Connected Components Accelerator Toolkit · Connected Components Workbench™ software Software...

Pump Control Building BlockConnected Components Accelerator Toolkit

Quick Start

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

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.

Labels may also be on or inside the equipment to provide specific precautions.

Allen-Bradley, Connected Components Workbench, Micro800, Micro820, Micro830, Micro850, PanelView, PowerFlex, ProposalWorks, Rockwell Automation, Rockwell Software, RSLinx, Stratix, and Stratix 2000 are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

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.

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

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.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Where to Start

To complete the Connected Components Accelerator Toolkit (CCAT) project, follow this path.

1 - PowerFlex Compact-class AC Drive

2 - System Validation on page 25

Getting Started Connected Components Accelerator Toolkit with System Design Assistant Quick Start,

publication CC-QS035

Rockwell Automation Publication CC-QS040A-EN-P - September 2015 3

http://literature.rockwellautomation.com/idc/groups/literature/documents/qs/cc-qs035_-en-p.pdf

Where to Start

Notes:

4 Rockwell Automation Publication CC-QS040A-EN-P - September 2015

Table of Contents

Preface About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Available Connected Components Accelerator Toolkits . . . . . . . . . . . . . . 8Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1PowerFlex Compact-class AC Drive Setup

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Configure Your Personal Computer and PowerFlex Drive Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Connect to Your Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Configure Your Drive by Using Connected Components Workbench Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 2System Validation Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Review the System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Configure the Controller Communication Ports . . . . . . . . . . . . . . . . . . . 28Configure the PanelView Terminal Communication Settings. . . . . . . . 30Configure the Initial Values for Your Program. . . . . . . . . . . . . . . . . . . . . . 32Download Your Program to the Controller . . . . . . . . . . . . . . . . . . . . . . . . 32Configure the IP Address for Your PanelView Terminal. . . . . . . . . . . . . 34Transfer Your HMI Application to the PanelView Terminal . . . . . . . . 34Validate Your System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Understand the Machine Functions Screen . . . . . . . . . . . . . . . . . . . . . 36Understand the Pump Control Configuration Screen . . . . . . . . . . . 37Understand the Pump Level Control Configuration Screen. . . . . . 38Understand the Pump Pressure Control Configuration Screen . . . 40Understand the Drive Configuration Screen. . . . . . . . . . . . . . . . . . . . 41Understand the Pressure Control Screen . . . . . . . . . . . . . . . . . . . . . . . 42Understand the Level Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 43Verify the Pressure Control Application. . . . . . . . . . . . . . . . . . . . . . . . 44Verify the Level Control Application . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Appendix APowerFlex Series User-defined Function Blocks

RA_PF_PCCALC_LOPWR User-defined Function Block . . . . . . . . . 49RA_PF_PCMBUS_CFG User-defined Function Block . . . . . . . . . . . . . 50RA_PF_PCMBUS_CMD User-defined Function Block . . . . . . . . . . . . 51RA_PF_PCMBUS_STS User-defined Function Block. . . . . . . . . . . . . . 52


Table of Contents

Appendix BGlobal Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53


Preface

About This Publication

This quick start provides instructions for implementing a pump control building block that is designed for level and pressure control applications. You can use pump control with PowerFlex® Compact-class (523, 525, 4, 4M, 40, 40P, 400) AC drives. You can use the information on the faceplate to configure the type of application you want to use.

To help with the design and installation of the system, application files and other information are provided by the Connected Components Accelerator Toolkit (CCAT). The CCAT provides bills of materials (BOM), CAD drawings for panel layout and wiring, control programs, human machine interface (HMI) screens, and more. With these tools and the built-in best-practices design, you are free to focus on the design the machine control and not on design overhead tasks.

The CCAT is available on the Connected Components Accelerator Toolkit DVD, publication CC-QR002, or through the Rockwell Software® Download and Registration System (SDRS) at http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/accelerator-toolkit.page.

The beginning of each chapter contains the following information. Read these sections carefully before you begin work in each chapter:

• Before You Begin – The chapters in this quick start do not have to be completed in the order in which they appear. However, this section defines the minimum amount of preparation that is 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, including, but not limited to, hardware and software.

• Follow These Steps – This section illustrates the steps in the current chapter and identifies the steps that are required to complete the examples.

TIP Only drives with proportional-integral-derivative (PID) capability can support pressure control applications. The pump control building block detects the drive and provides the available configuration parameters.


http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/accelerator-toolkit.page


Preface

Terminology

Available Connected Components Accelerator Toolkits

For the most up-to-date listing of available Connected Components Accelerator Toolkits and related quick starts, see these resources:

• Rockwell Automation Connected Components Accelerator Toolkit website at http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/accelerator-toolkit.page

• Connected Components Accelerator Toolkit Building Block Project Descriptions Quick Reference, publication CC-QR003

Term (Abbreviation) Definition

Application Sequence Programs User-modified programs that work together with the standard-state machine logic to control what the machine does while in the abort, clear, reset, run, and stop states.

Auto/manual operation When the PanelView™ 800 terminal is in Auto mode, the controller logic controls the machine and monitors machine status. When the PanelView 800 terminal switches to Manual mode, the terminal takes over control. Command buttons and numeric entry fields are available only when the machine is in Manual mode.

Bill of Materials (BOM) A list of components that are needed for the system.

Building block (BB) Tools to accelerate and simplify the development of a Micro800® controller-based application. A typical building block includes a starting Bill of Material (BOM), Computer-Aided Design (CAD) drawings, Micro800 controller programs, PanelView 800 terminal applications, and a quick start document.

Computer-Aided Design (CAD) A computer-based system that is developed to facilitate design of mechanical parts.

Connected Components Accelerator Toolkit (CCAT) Software with application files and other information to speed the design and startup of component-based machines.

CCAT project A project that consists of these items:• A ProposalWorks™-based bill of materials• A set of CAD drawings (dimensions and schematics)• A Connected Components Workbench project• HMI screens• A set of Quick Start documents• A project document with information about the project components and links to reference materials

Connected Components Workbench™ software Software environment for configuring or programming Micro800 controllers, PanelView 800 terminals, PowerFlex drives, and other component-level products.

Connected Components Workbench project A project consists of one or more of the following:• Micro800 controller configuration• Up to 256 Micro800 programs, each with program local variables• Micro800 global variables• PanelView 800 terminal application• PowerFlex drive parameter lists

Global variables Project variables that any program can access, including all I/O and system variables.

State Machine control code Machine logic for coordinating overall machine operation that is based on states. The state machine broadcasts commands and receives feedback information from each of the building blocks via user-modified application sequence programs.

