February 2015 TechConnect Genius Webinar

February 2015 TechConnect Genius Webinar
Troubleshooting Your Integrated Motion System Steve Wirtz Senior Project Application Engineer

Agenda Overview Machine startup of a new system
Running system evaluation Architecture definition

Overview Objective: Provide you with various techniques to evaluate and troubleshoot your Integrated Motion on EtherNet/IP system We will breakdown the subject into various categories Typical drives in an Integrated Motion on EtherNet/IP are: Kinetix® 350, Kinetix® 5500 and Kinetix® 6500 PowerFlex® 755 There are individual product differences, but troubleshooting is common Today’s focus is primarily on common troubleshooting of the PowerFlex® 755 in an Integrated Motion on EtherNet/IP system

Overview We will ask questions to know if the system is a startup issue or new issue on an existing system System Startup, i.e., not all drives or components powered Machine startup evaluation indicates not much run time, if any, therefore there are different techniques to evaluate Configuration of the axis and I/O tree Including any drive required configuration Most issues are the use of RSLogix/Studio 5000 Connection or network layout Proper use of Ethernet media Routing of Ethernet media vs drive ‘dirty power’ Programming RSLogix/Studio programming techniques Here is a list of items required to successfully troubleshoot an Integrated Motion on EtherNet/IP system. Today we will focus on the Configuration of the Axis and I/O tree issues that may arise in any new system.

Overview Tools for troubleshooting
Primary tool for troubleshooting will be RSLogix/Studio software The primary tool we will be using is RSLogix / Studio 5000 to troubleshoot Integrated Motion on EtherNet/IP systems. RSLogix / Studio 5000 is used to configure, program and troubleshoot Integrated Motion on EtherNet/IP systems Integrated Motion on EtherNet/IP was first implemented in version 18 of RSLogix 5000 / Logix Version 18 Starting in version 19 the PowerFlex 755 drive was added to the Integrated Motion on EtherNet/IP selection.

Overview Controller Organizer Quick View
Controller Organizer and the Quick View are valuable tools in troubleshooting an Integrated Motion on EtherNet/IP. There are two methods to bring up the Quick View window. 1. Right click in the controller 2. Move your mouse pointer to the lower edge of the Controller Organizer until the double arrow double line cursor appears then you can click and drag it open as well. The PowerFlex 755 properties can be used to troubleshoot along with the axis properties categories

Machine startup of new system
Configuration of the I/O connection PowerFlex 755-EENET-CM PowerFlex 755-EENET-CM-S PowerFlex 755-EENET-CM-S1 First we will begin with selecting the correct I/O device for the Axis to use. The PowerFlex 755 drive can be configured in one of six configurations for Integrated Motion on EtherNet/IP Today we will just focus on the low power versions of the drive. Low power is 415 amps and below. As we progress through the following slides I will point out common errors that keep a system from completing even the testing phase. We will focus on completing the testing of the motor and axis for this presentation.

Configuration of the I/O connection PowerFlex 755-EENET-CM PowerFlex 755-EENET-CM-S PowerFlex 755-EENET-CM-S1 Several items can keep the I/O from reaching the “Running” state as First we will begin with selecting the correct I/O device for the Axis to use. The PowerFlex 755 drive can be configured in one of six configurations for Integrated Motion on EtherNet/IP Today we will just focus on the low power versions of the drive. Low power is 415 amps and below. As we progress through the following slides I will point out common errors that keep a system from completing even the testing phase. We will focus on completing the testing of the motor and axis for this presentation.

I/O connection issues that may occur Connection Request Error Code 16#0204 Connection Request Error: Connection request timed out Is the drive powered? Is the IP address set correctly? We will start by looking at common connection errors that occur thus keeping the I/O connection from functioning properly Quick Pane in RSLogix / Studio 5000 is a valuable tool and an easy method to find out any fault codes. I/O Connection Faults are shown in the Module Fault area as well as on the connection tab of the Drive properties under the I/O tree The controller is attempting to make a connection, however, the target module is not responding. The device also appears to be missing from the network. To recover, take these actions: Connection Not Responding Code 16#0204 Some of the Items that will give you this message. Is the product powered up? Verify that the module has not been removed and is still functioning and receiving power. Verify that the module is properly connected to the network. Is the IP address set correctly in the Module Properties in the I/O tree? If it is than is the IP address set correctly on the drive? Is there a duplicate IP address problem? Firmware supervisor enabled and attempting to flash the firmware to the correct version for the project? New drive installed and the system was setup with version 10 or earlier with firmware supervisor enabled. The Flash attempts will fail because flashing from version 11 to an earlier version Will require secure signed firmware. Starting Dec PowerFlex 755 drives and Main control boards leaving production will be set to Version 11 and can be flashed back to secure signed versions from to This was done to meet Nuclear Regulatory standards of drive output frequencies not being able to exceed 600 Hz. Is there a managed switch that is not allowing quality of service or PTP (IEEE1558) time synch messaging

