3.1. Download and extract the AOI files for the axes and the UDT files for the gateway. The axis AOI files also contain the axis UDT’s.

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Figure 4-24

4.3.3. Navigate to the folder that contains the AOI files and select the auto AOI file (.L5X) for this gateway and then click the Import button.

Figure 4-25


Figure 4-26

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Figure 4-27

4.3.6. Repeat steps 4.3.2 through 4.3.5 but select the manual AOI file for the gateway instead of the auto AOI file. The next figure shows the imported AOI’s and UDT’s for this example.

Figure 4-28

4.4. Import the Gateway UDT’s

4.4.1. Right click the User-Defined folder in the Controller Organizer and click Import Data Type…

Figure 4-29

4.4.2. Navigate to the folder that contains the UDT files and select the ERC3_Gateway_Input_UDT.L5X file and then click the Import button.

Figure 4-30

4.4.3. The Import Configuration window will open, like it did for the AOI’s. Click the OK button to continue.

4.4.4. The UDT will be added to the Data Types folder.

Figure 4-31

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4.4.5. Repeat steps 4.4.1 through 4.4.4 but select the ERC3_Gateway_Output_UDT.L5X file. The Data Types folder should list the gateway input and output UDT’s when you are done:

Figure 4-32

4.4.6. If you double-click the ERC3_Axis_Input UDT you can see the contents, or Members, that make up this data type. The members are internal tags of various data type. Some of the members are shown in the next figure.

Figure 4-33


4.5.1. Create input and output tags for the Gateway inputs and outputs. The data types will be ERC3_Gateway_Input and ERC3_Gateway_Output, respectively. These tags are used in Synchronous Copy File (CPS) instructions to transfer data from and to the controller. Examples are shown below.

Figure 4-34

The Destination tag of an instruction determines its Length. UDT ERC3_Input_GW is a single tag so Length = 1 on the first CPS above. The processor copies data starting at ERC3_GW:I:Data[0], until the tag is filled, which takes 8 integer words (0 – 7).

Destination ERC3_GW:O.Data[0] is an array of integer words and source ERC3_Output_GW contains 8 integer words of data, so Length = 8 for the second CPS.

4.5.2. Create input and output tags that uniquely identify each axis of the gateway. For the Data Types, select the ERC3_Axis_Input and ERC3_Axis_Output UDT’s that were imported with the AOI’s. You can either create a tag for each axis or use an array of tags.

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Each axis uses 8 integer words of the “raw” data arrays, from and to the controller. The example below shows instructions that copy data from the first 3 axes of the controller to 3 UDT’s. Each UDT requires 8 integer words from the raw data. The Gateway uses words 0 to 7, the first axis uses words 8 to 15, etc.

Figure 4-35

Below are the corresponding output instructions for the 2 axes in the figure above.

Figure 4-36

4.5.3. The next figure is an example that uses UDT arrays instead of individual UDT’s. The instructions copy data for 3 axes to and from arrays of UDT tags. The first axis is ERC3_Input_Axis[0] and the second is ERC3_Input_Axis[1]. Each of these tags uses 8 words of the input and output data files. The output CPS destination is specified to the word level of the MSEP_O tag, so the length must be 16 (2 axes * 8 words).

Figure 4-37

The next figure shows the input and output UDT tag arrays of this example. Axis 1 is expanded to shows some of its members. Tags named unavailable are bits or words that not used by the gateway, but they must be configured to keep succeeding tags in the correct order.

Figure 4-38

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4.5.4. The members of a UDT can be used individually or the entire contents of the tag can be used by an AOI. A period (.) is used as a delimiter to specify a member of a UDT. In the next figure, ERC3_Input_Axis[0] member Actual_ Position is copied to a tag that is read by a Human Machine Interface (HMI).

Figure 4-39

4.5.5. The AOI’s provide convenient methods to program the controller functions. They are inserted in ladder logic like any other instruction; they are located at the bottom of the list in the Add Ladder Element popup window. Click the + symbol to expand Add-On and select the AOI that you want.

Figure 4-40


The Axis Auto AOI commands the controller to move to a position and supplies the motion data for the move, such as speed and acceleration. It allows selecting absolute, incremental, or push moves. Both AOI’s have tags for status conditions and data from the controller. The enable coil (EN) is true whenever the instruction is true.

The question marks in the next figure must be replaced with tag names or constants. You can enter 10 in the Accel_Decel field, for example, if you always want the actuator to accelerate and decelerate at 0.10 G. Some tags supply data to the AOI and some are data from the AOI, available for use in the ladder logic. Constants cannot be used as outputs from the AOI.


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Figure 4-41

4.5.7. These tables show which tags are inputs to each AOI and which ones are outputs from it.

Manual AOI Tags




Jog_or_Inch BOOL




Auto AOI Tags





Accel_Decel INT Last_Command_Current DINT


Pause_Motion BOOL

Increment_Mode BOOL

Push_Mode BOOL

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Push_Forward BOOL


4.5.8. Tags must be created for the ERC3_Axis_Manual and ERC3_Axis_Auto fields in the AOI’s, as shown in the next figure. The black tag names on the left side of the AOI’s are members of these tags.

Figure 4-42

The next figure is an example of a manual AOI that is filled out.

Figure 4-43




Actual_ Position DINT The actual position of the actuator x 0.01 mm

Command_Current DINT The current, in milliamps, that the last motion command required. This is not live data.