Tags A PanelView 800 terminal term for variables.

User-defined Function Blocks (UDFBs) Function block instructions that can be used like standard function block instructions within any Connected Components Workbench programming language. Anyone that uses Connected Components Workbench software can write these functions blocks. Many UDFBs are posted on the Rockwell Automation® sample code website:http://samplecode.rockwellautomation.com/idc/groups/public/documents/webassets/sc_home_page.hcst.

User-defined Object (UDO) A collection of PanelView 800 terminal screen objects that can be pasted into a new screen.


http://samplecode.rockwellautomation.com/idc/groups/public/documents/webassets/sc_home_page.hcst




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Preface

Additional Resources

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

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

Resource Description

Connected Components Accelerator Toolkit DVD, publication CC-QR002

Provides files for the Connected Component Accelerator Toolkits.

Micro800 Programmable Controller External AC Power Supply Installation Instructions, publication 2080-IN001

Provides information on how to mount and wire the optional external power supply.

Micro830 and Micro850 Programmable Controllers User Manual, publication 2080-UM002

Provides information on how to install the Micro830® and Micro850® programmable controllers, including how to wire and troubleshoot.

PanelView 800 HMI Terminals User Manual, publication2711R-UM001

Provides information on how to configure the PanelView 800 terminal.

PanelView 800 HMI Terminals Installation Instructions, publication 2711R-IN001

Provides instructions on how to install, wire, ground, and troubleshoot PanelView 800 terminals.

PowerFlex 4 Adjustable Frequency AC Drive User Manual, publication 22A-UM001

Provides information on how to install, start, and troubleshoot PowerFlex 4 adjustable frequency AC drives.

PowerFlex 40 Adjustable Frequency AC Drive User Manual, publication 22B-UM001


PowerFlex 400 Adjustable Frequency AC Drive for Fan and Pump Applications User Manual, publication 22C-UM001


PowerFlex 40P Adjustable Frequency AC Drive User Manual, publication 22D-UM001

Provides information on how to install, start, and troubleshoot PowerFlex 40P adjustable frequency AC drives.

PowerFlex 4M Adjustable Frequency AC Drive User Manual, publication 22F-UM001

Provides information on how to install, start, and troubleshoot PowerFlex 4M adjustable frequency AC drives.

PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001

Provides information on how to install, start, and troubleshoot PowerFlex 520-Series adjustable frequency AC drives.


http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711r-um001_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2711r-in001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2080-in001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2080-um002_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22a-um001_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22b-um001_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22c-um001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22d-um001_-en-e.pdf

http://www.rockwellautomation.com/literature

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22f-um001_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/520-um001_-en-e.pdf

Preface

Notes:


Chapter 1

PowerFlex Compact-class AC Drive Setup

This chapter provides instructions to configure your PowerFlex® AC drive to communicate with a Micro800® programmable logic controller (PLC) by using the Modbus RTU (Remote Terminal Unit transmission mode) protocol. Later in this guide, the PLC is programmed to use the sample building-block code that is supplied in this Connected Components Accelerator Toolkit (CCAT). Micro850® controllers and PowerFlex 523 drives are referenced throughout this Quick Start. Wherever a Micro850 controller is referenced, a Micro830® or Micro820™ controller can also be used. Wherever a PowerFlex 523 drive is referenced, a PowerFlex 525, 4, 4M, 40, 40P, or 400 drive can also be used.

These drives do not have PID capability. The pump control building block is limited to only level control for these drives:• PowerFlex 4 drives• PowerFlex 4M drives

These drives do have PID capability. The pump control building block supports level and pressure control for these drives:• PowerFlex 40 drives• PowerFlex 40P drives• PowerFlex 400 drives• PowerFlex 523 drives• PowerFlex 525 drives

Before You Begin• Review the Connected Components Accelerator Toolkit with System Design Assistant Quick Start, publication

CC-QS035.• Wire the drive according to the provided CAD diagram.• Apply power to the drive.

What You Need• Personal computer with an available USB port• Connected Components Workbench™ software, version 6 or later• 1203-USB converter with 22-HIM-H10 cable• PowerFlex 523, 525, 4, 4M, 40, 40P, or 400 drive


http://literature.rockwellautomation.com/idc/groups/literature/documents/qs/cc-qs035_-en-p.pdf

Chapter 1 PowerFlex Compact-class AC Drive Setup

Follow These Steps

To configure your PowerFlex AC drive for the pump control application, follow these steps.

Configure Your Personal Computer and PowerFlex Drive Connection

To configure the connection between your personal computer and your drive, follow these steps.

1. Connect the RJ45 connector from the 1203-USB serial adapter to the DSI communication port on your drive.

2. Connect the USB connector from the 1203-USB serial adapter cable to an available USB port on your computer.

If you are prompted to install drivers, use the recommended drivers.

3. To verify the COM port number of the 1203-USB serial adapter in Device Manager on your computer, choose Run from the Start menu.

4. In the Open box, type devmgmt.msc.

Start

Configure Your Personal Computer and PowerFlex

Drive Connection on page 12

Connect to Your Drive on page 17

Configure Your Drive by Using Connected

Components Workbench Software on page 18


PowerFlex Compact-class AC Drive Setup Chapter 1

5. Click OK.

6. In the Device Manager dialog box, expand the Ports (COM & LPT) group, and locate the Allen-Bradley® 1203-USB device.

The COM port is specified in parentheses next to the device name (COM3 in this example). It can be different on your computer.

7. Note your port name and close the Device Manager window.

8. To configure an RS-232 DF1 driver, start RSLinx® Classic software.

9. From the Communications menu, choose Configure Drivers.



10. In the Configure Drivers dialog box, from the Available Driver Types pull-down menu, choose RS-232 DF1 devices.

11. Click Add New.

12. In the Add New RSLinx Classic Driver dialog box, type a name for your driver (you can use the default name, if desired).

13. Click OK.



14. In the Configure RS-232 DF1 Devices dialog box, configure the driver settings as follows:a. From the Comm Port pull-down menu, choose the port number of your 1203-USB serial adapter.b. From the Device pull-down menu, choose 1770-KF2/1785-KE/SCANport.c. From the Baud Rate pull-down menu, choose 115200.

15. Click OK.

16. In the RSLinx toolbar, click the RSWho icon to verify that your drive is properly communicating with RSLinx Classic software.

IMPORTANT Do not click Auto-Configure.



17. Expand your RS-232 DF1 driver, and verify that your drive is displayed.

The drive is listed as 01, AB DSI. If the drive does not appear below the driver, check your COM port and driver settings.

18. Close RSLinx Classic software.

Do not shut down. The RSLinx Classic icon still appears in your icon tray.