I/O connection issues that may occur Connection Request Error Code 16#0204 Connection Request Error: Connection request timed out Is the drive powered? Is the IP address set correctly? Firmware supervisor enabled and attempting to flash the drive firmware to the correct version? Drive at firmware version or higher and firmware supervisor attempting to flash to an older revision? Is there a network switch not allowing PTP or QoS traffic We will start by looking at common connection errors that occur thus keeping the I/O connection from functioning properly Quick Pane in RSLogix / Studio 5000 is a valuable tool and an easy method to find out any fault codes. I/O Connection Faults are shown in the Module Fault area as well as on the connection tab of the Drive properties under the I/O tree The controller is attempting to make a connection, however, the target module is not responding. The device also appears to be missing from the network. To recover, take these actions: Connection Not Responding Code 16#0204 Some of the Items that will give you this message. Is the product powered up? Verify that the module has not been removed and is still functioning and receiving power. Verify that the module is properly connected to the network. Is the IP address set correctly in the Module Properties in the I/O tree? If it is than is the IP address set correctly on the drive? Is there a duplicate IP address problem? Firmware supervisor enabled and attempting to flash the firmware to the correct version for the project? New drive installed and the system was setup with version 10 or earlier with firmware supervisor enabled. The Flash attempts will fail because flashing from version 11 to an earlier version Will require secure signed firmware. Starting Dec PowerFlex 755 drives and Main control boards leaving production will be set to Version 11 and can be flashed back to secure signed versions from to This was done to meet Nuclear Regulatory standards of drive output frequencies not being able to exceed 600 Hz. Is there a managed switch that is not allowing quality of service or PTP (IEEE1558) time synch messaging

I/O connection Issues that may occur Electronic Keying Mismatch Code 16#0114 Electronic keying product code and/or vendor ID mismatch The Logix processor has found a device at the IP address specified but it is not of the same type specified Another I/O connection error that is common is Electronic Keying Mismatch 16# Wrong Module type selected, ENETR without being set to Tap mode and/or vendor ID mismatch. The Product Code of the actual module hardware does not match the Product Code of the module created in the software. Electronic Keying failed for this module. You may have a mismatch between the module created in the software and the actual module hardware Holding the cursor above the Module Fault description on the Quick View will display the entire text of the fault if the Quick view is not wide enough to display it. You can also scroll the view in the quick view with the scroll bar at the bottom. The Logix processor has found a device at the IP address specified but it is not of the same type specified Are the system IP addresses set correctly? IP addresses could be incorrect or Duplicate IP addresses can cause this as well Multiple axes using both PowerFlex and Kinetix products? Using a ENETR module for Linear or ring connection and the IP address is set on the ENETR instead of the PowerFlex 755 main control board? ENETR not set to “Tap” mode with the rear port connected to the main control board Ethernet port of the PowerFlex 755? The ENETR may have an IP address for management reasons but if must be different from the IP address used for the Main control board Ethernet port

I/O connection Issues that may occur Electronic Keying Mismatch Code 16#0114 Electronic keying product code and/or vendor ID mismatch The Logix processor has found a device at the IP address specified but it is not of the same type specified Are the system IP addresses set correctly? Multiple axes using both PowerFlex and Kinetix products? Using a ENETR module for Linear or ring connection and the IP address is set on the ENETR instead of the PowerFlex 755 main control board? ENETR not set to “Tap” mode with the rear port connected to the main control board of the PowerFlex 755? Another I/O connection error that is common is Electronic Keying Mismatch 16# Wrong Module type selected, ENETR without being set to Tap mode and/or vendor ID mismatch. The Product Code of the actual module hardware does not match the Product Code of the module created in the software. Electronic Keying failed for this module. You may have a mismatch between the module created in the software and the actual module hardware Holding the cursor above the Module Fault description on the Quick View will display the entire text of the fault if the Quick view is not wide enough to display it. You can also scroll the view in the quick view with the scroll bar at the bottom. The Logix processor has found a device at the IP address specified but it is not of the same type specified Are the system IP addresses set correctly? IP addresses could be incorrect or Duplicate IP addresses can cause this as well Multiple axes using both PowerFlex and Kinetix products? Using a ENETR module for Linear or ring connection and the IP address is set on the ENETR instead of the PowerFlex 755 main control board? ENETR not set to “Tap” mode with the rear port connected to the main control board Ethernet port of the PowerFlex 755? The ENETR may have an IP address for management reasons but if must be different from the IP address used for the Main control board Ethernet port