Actual_ Speed INT The actual speed of the actuator x 0.1 or 1 mm/sec, as set by the Parameter Configuration Tool.




Alarm_Active BOOL ON when the axis has an active alarm condition

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Ready BOOL The axis is ready to execute moves.

E_Stop_Active BOOL When ON the controller is in an E-stopped condition. Table 4-3





Target_Speed INT The speed set point in 0.1 or 1 mm/sec, as set by the Gateway Parameter Configuration Tool .

Accel_Decel INT The acceleration & deceleration rate of the commanded move x 0.01 G (10 = 0.1 G)



Home BOOL Home the axis.


Reset BOOL Resets low priority alarms. If turned on while Pause_Motion is on, it aborts the move in progress.

Servo_On BOOL Turns on the servo.

Jog_Inch_Select BOOL OFF = jog mode, ON = inch mode.

Jog_Parameters BOOL Selects between 2 sets of jog speeds & inching distances. See JVEL in the ERC3 Gateway manual for details.

Jog_Reverse BOOL Jog towards the home position.

Jog_Forward BOOL Jog away from the home position.

Push_Mode BOOL Selects a push move. The actuator will push against an object like an air cylinder.

Push_Direction BOOL ON = push away from home, OFF = push toward home.


Table 4-4

4.5.10. The Gateway output UDT has a bit that places the controller in remote mode (.Remote_Control). The PLC must turn this bit on or the controller will ignore all commands that it receives. The rung can be conditioned with safety circuit inputs or other conditions if you want; an E-stop contact is shown in the rung below.

Figure 4-44

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Programming Information Page 49

4.5.11. There is a bit that can be used to reset a communication error (.Reset_ERR_T_or_C). Most communication errors reset automatically after communication is restored so this is optional.

5. Programming Information

5.1. Communication Errors

The PLC monitors communication with the controllers. You can use a Get System Value (GSV) instruction to retrieve a fault code and then turn on a fault tag if it does not equal zero. The next figure shows one way to program this. PCON_Comm_Status and PCON _Comm_Fault are individual tags; they are not members of a UDT.

Figure 5-1

5.2. Using the AOI’s and UDT’s

5.2.1. CPS instructions for the input UDT’s should be located before the ladder logic that uses the input data and the CPS that writes to the outputs should be located after the logic. The general rule is: read the inputs, solve the logic, and then write the outputs.

5.2.2. Alarm codes are in decimal but the IAI manuals list them in hexadecimal so you must convert them before looking them up.

5.2.3. An alarm code of 163 (0A3 hexadecimal) means the controller received an out-of-range value in one of the move data.

These values must always be greater than zero: speed, acceleration, deceleration, and position band.

Target position can be a negative number but only if an incremental move is selected.

To find the valid range of a motion value, log onto the controller with the Robo Cylinder software. Open the position edit window and click on a cell in the column you want to know about. The valid range will be displayed at the bottom of the window.

CON-type controller speeds are in units of 0.01 mm/sec. Speeds for multiple-axis controllers and gateways are in units of 0.1 or 1 mm/sec, as selected by the Parameter Configuration Tool (Setting, Specialty Parameter in the menu).

5.2.4. If Start_Move is held on, the Movement_Complete bit will not turn on.

5.2.5. You don’t need to load the position and other move values prior to turning on the Start_Move bit. They can be sent to the controller in the same scan.

5.2.6. The Pause_Motion bit stops the actuator while it is turned on. The actuator resumes its motion when the bit is turned off.

5.2.7. To cancel a move in progress, turn on the Pause_Motion bit and the Reset bit.

5.2.8. A move command will replace a move in progress. If the actuator is at 50 mm, moving to 70 mm, and you command it to 30 mm, it will immediately abort the previous command and move to 30 mm. In this example it will stop at the commanded deceleration rate and move at the commanded acceleration rate & speed in the opposite direction.

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5.2.9. Position band determines when the controller turns on the movement complete bit. The actuator does not stop when it enters this band. Widening the band just turns on the movement complete bit earlier.

For example if the target position is 50 mm and position band is 5 mm, movement complete will turn on at 45 mm when moving in a positive direction, or 55 mm when moving in a negative direction. The actuator will continue to the 50 mm target position.

This feature can be useful if you need to know when the actuator is close enough to the target position to start another axis or to perform some other function on the machine, to reduce cycle time.

5.2.10. The Home and Start_Move bits should be momentary. One way to program this is to use a timer to provide a short pulse (next figure).

Figure 5-2

Another way is to turn a bit on until the actuator starts moving, using a branch or latch/unlatch coils. In the example below tag PCON_Control.Start would be entered in the manual auto AOI Start_Move field.

Figure 5-3

The Homing bit could be used in place of the Moving bit, in a similar rung that homes the actuator.

5.2.11. The Servo_On bit is not momentary; it must be held on to keep the servo turned on.

5.3. Troubleshooting

5.3.1. If data from the controller is missing or if the controller doesn’t perform the commanded operations, you can check the input and output tags created by the PLC. The input tags contain the “raw data” from the controller and the output tags contain the data being sent to it.

For example, assume we have a PCON controller and the I/O tags shown in the next figure.

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Figure 5-4

The 15 integer words in PCON:I contain the information that gets sorted and loaded into an input UDT.

Documents

Ethernet/IP Add-On Instruction (AOI) and User-defined … the Controller to RSLogix 5000. 2.2.1. Right-click the Ethernet network below the PL’s Ethernet Port, in the I/O Configuration