Connect to Your Drive

Follow these steps to connect to your drive by using Connected Components Workbench software.

1. Open the Pump Control Building Block Connected Components Workbench project or the Connected Components Accelerator Toolkit (CCAT) version 2.0 generated project.

Use Controller Type Change if necessary to match your Micro800 controller. See the software help instruction for Controller Type Change.

2. In the Connected Components Workbench Device Toolbox, expand Discover, and click Browse Connections.

3. From the Connection Browser dialog box, select your drive (01, AB DSI) and click OK.



A drive is added to the Project Organizer and the drive appears in the Device Details window in the main project workspace. This example shows a PowerFlex 523 drive.

Configure Your Drive by Using Connected Components Workbench Software

The following steps show you how to configure your drive to work with the Pump Control Building Block. The example shows a PowerFlex 523. However, the steps are the same for different PowerFlex drives.

1. In the toolbar, click the Wizards icon.



2. From the list of Available Wizards, select the applicable Startup Wizard and click Select.

3. Complete each step of the Startup Wizard sequentially.

4. When the Reset Parameters step appears in the Wizard, click Reset below Reset all settings to factory defaults (including the custom parameter group).



5. To confirm the reset, click Yes.

A confirmation message with a green check mark appears in the window to indicate that the reset was completed successfully. It is acceptable if your drive faults after resetting the parameters.

6. Continue the Startup Wizard steps and enter the proper data to commission your drive.



7. When the Digital Inputs step appears, from the Start Source pull-down menu, choose Serial/DSI as the Start Source.

8. To avoid a conflict with the Start Source choice, from the Start Source 3 pull-down menu, choose Keypad.

9. From the DignIn TermBlk xx pull-down menus, choose Not Used.

10. Continue the Startup Wizard steps to complete your drive commissioning.



11. When the Applied and Pending Changes step appears, click Finish to complete and exit the wizard.

12. Set the RS485 Data Rate parameter to 19,200.

See the table for the respective parameter addresses of different drives.

PowerFlex 4 PowerFlex 4M PowerFlex 40 PowerFlex 40P PowerFlex 400 PowerFlex 523 PowerFlex 525

Parameter Address #103 #302 #103 #103 #103 #123 #123



13. Select the input type for the PID feedback.

In this example, we select 4 – 20 mA Input to use as our PID feedback.

See the table for the respective parameter addresses of different drives.

14. (Applicable only to PowerFlex 400 drives. If the drive is not a PowerFlex 400 drive, continue with step 15.)

Configure the Analog In 2 (#153) as a 4 – 20 mA input. Select Analog In 2 Sel (#73) as 4 – 20 mA.

This step configures Analog In 1 to provide a 0 – 10V signal, and Analog In 2 to provide a 4 – 20 mA signal.

The RS-485 Data Rate must be the same for all drives that are connected on the serial/Modbus connection, with 19200 baud being the fastest rate possible. Each drive on the serial/Modbus connection must have a unique RS-485 node address from 1…247.

Changes are made and saved immediately because you are connected to the drive.

PowerFlex 4 PowerFlex 4M PowerFlex 40 PowerFlex 40P PowerFlex 400 PowerFlex 523 PowerFlex 525

Parameter Address NIL NIL #133 #133 #153 #460 #460



15. To close the Parameter list editor, click the X in the upper right corner.

16. Cycle power to the drive to change the RS-485 Data Rate and the RS-485 Node Address.

Remove power from the drive and wait 10 seconds before restoring power.

17. Disconnect the 1203-USB cable from your personal computer and from the drive.

The drive configuration is now complete.


Chapter 2

System Validation

This chapter provides instructions on how to configure, connect, and validate communication between the devices in your PowerFlex® Compact-class AC drive device pump control building block system.

Before You Begin• Complete the steps in Chapter 1.• Verify that the devices are connected as shown in the assembled wiring diagrams.• Verify that your Micro800® controller, the PowerFlex AC drive, and the PanelView™ 800 terminal have power that is

applied to them.

What You Need• Micro820™, Micro830®, or Micro850® controller with Isolated Serial Port plug-in module (catalog number 2080-

SERIALISOL)• PowerFlex 523, 525, 4, 4M, 40, 40P, or 400 drive• 4 in. (or larger) PanelView 800 terminal• 1761-CBL-PM02, 9-pin to 8-pin MINI-DIN RS-232 communication cable, if a CIP serial connection for the

PanelView 800 terminal is used• Two 1585J-M8xxxx-2 RJ45 Ethernet patch cords, if a CIP on Ethernet connection for the PanelView 800 terminal

is used• 1783- USxxx Stratix 2000™ unmanaged Ethernet switch• Two-wire, twisted-pair shielded RS-485 communication cable (Belden 3105A recommended)• AK-U0-RJ45-TB2P, RJ45 two position terminal block with a 120 Ω terminating resistor• USB programming cable (A to B) or Ethernet cable for personal computer to Micro800 controller communication• Personal computer with available USB port and Ethernet connection with Connected Components Workbench™

software, version 6.00 or later, installed


Chapter 2 System Validation

Follow These Steps

To validate your system, complete these steps.

Review the System Overview on page 27

Validate Your System on page 36

Configure the Controller Communication Ports on page 28

Configure the PanelView Terminal Communication Settings on

page 30

Configure the Initial Values for Your Program on page 32

Download Your Program to the Controller on page 32

Transfer Your HMI Application to the PanelView Terminal on

page 34

Start

Configure the IP Address for Your PanelView Terminal on page 34


System Validation Chapter 2

Review the System Overview

The PanelView Graphic Terminal can be connected to the Micro800 controller with a CIP serial or CIP on Ethernet connection:

• For a CIP serial connection, use a 1761-CBL-PM02 cable to connect the PanelView 800 terminal to the embedded serial port of the Micro800 controller.

• For a CIP-on-Ethernet connection, connect the PanelView 800 terminal to the Stratix™ Ethernet switch. Then use the Ethernet patch cords to connect the Stratix™ Ethernet switch to the embedded Ethernet port of the Micro800 controller.

Both methods of connection are explained in this manual, but choose only one method for your project.

The PowerFlex drive is connected to the Micro800 controller by the Isolated Serial Port plug-in module (catalog number 2080-SERIALISOL) with two-wire, twisted-pair, shielded cable (Belden 3105A recommended), and one AK-U0-RJ45-TB2P terminal block connection per drive. These devices communicate with the Modbus RTU protocol (RS-485). The Micro800 controller is the Modbus master, and the PowerFlex drive is the Modbus slave. Additional Modbus RTU slave devices can be daisy chained on this RS-485 network.