I/O connection issues that may occur Electronic Keying Mismatch Code 16#0116 Major and/or Minor revision invalid or incorrect Electronic Keying selected Exact Match Compatible Module Exact match - Major and Minor revisions must match Compatible Keying – Major revision must match, if the drive firmware is version 10.xxx and higher of the connected drive it will work as compatible with lower firmware revision selections in the Module definition Keying Missmatch 16# Major Rev incorrect, Selected latest firmware and the drive is not or visa versa Electronic Keying selected Exact Match Compatible Module Exact match = Major and Minor revisions must match Compatible Keying – Major revision must match until the drive firmware is version 10.xxx and higher The Major and/or Minor revisions of the module do not match the Major and/or Minor revisions of the module created in the software. Verify that you have specified the correct Major and Minor Revision if you have chosen Compatible Module or Exact Match keying. Electronic Keying failed for this module. You may have a mismatch between the module created in the software and the actual module hardware Using Electronic Keying set to Exact Match the Major Revision and the minor revisions must be exactly as specified in the Module Definition. This may be used as a system verification For compliance but is not required by the Logix system. It can also be turned on for use with firmware supervisor. Compatible Keying only requires the Major revision to be compatible. For exemple V2.003, V2.006, V2.009 and V2.010 are all compatible keying versions

I/O connection issues that may occur Code 16#0010 Mode or State of Module does not allow object to perform requested service Digital I/O module installed in the chassis of the drive? The most common I/O connection issue we have seen is Code 16#0010 Mode or State of Module does not allow object to perform requested service The state of the device prevents a service request from being handled. The most common problem seen is that there is an I/O module present in the backplane of the PowerFlex 755 drive. With any of the Digital / Analog modules present in the Chassis the drive will reject the integrated motion connection request from the Logix processor. Power down the drive and remove the I/O module is the only solution. Second would be that there is a Safety module installed in the drive in a port other than port 6. Since Logix communicates with port 6 of the drive for Guard Status the drive will reject any connection request to a drive that does not have the safety module in port 6. Another reason would be a safety module in a drive that is not expecting there to be a module or the wrong type of Safety module in the drive. If the drive had been used in a stand alone application prior to being connected to an Integrated Motion on EtherNet/IP system, there may be a DeviceLogix program running in the drive. Since the connection request from Logix causes the drive to be reset to defaults for a Motion connection the connection will fail. The connection fails because the reset to defaults is not allowed when a DeviceLogix program is running. To correct this the DeviceLogix program must be disabled first in Parameter 53 of Port 14 Possible issues keeping it from running Wrong module selected - S -S1 Invaild I/O module in the chassis Safety module in wrong port or not at all Drive was running as stand alone previously and now there is a DeviceLogix program running

I/O connection issues that may occur Code 16#0010 Mode or State of Module does not allow object to perform requested service Digital I/O module installed in the chassis of the drive? Safety card not in Port 6 or the incorrect drive selected in the I/O tree? The most common I/O connection issue we have seen is Code 16#0010 Mode or State of Module does not allow object to perform requested service The state of the device prevents a service request from being handled. The most common problem seen is that there is an I/O module present in the backplane of the PowerFlex 755 drive. With any of the Digital / Analog modules present in the Chassis the drive will reject the integrated motion connection request from the Logix processor. Power down the drive and remove the I/O module is the only solution. Second would be that there is a Safety module installed in the drive in a port other than port 6. Since Logix communicates with port 6 of the drive for Guard Status the drive will reject any connection request to a drive that does not have the safety module in port 6. Another reason would be a safety module in a drive that is not expecting there to be a module or the wrong type of Safety module in the drive. If the drive had been used in a stand alone application prior to being connected to an Integrated Motion on EtherNet/IP system, there may be a DeviceLogix program running in the drive. Since the connection request from Logix causes the drive to be reset to defaults for a Motion connection the connection will fail. The connection fails because the reset to defaults is not allowed when a DeviceLogix program is running. To correct this the DeviceLogix program must be disabled first in Parameter 53 of Port 14 Possible issues keeping it from running Wrong module selected - S -S1 Invaild I/O module in the chassis Safety module in wrong port or not at all Drive was running as stand alone previously and now there is a DeviceLogix program running