Figure 1 - Device and Network Layout Diagram

PanelView 800 Terminal

Micro800 PowerFlexAC Drive

OtherModbus Devices

1761-CBL-PM02 (CIP serial) Cableor

Ethernet Switch and Cables

2080-SERIALISOL

RS-485 (Belden 3105A) Cable toAK-U0-RJ45-TB2P Terminal Block



Configure the Controller Communication Ports

The following settings are used for CIP serial communication.

Table 1 - Default Serial Port Settings

Embedded Serial Port(to PanelView 800 Terminal)

Setting Value

Driver CIP Serial

Baud Rate 38400

Parity None

Unit Address 1

Advanced Settings

Error Detection CRC

Embedded Responses After One Received

Duplicate Packet Detection Yes

Ack Timeout (x 20 ms) 50

NAK Retries 3

ENQ Retries 3

Transmit Retries 3

RTS Off Delay 0

RTS Send Delay 0

2080-SERIALISOL Plug-in Module(to PowerFlex AC Drive)

Setting Value

Driver Modbus RTU

Baud Rate 19200

Parity None

Modbus Role Modbus RTU Master

Advanced Settings

Media RS-485

Data Bits 8

Stop Bits 1

Response Timer 200

Broadcast Pause 200

Inter-Char Timeout 0

RTS-Pre Delay 0

RTS-Post Delay 0



To modify these settings in the default Connected Components Workbench project, follow these steps.

1. Open the Pump Control Building Block generated from CCAT version 2 or downloaded from sample code website.

2. In the project Organizer, double-click the controller icon. This example shows a Micro850 controller.

The Controller Detail view appears in the main project window.

3. Configure the settings for your PanelView graphic terminal communication port:• If a CIP serial connection is used, select the embedded serial port in the controller configuration list and edit the

required settings.

• If a CIP on Ethernet connection is used, complete the following steps.a. Select the Ethernet port in the controller configuration list.b. Click Configure IP address and settings.c. Edit the IP Address, Subnet Mask, and Gateway Address settings.



Configure the PanelView Terminal Communication Settings

In the default project, the CIP serial communication and controller settings have already been configured. The following settings are used.

Table 2 - Default CIP Serial Communication and Controller Settings

To modify these settings in the default Connected Components Workbench project, follow these steps.

1. Double-click the PanelView terminal device icon.

The PanelView Communication Settings pane appears in the main project window.

Driver Configuration

Protocol CIP Serial

Port RS-232

Baud Rate 38400

Data Format: 8-N-1 8-N-1

Flow Control None

Controller Settings

Name PLC-1

Controller Type Micro800

Address 1



2. Configure the appropriate communication settings for the communication type:• For CIP Serial communication, configure the settings that are shown here.

• For CIP on Ethernet communication, configure the settings that are shown here.



Configure the Initial Values for Your Program

To configure the initial values for your controller, follow these steps.

1. Open the local variable of Pump1_PF_CmdSts

2. Update the Initial Value of the following variables.• a_Channel – Serial plugin slot number. Default is 5, which indicates the first slot on the left.• a_Drv_AnalogIn – Indicates the type of analog input that is connected to the drive terminal. Default is False,

which indicates that the input is 4 – 20 mA. If it is 0 – 10V, set this parameter to TRUE.• a_Interval – Set the time interval for the building block to send command and receive feedback. Default is 1000

ms, which indicates that a message is sent and received every second.• a_Node – Set the target node address of the drive. The default address is 100.

Download Your Program to the Controller

To download your program to the controller, follow these steps.

1. Connect the computer to the controller by using the Ethernet or USB connection.



If you are prompted to install any driver, use the recommended drivers.

2. In your Connected Components Workbench project, in the Project Organizer, right-click your controller icon and choose Build.

3. When the program is finished building, check the Output pane at the bottom of your project window for a build success message.

Example Output Pane: Build Successful

If the build is successful, continue to step 4.

If the build is unsuccessful, an errors list appears. Continue to step a.

Example Output Pane: Error List

a. Double-click an error description to go to that error.b. Correct each error.c. Repeat step 2 and step 3 until the build is successful and continue to step 4.

4. From the Project Organizer, right-click your controller icon and choose Download.



5. From the connection browser, select your controller and click OK.

6. If prompted to change the controller mode to Remote Program mode, click Yes.

Configure the IP Address for Your PanelView Terminal

To configure a static IP address on the PanelView terminal, follow these steps.

1. To open the Communication screen, from the Main menu, press Communication.

2. Press Set Static IP Address.

3. Configure the IP Address and Mask values so they are in the same range as your Micro800 controller.

4. To return to the Main menu, press Main.

Transfer Your HMI Application to the PanelView Terminal

To transfer your HMI application to the PanelView terminal by using Connected Components Workbench software, follow these steps.

1. In the Project Organizer, right-click the PanelView 800 terminal icon and choose Download.

If project is not validated, choose validate before download.



2. The Connection Browser window would appear. Select the PanelView 800 terminal and click OK.

3. Verify that the download completed successfully.

4. From the Main menu of your PanelView 800 terminal, press File Manager.

5. On the File Manager screen, select Internal as your Source.

6. Select your application PC_T7T_M800_CIPS_r8.



7. Press Run.

Validate Your System

In this section, you review the Machine Functions screen and explore the Status and Command screens to test the manual control of the building block.

Understand the Machine Functions Screen

The Machine Functions screen is the screen that links to the installed building blocks. When this screen is first loaded, you can complete the following tasks:

• Return to the Machine Overview screen by pressing the X in the upper right corner of the screen.• View a device in detail by pressing its button.• View the current machine Auto/Manual state.• Change the current machine Auto/Manual state.• Clear machine faults, start/stop the machine (while in Auto mode), and go to the machine-state diagram overview

screen.

Figure 2 - Machine Functions Screen

The border of the device button changes color to indicate a specific status. For the Pump Control Building Block, the button border colors indicate the following status:

• A green border indicates that the safety relay is active and operating.• A gray border indicates that the safety relay is inactive and stopped.• A red border indicates that there is a fault, or an alarm is present.



Understand the Pump Control Configuration Screen

This section provides descriptions of the pump control configuration screen.

Table 3 - Pump Control Configuration Screen

Pump Control Configuration Screen Name Selection Description

Application Level The application is configured for level control. The Level Ctrl Config button is available for configuration.

Pressure The application is configured for pressure control. The Pressure Ctrl Config button is available for configuration.

Auto Drive Detect – Identifies one of these supported Rockwell Automation drives:• PF4 = PowerFlex 4 drive • PF4M = PowerFlex 4M drive • PF40 = PowerFlex 40 drive • PF40P = PowerFlex 40P drive • PF400 = PowerFlex 400 drive • PF523 = PowerFlex 523 drive • PF525 = PowerFlex 525 drive If an unknown drive is detected, the field displays Unknown Drive.

Sec. PV Not Used The secondary input is not enabled.

PLC The secondary input is enabled and the reference signal is taken from the PLC analog input terminal. A secondary gauge appears in the control panel for monitoring purposes.

Alarm config Not Configured

No pump alarm is configured. The building block only reports drive-related errors. Pump alarms include these conditions:• High-level or low-level• Dry pump• Run out pump• Low-flow or no-flow

Alarm only This process reports the pump alarm, but does not terminate the application.

Alarm-Stop This process reports the pump alarm, and does terminate the application.

Level Control Configuration Application

Pressure Control Configuration Application



Understand the Pump Level Control Configuration Screen

This section provides descriptions of the pump level control configuration screen.

Table 4 - Pump Level Feedback From Panel

Table 5 - Pump Level Secondary Input From Panel

Pump Level Feedback From Panel Name Selection Description

Level Fdbk From Drive The reference signal from the drive analog input terminal. The scale factor is fixed at 0…100%.

PLC Take in reference signal from the PLC analog input terminal. The scale factor is fixed at 0 …100%.

Pump Level Secondary Input From Panel Name Selection Description

Sec PV From Not Used The secondary input is not enabled.

PLC The secondary input is enabled and the reference signal is from the PLC analog input terminal. A secondary gauge appears in the control panel for monitoring purposes.

Scaling 0V/4mA Enter the lower limit value of the sensor value. If you are not sure what value to enter, use 0 and read it as 0%.

10V/20mA Enter the upper limit value of the sensor value. If you are not sure what value to enter, use 100 and read it as 100%.



Table 6 - Alarm Limit Configuration Panel

Table 7 - Level SP ON/OFF Configuration Panel

Alarm Limit Configuration Panel Name Description

L_Limit (%) The low-limit setting for level control. If the water level drops below this percentage point, the alarm reacts according to the alarm configuration setting.

H_Limit (%) The high-limit setting for level control. If the water level reaches this percentage point, the alarm reacts according to the alarm configuration setting.

Level SP ON/OFF Configuration Panel Name Description

Off SP (%) The setpoint where the pump is switched off. Typically indicates that the water in the tank is filled to the required level.

On SP (%) The setpoint where the pump is switched on to begin filling the tank with water until it reaches the Off SP level.

IMPORTANT The software checks for the Alarm Limit and Off/On SP (%) configuration that is based on the following rule:L_Limit < On SP < Off SP < H_Limit.If the setting does not fit the rule, you cannot access the level control screen.



Understand the Pump Pressure Control Configuration Screen

This section provides descriptions of the pump pressure control configuration screen.

Table 8 - Pump Pressure Control Configuration – Primary Input Scaling

Table 9 - Pump Pressure Control Configuration – Secondary Input Scaling

Table 10 determines the conditions that trigger the dry pump, run out, low-flow, and no-flow alarms.

Table 10 - Pump Pressure Control Configuration – Max Pressure and Alarm Timer

Primary Input Scaling Name Selection Description

Scaling 0V/4mA Enter the lower limit value of the pressure sensor value. If you are not sure what value to enter, use 0 and read it as 0%.

10V/20mA Enter the upper limit value of the pressure sensor value. If you are not sure what value to enter, use 100 and read it as 100%.

Secondary Input Scaling Name Selection Description

Sec PV From Not Used The secondary input is not enabled.

PLC The secondary input is enabled and the reference signal is taken from the PLC analog input terminal. A secondary gauge appears in the control panel for monitoring purposes.

Scaling 0V/4mA Enter the lower limit value of the sensor value. If you are not sure what value to enter, use 0 and read it as 0%.

10V/20mA Enter the upper limit value of the sensor value. If you are not sure what value to enter, use 100 and read it as 100%.

Max Pressure and Alarm Timer Name Description

Max Pressure Enter the maximum pressure for the system.

NF Pwr @ 25Hz Enter the power reading of the drive when it is running at 25 Hz without water flow. You can access the drive display menu to determine the value.

NF Pwr @ 42.5Hz Enter the power reading of the drive when it is running at 42.5 Hz without water flow. You can access the drive display menu to determine the value.

Run Out Timer The run out alarm is activated when a run out condition continues beyond the configured duration.

Low/NF Timer The low/no flow alarm is activated when a low/no flow condition continues beyond the configured duration.

Dry Pump Timer The dry pump alarm is activated when a dry pump condition continues beyond the configured duration.



Understand the Drive Configuration Screen

This section provides descriptions of the drive configuration screen.

Table 11 - Drive Configuration Screen

The following parameters are available only when the building block detected a Rockwell Automation drive with PID capability.

Table 12 - Rockwell Automation Drive with PID Capability Configuration

Drive Configuration Screen Name Description

Max Freq Sets the highest frequency that the drive outputs.

Min Freq Sets the lowest frequency that the drive outputs.

Acc Time (s) Sets the time for the drive to accelerate from 0 Hz to maximum frequency.

Dec Time (s) Sets the time for the drive to decelerate from maximum frequency to 0 Hz.

Rockwell Automation Drive with PID Capability Configuration

Name Description

Kp Sets the value for the PID proportional component.

Ki (s) Sets the value for the PID integral component.

Kd Sets the value (in 1/second) for the PID differential component.

DeadBand (%) Sets the lower limit of the PID output.



Understand the Pressure Control Screen

This section provides descriptions of the pressure control configuration screen.

Table 13 - Process Valve Gauges Panel

Table 14 - Main Control Panel

Table 15 - Drive Control Panel

Primary and Secondary Process Valve Gauges Panel Name Description

Pri PV Primary process value gauge. This gauge display the scaled primary process value. The scale factor is determined in the pressure control configuration screen.

Sec PV Secondary process value gauge. This gauge display the scaled secondary process value. The scale factor is determined in the pressure control configuration screen.

Main Control Panel Name Description

Pump Ready Green = indicates that the pump is ready to start.Gray = indicates that the pump is not ready to start.

Run Out – The pump is running at full speed with low-pressure feedback.

Red = indicates that the run out alarm is activated.Gray = indicates that the run out alarm is not activated.

Dry Pump – The pPump is running at full speed with low power consumption.

Red = indicates that the dry pump alarm is activated.Gray = indicates that the dry pump alarm is not activated.

Low/ No Flow – The pump is running at low speed, or less than maximum speed, with low power consumption.