I/O connection issues that may occur Code 16#0010 Mode or State of Module does not allow object to perform requested service Digital I/O module installed in the chassis of the drive? Safety card not in Port 6 or the incorrect drive selected in the I/O tree? Drive was running as stand alone previously and a DeviceLogix program is still running? The most common I/O connection issue we have seen is Code 16#0010 Mode or State of Module does not allow object to perform requested service The state of the device prevents a service request from being handled. The most common problem seen is that there is an I/O module present in the backplane of the PowerFlex 755 drive. With any of the Digital / Analog modules present in the Chassis the drive will reject the integrated motion connection request from the Logix processor. Power down the drive and remove the I/O module is the only solution. Second would be that there is a Safety module installed in the drive in a port other than port 6. Since Logix communicates with port 6 of the drive for Guard Status the drive will reject any connection request to a drive that does not have the safety module in port 6. Another reason would be a safety module in a drive that is not expecting there to be a module or the wrong type of Safety module in the drive. If the drive had been used in a stand alone application prior to being connected to an Integrated Motion on EtherNet/IP system, there may be a DeviceLogix program running in the drive. Since the connection request from Logix causes the drive to be reset to defaults for a Motion connection the connection will fail. The connection fails because the reset to defaults is not allowed when a DeviceLogix program is running. To correct this the DeviceLogix program must be disabled first in Parameter 53 of Port 14 Possible issues keeping it from running Wrong module selected - S -S1 Invaild I/O module in the chassis Safety module in wrong port or not at all Drive was running as stand alone previously and now there is a DeviceLogix program running

I/O connection issues that may occur Proper selection and configuration will result in a Status of “Running” instead of “I/O Faulted” Until the status of Running is achieved for the I/O connection all other troubleshooting of the axis properties will not help I/O status issues are the most common issue dealt with in Technical support For a system to function the I/O status will need to be in a running state before proceeding to the next step of troubleshooting the axis. Running in the Status is the connection data is functioning properly, it does not mean the drive is modulating the output as it would mean in an Add on Profile I/O connection of Premier integration as it has been know since Logix v16.

Configuration of the Axis Motor Type Mismatch No Motor type selected? If changes were made to the I/O device, the motor data will be cleared Motor Data - Axis Config Fault - Motor type mismatch is a common axis config fault that occurs from troubleshooting I/O connection errors If you have had to make changes to the I/O connection device the data will be cleared from the Axis. This is a safety feature of Integrated Motion on EtherNet/IP. You can make minor changes like minor revisions without having the data cleared. If you change anything in the power structure or the motor feedback the axis data will be cleared. This is done because the axis structure can be used on several different drive types that may not support options previously selected. To remedy this problem will require going Offline. Entering the motor data again and verifying all other axis data before downloading the program to the processor.

Configuration of the Axis Axis State Initializing Are all of the drives/Axes powered in the Motion Group? Are all of the network connections made to the drives? Another common axis configuration question we get is “Why is my Axis State stuck in Initializing?” Are all of the axes/drives powered up in the motion group? Are all of the network connections made? Is the system set up for linear and not all of the connections are complete? For those who have used integrate motion in the past with SERCOS, the same is true for the motion group on an EtherNet/IP connection. The motion group requires all of the axes listed in the motion group to be powered before any of them will be synchronized. All of the I/O connections must be properly configured before the module status will transition to Running and then the axis state will transition to the STOPPED state. There are two methods to use to correct this issue for testing a system or a single axis. If this is just to test a particular axis and downloading to the processor is not desired. Then open the Module Properties in the I/O tree for the drive that is used for the axis to be tested. On the “Connection” tab check the box next to Inhibit Module and then Click Apply. Repeat for all of the drives that are not powered. When this is complete the Module Group should be synchronized and the Axis State should be stopped. If you have not done any programming or if not all of the modules have been configured the other method would be to go offline with your project and move the axis or axes to the ungrouped axes and download the program to the logix processor again. Attempting to use the SSV to inhibit the axis if it has not already been synchronized at one point will not work. The answer is usually no we are just testing the one axis at this time.

Configuration of the Axis Start Inhibited Are you using a permanent magnet (PM) motor? The PowerFlex 755 requires the commutation angle be measured and accepted before transitioning to the “Stopped” Axis State Start Inhibited- Are you using a rotary permanent magnet motor? In this example I have selected a Permanent magnet motor with an absolute feedback device. When the program is downloaded to the processor the commutation offset is set to not configured. This requires selecting the commutation test tab in the Axis Hookup Test category. Start the test on a motor that is not connected to the load and with the brake released if so equipped. After the test is complete “Accept Test Results” to save the commutation angle to the Logix processor. This will be saved and downloaded to the drive on every program download or power cycle to the drive or system. Are you using a safe torque off or Safe speed module? Another reason a Start Inhibit may occur is that you have a –S Safe Torque off module in the chassis and the Safety Circuit is not satisfied thus keeping the IGBT gate power disabled. Or you have a –S1 Safe Speed Monitoring Card installed. The safe speed monitoring card must be in the Run mode and all of the programmed features satisfied before it will allow the IGBT gate power. Either of these safety modules not having their safety circuits satisfied will keep you from running the commutation test as well. Scroll the Quick view to see all of the information in the Start Inhibit description. The safety circuit must be satisfied for you to transition to the Stopped State

Configuration of the Axis Start Inhibited Are you using a permanent magnet (PM) motor? The PowerFlex 755 requires the commutation angle be measured and accepted before transitioning to the “Stopped” Axis State Is the I/O module configured as a Safety device? -S or –S1? The Safety circuits must be satisfied for a transition to the Stopped Axis State Start Inhibited- Are you using a rotary permanent magnet motor? In this example I have selected a Permanent magnet motor with an absolute feedback device. When the program is downloaded to the processor the commutation offset is set to not configured. This requires selecting the commutation test tab in the Axis Hookup Test category. Start the test on a motor that is not connected to the load and with the brake released if so equipped. After the test is complete “Accept Test Results” to save the commutation angle to the Logix processor. This will be saved and downloaded to the drive on every program download or power cycle to the drive or system. Are you using a safe torque off or Safe speed module? Another reason a Start Inhibit may occur is that you have a –S Safe Torque off module in the chassis and the Safety Circuit is not satisfied thus keeping the IGBT gate power disabled. Or you have a –S1 Safe Speed Monitoring Card installed. The safe speed monitoring card must be in the Run mode and all of the programmed features satisfied before it will allow the IGBT gate power. Either of these safety modules not having their safety circuits satisfied will keep you from running the commutation test as well. Scroll the Quick view to see all of the information in the Start Inhibit description. The safety circuit must be satisfied for you to transition to the Stopped State

Configuration of the Axis Proper Axis configuration The Axis State must be “Stopped” before enabling the axis or running any other tests Proper Axis configuration will result in the Axis State reaching the Stopped state. Once you have reached the axis State of Stopped you are ready to proceed with your testing.

Machine startup of vew system
Motion Group configuration issues While attempting to run the Hookup Tests the tests never complete and time out? Position Error fault is set without ever enabling the axis? Motion Group configuration issues Another group of questions that come in are about tests that look like they have run at the drive but the test never completes in RSLogix/Studio 5000 and times out. They cannot get to the stopped state because the axis is indicating a position error fault and the axis has never been enabled yet Another indication of this could also be that the Status Category under the axis properties says Axis State of Stopped and have a position but none of the status indications are valid. The DC Bus up is off even thou the Drive dc bus is correct. The Standstill, Position Lock and Velocity lock are all off. And the Enable is not on even without and enable system or safety card being used.

Machine startup of vew system
Motion Group configuration issues While attempting to run the Hookup Tests the tests never complete and time out? Position Error fault is set without ever enabling the axis? The Axis state is Stopped but the Axis status is not updated Motion Group configuration issues Another group of questions that come in are about tests that look like they have run at the drive but the test never completes in RSLogix/Studio 5000 and times out. They cannot get to the stopped state because the axis is indicating a position error fault and the axis has never been enabled yet Another indication of this could also be that the Status Category under the axis properties says Axis State of Stopped and have a position but none of the status indications are valid. The DC Bus up is off even thou the Drive dc bus is correct. The Standstill, Position Lock and Velocity lock are all off. And the Enable is not on even without and enable system or safety card being used.