Red = indicates that the low/no flow alarm is activated.Gray = indicates that the low/no flow alarm is not activated.

Mode Speed = indicates that user input speed command to control drive frequency.Pressure = indicates that user input pressure set point to control the pressure of the system.

Pa SP Enter the pressure setpoint value.

Drive Control Panel Name Description

Drive Ready Green = indicates that the drive is ready to start.Gray = indicates that the drive is not ready to start.

Drive Act Green = indicates that the drive is active.Gray = indicates that the drive is not active.

Drive Fault Red = indicates that the drive is faulted.Gray = indicates that the drive is not faulted.

Comm Loss Red = indicates that the drive communication is lost.Gray = indicates that the drive communication is not lost.

Act Freq Display the actual frequency in which the pump is running.

Cmd Freq Enter the required frequency for the pump.



Table 16 - Fault Panel

Understand the Level Control Screen

This section provides descriptions of the level control configuration screen.

Table 17 - Level Control High/Low Panel

Table 18 - Main Control Panel

Fault Panel Name Description

Start Start the speed or pressure mode.

Stop Stop the speed or pressure mode.

Clr Fault Clear the pump and drive fault.

Pump Fault Access the pump fault screen.

Level Control High/Low Panel Name Description

High Red = indicates that the water level exceeds the high-limit setting.Gray = indicates that the water level is below the high-limit setting.

OFF (%) Enter the level (in percentage) to switch off the pump.

ON (%) Enter the level (in percentage) to switch on the pump.

Low Red = indicates that the water is below the low-limit setting.

Level Control Main Control Panel Name Description

Prgm/Opr Manual = Operator can manually start and stop the pump at the command frequency.Auto = The level control program controls when the pump starts and stops at the command frequency.

Level (%) The current level of water in the tank (in percentage).

Sec. PV Indicates the scaled value of the secondary sensor.



Table 19 - Drive Control Panel

Verify the Pressure Control Application

To verify the pressure control application, follow these steps.

1. Configure the Application as Pressure.

2. Press Pressure Ctrl Config.

3. Configure the scale factor for the Primary PV as shown here.

Level Control Drive Control Panel Name Description

Drive Ready Green = indicates that the drive is ready to start.Gray = indicates that the drive is not ready to start.

Drive Act Green = indicates that the drive is active.Gray = indicates that the drive is not active.

Drive Fault Red = indicates that the drive is faulted.Gray = indicates that the drive is not faulted.

Act. Freq Displays the actual frequency at which the pump is running.

Cmd. Freq Enter the required frequency for the pump.

Start Start the pump.

Stop Stop the pump.

Clr Fault Clear pump and drive faults.

Fault Access the fault help screen.

IMPORTANT You must use a drive with PID capability. The building block detects the drive. This example uses a PoweFlex 523 drive.



4. To return to the Pump Control Config screen, press X.

5. To access the Pressure Control screen, press Pressure Control.

6. If there is a fault, press Clear Fault.

7. Set Mode to Speed.

8. Enter Cmd. Freq as 30.

9. Press Start.

Pump accelerates to 30 Hz.

10. Press Stop.

Pump decelerates to a stop.

11. Change the mode to Pressure.

12. Enter the Pa SP as 30%.

13. Press Start.

The motor accelerates and adjusts its own speed until the Pri PV stabilizes at 30%.

14. To stop the application, press Stop.



Verify the Level Control Application

To verify the level control application, follow these steps.

1. To return to the Pump Configuration screen, press X.

2. Configure the Application as Level.

3. Press Level Ctrl Config.

4. Configure the required Low Limit, High Limit, Off Setpoint, and On Setpoint by using this equation.

Low Limit < On Setpoint < Off Setpoint < High Limit

5. To return to Pump Configuration screen, press X.

6. To access the level control screen, press Level Control.

7. If there is fault, press Clear Fault.

8. Set to Manual mode.

9. Set Cmd. Freq to 20 Hz.

10. Press Start.



Pump accelerate 20 Hz.

11. Press Stop.

Pump decelerate to stop.

12. Change mode to Program.

13. To start Program mode, press Start:• The pump turns on when the level falls below the On Setpoint level.• The pump turns off when the level exceeds the Off Setpoint level.

14. To stop Program mode, press Stop.



Notes:


Appendix A

PowerFlex Series User-defined Function Blocks

This appendix describes the available user-defined function blocks and the associated inputs and outputs.

RA_PF_PCCALC_LOPWR User-defined Function Block

This function block estimates the operating and no-flow power of the system.

Table 20 - RA_PF_PCCALC_LOPWR Inputs

Table 21 - RA_PF_PCCALC_LOPWR Outputs

Function Block Inputs Data Type Description

FBEN BOOL Set this bit to TRUE to enable the function block.

SpdFdbk REAL Assign the drive speed feedback in Hz to this input.

MaxSpd REAL Set the max speed of the drive in Hz.

DrvCurrent REAL Assign the drive operating current to this input.

DrvVoltage REAL Assign the drive operating voltage to this input.

NoFlo_OutPwr_HiSpd REAL Set the estimated power consumption of the system at 85% drive speed.

NoFlo_OutPwr_LoSpd REAL Set the estimated power consumption of the system at 50% drive speed.

Function Block Outputs Data Type Description

FBENO BOOL This bit is TRUE when the function block is enabled.

OutputPwr REAL Estimate of the operating power.

NoFlo_OutputPwr REAL Estimate of the operating power when there is no flow.


Appendix A PowerFlex Series User-defined Function Blocks

RA_PF_PCMBUS_CFG User-defined Function Block

This function block configures the listed parameters for the drive.

Table 22 - RA_PF_PCMBUS_CFG Inputs

Table 23 - RA_PF_PCMBUS_CFG Outputs



Channel UINT Set this value to the channel of the serial port for the drive communication.

NodeAddr USINT Set this value to the Modbus node address of the drive.

Interval UINT Set this value to the rate in milliseconds used to update the drive status variables.

Accel_Time REAL Set the time for the drive to accelerate from 0 Hz to P044 [Maximum Freq].

Decel_Time REAL Set the time for the drive to decelerate from P044 [Maximum Freq] to 0 Hz.

MinFreq REAL Set the minimum frequency of the drive.

MaxFreq REAL Set the maximum frequency of the drive.

Kp REAL Set the proportional gain of the drive (only applicable to drives with PID capability).

Ki REAL Set the integral time of the drive (only applicable to drives with PID capability).

Kd REAL Sets the differential rate of the drive (only applicable to drives with PID capability).

Deadband REAL Set the lower PID output limit as a percentage.



FB_Err BOOL This bit is TRUE when an error in the function block occurs.