Configuration of the Motion Group Coarse Update Period minimum is 3ms for the PowerFlex 755 Default is 2ms on a new project and can cause the previous mentioned problems The problems shown in the previous slide can all be caused by the Coarse Update Period set less than 3 ms. The default coarse update period for any RSLogix/Studio 5000 project will be 2ms. Any of these problems may occur with the coarse update set to 2ms. To correct this the program must be taken offline , Change the coarse update period to 3 ms or greater and then download to the processor again

Configuration of the Motion Group Axis status in the Axis properties with the correct Coarse Update Period When the axis and Motion group are correctly configured the Status screen under the axis properties will show up as the image in the slide.

Troubleshooting Axis Faults Those familiar with the Standalone drive may attempt to use the Human Interface Module (HIM) to view any faults The HIM module will not always display the proper number The example will display “Fault S 45” on the HIM module indicating Phase Vneg to Ground Troubleshooting actual axis faults is also done with RSLogix / Studio 5000. For customers familiar with the PowerFlex drives in a stand alone or RSLogix/Studio 5000 I/O connection using the Human Interface Module, or HIM as I will refer to it as, to view the fault information for the drive. This may work for some faults but not all. In the example I created a Feedback Loss fault by removing the encoder connector from the encoder card. The HIM module does display all of the motion faults as it would in a Stand Alone mode. The HIM module indicates “Fault S 45”. If you look up fault 45 in the programming manual for the PowerFlex 755 drive you will see that it is a Phase V negative to Ground. This is not the correct fault and can lead to incorrect troubleshooting technics.

Troubleshooting Axis Faults The proper method of viewing faults is from the axis properties With the cursor above the fault the Code and Subcode will appear allowing translation in Publication 750-PM001 Proper use of the RSLogix/Studio 5000 software to troubleshoot the faults would be to look at the quick view window first. If that is not enough information then open the axis properties and select the Faults & Alarms category. Place the mouse cursor above the fault that more information is required and a pop up window will appear. In the window is the Code and Subcode to record. In publication 750-PM001 appendix on Integrated Motion on EtherNet/IP ->Faults section the fault can be cross referenced to the descriptions in the Programming manual.

Troubleshooting other Axis Faults Attempting to run an Autotune test and receive a message “Test completed with errors” and the Axis is faulted. Or an Online command failed. The PowerFlex 755 requires the speed be greater than 25% of the motor base speed to do the inertia test This indicates that the travel limit or the speed selected for the Autotune are not high enough. After setting up the scaling it is recommended to use 60% of the max speed from the Planner category Other faults may occur in the Autotune or Inertia test portion of your testing. When you attempt to run the Autotune test RSLogix may come back with a message that reads “Test completed with errors”. This could be caused by one of three things. If the online Command failed appeared. RSLogix/ Studio 5000 determined that it could not run the test. This usually results from the motor speed not being greater than 25% of the motor base speed. This speed is in units/sec based on the system scaling The Auto tune distance is not great enough to complete the move. This could be either the Online command failed or it did not finish the test and completed with errors. Both would require an increase in the distance allowed to complete the test Processor could be in run mode and stopping the test because of programming in the system or someone aborted the test. If it completed with errors you can use the Faults & alarms category to determine the exact cause.

Motion Polarity If the motor and feedback polarity are the same during the motor and feedback test of the Hookup Tests. And you answer that the direction is not correct, Logix will invert the Motion polarity and keep the Motor and feedback polarity normal. Looking at the HIM module will indicate reverse direction when the axis is being commanded in the forward direction. This is normal as the drive is running reverse because of the motion polarity being commanded. After completing the Motor and Feedback tests in the Hookup Tests, the test determines both the motor and the feedback are rotating in the same direction and you answer that the direction was not forward, Logix will change just the motion polarity. This was done in Version 20 and above to keep from having problems with commutation. If a customer has a HIM module in the drive it will indicate that the drive is running in the reverse direction when the motion command is in the forward direction. This is normal because the Motion planner takes the command and reverses it from the program before sending it to the drive. DON’T PANIC

Absolute Position after a power cycle is not correct and no fault The absolute home position is stored in the Logix controller with Integrated Motion on EtherNet/IP. The drive just indicates the counts returned by the absolute device and does not determine absolute position. The absolute home position is stored in the Logix processor for Integrated Motion on EtherNet/IP and not in the drive as in the SERCOS implantation of Integrated motion. When the connection request from Logix is received, and the drive is configured by Logix, the drive populates the position count and then indicates to the Logix processor that the drive is configured and ready. The problem occurred on a rail switch for moving a train to the correct maintenance bay location. Customer was using a gear motor combination with a Hiperface multi-turn absolute encoder. The customer connected the feedback from the wiring diagram on the motor that indicated the data channel and A / A- and B/B- for the signals. Customer ran all of the tests and tuning with the system working to their specifications. They then moved the switch to the center position and performed an immediate home to save the current position as the zero position. All of the moves worked for a couple of days until the system was power cycled. They saw on their HMI screen that the switch was at the opposite side of the center position than it physically was. They did not complain but just rehomed it at the center position and wrote some logic to set the position to the last position before powering down for recovery. The issue was mentioned when they called in for problems with another system and wanted to let us know that absolute homing did not work. To check on how the system was connected we asked if they had a HIM module or any of the Drive software to connect to the drive and read out a position count parameter. They had Drive Executive software. Had the customer cycle the power to the system and then connect to the drive and read what encoder count parameter of the Universal Feedback Card read. Recorded the count and calculated the position as turns and counts. Had the customer rotate the motor forward approximately 50 revolutions and read back the encoder counts parameter, recorded and calculated the position as turns and counts. Then had them cycle the power to the drive and read the encoder counts parameter after the power cycle. Recorded the counts and calculated the position as turns and counts. It was determined that the sine and cosine were not connected to the drive as they were in the internals of the encoder. Checking further in the feedback documentation indicated that the A channel was cosine and the B channel was Sine. Corrected the feedback wiring , changed the feedback direction and ran the test again with the counts staying the same as the moved position after a power cycle. The reason for this is the absolute encoder interpolates it’s own sine and cosine feedback cycles internally and upon a power cycle the drive queries the encoder on the serial channel for the absolute position. After the serial query the drive uses the sine and cosine to calculate position and speed.

Absolute Position after a power cycle is not correct and no fault The absolute home position is stored in the Logix controller with Integrated Motion on EtherNet/IP. The drive just indicates the counts returned by the absolute device and does not determine absolute position. This problem can occur when the Sine and Cosine wires are not connected to the drive universal feedback module in the same manner they are connected internally to the feedback device Example: Hiperface multi-turn encoder on the back of a gear motor Signal channel A and A- connected to Sine + and Sine –-on the drive Signal channel B and B- connected to Cosine + and Cosine - on the drive Motor direction and feedback direction tested fine and an Absolute home was completed. Position testing worked fine until the power was cycled or a program change was downloaded. On a power cycle the encoder position is read on the serial channel and the counts are populated in the drive. Logix determines the position from the feedback counts Corrected the feedback wiring and ran hookup tests. Reset absolute home position The absolute home position is stored in the Logix processor for Integrated Motion on EtherNet/IP and not in the drive as in the SERCOS implantation of Integrated motion. When the connection request from Logix is received, and the drive is configured by Logix, the drive populates the position count and then indicates to the Logix processor that the drive is configured and ready. The problem occurred on a rail switch for moving a train to the correct maintenance bay location. Customer was using a gear motor combination with a Hiperface multi-turn absolute encoder. The customer connected the feedback from the wiring diagram on the motor that indicated the data channel and A / A- and B/B- for the signals. Customer ran all of the tests and tuning with the system working to their specifications. They then moved the switch to the center position and performed an immediate home to save the current position as the zero position. All of the moves worked for a couple of days until the system was power cycled. They saw on their HMI screen that the switch was at the opposite side of the center position than it physically was. They did not complain but just rehomed it at the center position and wrote some logic to set the position to the last position before powering down for recovery. The issue was mentioned when they called in for problems with another system and wanted to let us know that absolute homing did not work. To check on how the system was connected we asked if they had a HIM module or any of the Drive software to connect to the drive and read out a position count parameter. They had Drive Executive software. Had the customer cycle the power to the system and then connect to the drive and read what encoder count parameter of the Universal Feedback Card read. Recorded the count and calculated the position as turns and counts. Had the customer rotate the motor forward approximately 50 revolutions and read back the encoder counts parameter, recorded and calculated the position as turns and counts. Then had them cycle the power to the drive and read the encoder counts parameter after the power cycle. Recorded the counts and calculated the position as turns and counts. It was determined that the sine and cosine were not connected to the drive as they were in the internals of the encoder. Checking further in the feedback documentation indicated that the A channel was cosine and the B channel was Sine. Corrected the feedback wiring , changed the feedback direction and ran the test again with the counts staying the same as the moved position after a power cycle. The reason for this is the absolute encoder interpolates it’s own sine and cosine feedback cycles internally and upon a power cycle the drive queries the encoder on the serial channel for the absolute position. After the serial query the drive uses the sine and cosine to calculate position and speed.