FB_ErrCode UINT This value is the enumerated function block error code if an error occurs.Bit 0 = Modbus Message Communication ErrorBit 1 = Invalid ChannelBit 2 = Invalid Node AddressBit 3 = Invalid Drive Type

DriveCommLoss BOOL This bit is TRUE when communication is lost between the controller and the drive.


PowerFlex Series User-defined Function Blocks Appendix A

RA_PF_PCMBUS_CMD User-defined Function Block

This function block issues pump control commands to operate the drive.

Table 24 - RA_PF_PCMBUS_CMD Inputs

Table 25 - RA_PF_PCMBUS_CMD Outputs






Start BOOL Set this bit to TRUE to start the drive.

Stop BOOL Set this bit to TRUE to stop the drive.

SetFwd BOOL Set this bit to TRUE to set the drive rotation to forward.

SetRev BOOL Set this bit to TRUE to set the drive rotation to reverse.

ClrFlt BOOL Set this bit to TRUE to clear a drive fault.

SetPoint REAL Set this value to the pressure that you want the drive to operate at, in percentage.

PIDmode BOOL Set this bit to TRUE to set the drive to Pressure mode.

Spdmode BOOL Set this bit to TRUE to set the drive to Speed mode.

SpeedRef REAL Set this value to the speed that you want the drive to operate at, in Hz.





DriveCommLoss BOOL This bit is TRUE when communication is lost between the controller and drive.


Appendix A PowerFlex Series User-defined Function Blocks

RA_PF_PCMBUS_STS User-defined Function Block

This function block reads the required drive status for the pump control.

Table 26 - RA_PF_PCMBUS_STS Inputs

Table 27 - RA_PF_PCMBUS_STS Outputs


FBEN BOOL Set this bit TRUE to enable the function block.








Ready BOOL This bit is TRUE when the drive is in the ready state.

Active BOOL This bit is TRUE when the drive is active.

CmdFwd BOOL This bit is TRUE when the drive is set to forward rotation.

CmdRev BOOL This bit is TRUE when the drive is set to reverse rotation.

Alarm BOOL This bit is TRUE when an active drive alarm is present.

DriveFault BOOL This bit is TRUE when a drive fault is present.

AtRef BOOL This bit is TRUE when the drives speed feedback is equal to its commanded speed.

DriveCommLoss BOOL This bit is TRUE when communication is lost between the controller and drive.

DriveFltCode UINT This value provides the drive fault code. For fault code definitions, see the user manual or programming manual for the drive.

CmdSpeed REAL This value is the commanded speed of the drive, in Hz.

SpeedFeedback REAL This value is the speed feedback of the drive, in Hz.

OutputCurrent REAL This value is the output current of the drive, in amps.

DCBusVoltage REAL This value is the DC bus voltage of the drive, in volts.

OutputVoltage REAL This value is the output voltage of the drive, in volts.

AnalogIn_Volt REAL This value is the percentage value of analog terminal voltage input.

AnalogIn_Amp REAL This value is the percentage value of analog terminal current input.

DriveType UINT This value displays the unique drive-type number of the connected drive.

PID_Mode BOOL This bit is TRUE when the drive is in PID (pressure) mode.


Appendix B

Global Variables

Table 28 contains the global variables that are used for the user program interfacing.

Table 28 - Global Variables

Name Description For Application (Pressure/Level)

Pump1_Cfg_Acc_Time Set the acceleration time in seconds. Pressure and level

Pump1_Cfg_AlmType Set the alarm type according to these values:0 = No pump control-related alarm is reported.1 = A pump control alarm is reported, and the drive does not stop.2 = A pump control alarm is reported, and the drive does stop.

Pressure and level

Pump1_Cfg_Dec_Time Set the deceleration time in seconds. Pressure and level

Pump1_Cfg_Max_Freq Set the maximum frequency for drive. Pressure and level

Pump1_Cfg_Min_Freq Set the minimum frequency for drive. Pressure and level

Pump1_Cfg_PumpCtrl_Mode Set the mode for Pump Control:0 = Level Control mode.1 = Pressure Control mode.

Pressure and level

Pump1_Cfg_Scale_Sec_Max Set the maximum value for scaling your secondary input. Pressure and level

Pump1_Cfg_Scale_Sec_Min Set the minimum value for scaling your secondary input. Pressure and level

Pump1_Cfg_Sec_Fdbk Configure the secondary input:0 = Disable the secondary input.1 = Enable the secondary input.

Pressure and level

Pump1_Cfg_Wrtie_Drv_Para Set to TRUE to update drive parameters. Pressure and level

Pump1_Cmd_ClrFlt Set to TRUE to clear a fault. Pressure and level

Pump1_Cmd_Freq_Auto Set the drive speed when the machine is in Auto mode. Pressure and level

Pump1_Cmd_Freq_Man Set the drive speed when the machine is in Manual mode. Pressure and level

Pump1_Cmd_ResetComm_Auto Set to TRUE to reset communication when the machine is in Auto mode. Pressure and level

Pump1_Cmd_ResetComm_Man Set to TRUE to reset communication when the machine is in Manual mode. Pressure and level

Pump1_Cmd_Start_Auto Set to TRUE to start the drive when the machine is in Auto mode. Pressure and level

Pump1_Cmd_Start_Man Set to TRUE to start the drive when the machine is in Manual mode. Pressure and level

Pump1_Cmd_Stop_Auto Set to TRUE to stop the drive when the machine is in Auto mode. Pressure and level

Pump1_Cmd_Stop_Man Set to TRUE to stop the drive when the machine is in Manual mode. Pressure and level

Pump1_In_Pri_Fdbk When the primary PV reference is from the drive, this variable displays the primary input value from drive. Pressure and level


Appendix B Global Variables

Pump1_Out_DriveType This variable shows the numeric value that represents the connected drive:8 = PowerFlex® 523 drive.9 = PowerFlex 525 drive.39 = PowerFlex 4 drive.40 = PowerFlex 40 drive.41 = PowerFlex 400 drive.129 = PowerFlex 40P drive.132 = PowerFlex 4M drive.

Pressure and level

Pump1_Out_Drv_AnalogIn Displays the analog value of the drive over the range of 0.0…65535.0. Pressure and level

Pump1_Out_DrvFreq Displays the drive frequency feedback. Pressure and level

Pump1_Out_PumpCode Displays the error code. Pressure and level

Pump1_Out_Scaled_Sec_Fdbk Displays the scaled value of secondary input. Pressure and level

Pump1_Out_Unscaled_Sec_Fdbk Displays the secondary feedback in terms of 0…100%. Pressure and level

Pump1_Sts_CommLoss There is no communication with the drive. Pressure and level

Pump1_Sts_Drv_Act The motor is moving. Pressure and level

Pump1_Sts_Drv_Fault The drive is faulted. Pressure and level

Pump1_Sts_Drv_Para_Writing The drive is busy. Pressure and level

Pump1_Sts_Drv_Rdy The drive is ready. Pressure and level

Pump1_Sts_Lvl_Ctrl_Mode_OK Permission to set mode to level control. Pressure and level

Pump1_Sts_LvlCtrl_Mode Pump control is in level control mode. Pressure and level

Pump1_Sts_Pa_Ctrl_Mode_OK Permission to set mode to pressure control. Pressure and level

Pump1_Sts_PaCtrl_Mode Pump control is in pressure control mode. Pressure and level

Pump1_Sts_Pri_Fdbk The current configuration for primary feedback. Pressure and level

Pump1_Sts_Pump_Fault The pump is faulted. Pressure and level

Pump1_Sts_PumpConfig_OK Check that the pump configuration is correct. Pressure and level

Pump1_Sts_PumpCtrl_Mode Check the status of the pump mode:0 = Level Control mode.1 = Pressure Control mode.

Pressure and level

Pump1_Sts_PumpRdy Pump control is ready. Pressure and level

Pump1_Sts_PumpType_PID_DRV When TRUE, indicates that the connected drive supports PID. Pressure and level

Pump1_Sts_PumpType_SPD_DRV When TRUE, indicates that the connected drive is a speed drive, and does not support PID. Pressure and level

Pump1_Sts_Sec_Analog When TRUE, the secondary output is enabled. Pressure and level

Pump1_Sts_Sec_Analog_Inv When TRUE, the secondary output is not enabled. Pressure and level

Pump1_Cfg_Level_Ctrl_Mode Set the mode for level control:0 = Operator mode. Operator can manually start or stop the drive.1 = Auto mode. The drive starts when the water level is below ON SP, and stops when the water level exceeds the OFF SP level.

Level

Pump1_Cfg_Lvl_AI_HighAlm Set the level (in percentage) for the high alarm to be activated. Level

Pump1_Cfg_Lvl_AI_LowAlm Set the level (in percentage) for the low alarm to be activated. Level

Pump1_Cfg_Lvl_AI_Off_Setpoint Set the level to stop drive. Level

Pump1_Cfg_Lvl_AI_On_Setpoint Set the level to start drive. Level

Table 28 - Global Variables (continued)



Global Variables Appendix B

Pump1_Cfg_Pri_Fdbk Set the reference for feedback terminal:0 = Feedback from the drive terminal.1 = Feedback from the PLC.

Level

Pump1_Out_Analog_In_REAL When the primary PV reference is from the PLC, this variable displays the primary input value from a plug-in or expansion module.

Level

Pump1_Out_Scaled_Lvl_Pri_Fdbk Displays the level in terms of 0…100%. Level

Pump1_Out_Unscaled_Pri_Fdbk Displays primary feedback in terms of 0…100%. Level

Pump1_Sts_Lvl_AI_Mode The level control mode is activated. Level

Pump1_Sts_Lvl_HighAlm Level control – high alarm. Level

Pump1_Sts_Lvl_LowAlm Level control – low alarm. Level

Pump1_Sts_Lvl_Motor_Off Level control – motor off. Level

Pump1_Sts_Lvl_Motor_On Level control – motor on. Level

Pump1_Sts_Lvl_Opr_Mode Level control is in Operator mode. Level

Pump1_Sts_Lvl_Prgm_Mode Level control is in Auto mode. Level

Pump1_Cfg_DeadBand Set the lower PID output for the drive, in percentage. Pressure

Pump1_Cfg_DryPumpTimer Set the delay timer for the dry pump alarm, in seconds. A dry pump alarm is reported when a dry pump condition lasts longer than the setting for the delay timer.

Pressure

Pump1_Cfg_Kd Set the proportional gain of the drive (only for drives with PID capability). Pressure

Pump1_Cfg_Ki Set the integral time of the drive (only for drives with PID capability). Pressure

Pump1_Cfg_Kp Sets the differential rate of the drive (only for drives with PID capability). Pressure

Pump1_Cfg_Max_Pa Set the maximum pressure for your system. Pressure

Pump1_Cfg_NoFloTimer Set the delay timer for the no flow alarm in seconds. A no flow alarm is reported when a no flow condition lasts longer than the delay timer.

Pressure

Pump1_Cfg_PaCtrl_Mode Set the mode for pressure control:0 = Speed control.1 = Pressure control.

Pressure

Pump1_Cfg_Pwr_50PCT_MaxSpd Set the estimated power consumption of the system at 50% of the drive speed. Pressure

Pump1_Cfg_Pwr_85PCT_MaxSpd Set the estimated power consumption of the system at 85% of the drive speed. Pressure

Pump1_Cfg_RunOutTimer Set the delay timer for the run out alarm in seconds. A run out alarm is reported when a run out condition lasts longer than the delay timer.

Pressure

Pump1_Cfg_Scale_Pri_Max Set the maximum value for scaling your primary input. Pressure

Pump1_Cfg_Scale_Pri_Min Set the minimum value for scaling your primary input. Pressure

Pump1_Cmd_Act_SP_Auto Set the pressure setpoint when machine is in Auto mode. Pressure

Pump1_Cmd_Act_SP_Man Set the pressure setpoint when machine is in Manual mode. Pressure

Pump1_Out_NoFlowPwr Displays the calculated power when there is no flow. Used to detect pump alarms. Pressure

Pump1_Out_PID_Mode TRUE = Pressure mode. Pressure

Pump1_Out_Scaled_Pri_Fdbk Displays the scaled value of pressure input. Pressure

Pump1_Out_Spd_Mode TRUE = Speed mode. Pressure

Pump1_Sts_DryPump Pump control error – dry pump fault. Pressure

Pump1_Sts_NoFlo Pump control error – no flow fault. Pressure

Pump1_Sts_PumpRunOut Pump control error – pump run-out error. Pressure

Table 28 - Global Variables (continued)



Appendix B Global Variables

Notes:


Publication CC-QS040A-EN-P - September 2015Copyright © 2015 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Rockwell Automation maintains current product environmental information on its website athttp://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.

http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf

http://www.rockwellautomation.com/support

https://rockwellautomation.custhelp.com/

http://www.rockwellautomation.com/literature/

http://www.rockwellautomation.com/rockwellautomation/distributor-locator/sales-locator.page

http://www.rockwellautomation.com/services/online-phone

http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page

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