Troubleshooting and configuration tool variations If you have a –S1 the safety functions are not configured via RSLogix/Studio at this time Use the Web browser to setup safety or use Connected Components Workbench to configure the Safe Speed Monitoring Card When using the Safe Speed monitoring card you must use another tool to configure the options of the card since RSLogix/Studio 5000 does not have the capability at this time to configure the card. When using the UFB-1 card the primary feedback must be a Sine / Cosine type device for the signals to reach the Safe Speed Monitoring card across the backplane. The circuitry in the UFB card does not allow an incremental encoder signal to the back plane even though you can use it for motor and position feedback. Two options exist Using a web browser connect to the IP address of the drive and then select the Safety in the web explorer on the left had side. Using the topics under safety configuration to setup the desired safety functions. This data cannot be saved to RSLogix and would require screen shots to be saved of the configuration Using CCW or Drive Executive. Setup the safety functionality after testing the axis for proper tuning and operation. Inhibit the axis in the I/O tree for the drive module used. Connect to the drive wil CCW or Drive Executive and use the safety configuration wizard to step you through the configuration of the Safe Speed Monitoring module.

Tuning After completing the Autotune you are now to a point where you can tune your axis response. After completing the tests you can now tune your system or work on the programming.

Running system evaluation
We will ask the question to know if the system had been in use and now having problems Was the machine built and tested at an OEM but now having problems at end user Machine at end user started out working but now has a problem

We will ask the question to know if the system had been in use and now having problems Was the machine built and tested at an OEM but now having problems at end user Machine at end user started out working but now has a problem Running system evaluation I/O connection ? Replacement of components? Programming changes?

We will ask the question to know if the system had been in use and now having problems Was the machine built and tested at an OEM but now having problems at end user Machine at end user started out working but now has a problem Running system evaluation I/O connection ? Replacement of components? Programming changes? What changed to cause the system anomaly? Did a component get replaced? Did something get added to the system?

Architecture Definition
A one-line diagram or layout of the architecture is important Include in the diagram the catalog numbers of components along with firmware revisions and types of switches, drives, etc. Include the network cabling and routing information so as to identify all IP addresses which can be beneficial in showing problem components

In the example of the previous page, the use of Rockwell Automation tools can help define the system layout Use Ethernet tools such as System Ferret or RSLinx to find out all component catalog and revisions on the network System Ferret technologies/integrated-architecture/tools/overview.page#/tab4 RSLinx included with RSLogix / Studio 5000 Cable lengths and routing of all Ethernet connections to and from the source

Some common issues with network layout that we’ve seen Ethernet cables used with a PWM type drive are recommended to be 1585J 600V shielded type cabling Kinetix® and PowerFlex® drive have ‘dirty power’ connections that may be routed in parallel or in the same conduit, with no spacing or barrier from the ‘clean power’ wiring Dirty power (a few common ones) Incoming main AC power Drive inverter output to motor Brake coil circuit DB/Shunt circuit

Integrated Motion Requirements for the PowerFlex 755
Motion Group Coarse Update Rate must be 3ms or greater S or S1 must be in Port 6 ENETR must be in Tap mode and use the short cable to connect from the back port to the port on the main control board Torque mode requires a feedback device PowerFlex 755 does not support ½ axis feedback only channel Only the UFB-1 supports Homing or Registration 1756-EN2T, EN2TR or EN3TR must be used in the Logix Chassis or use one of the CompactLogix LxxERM processors V20 for CompactLogix Refer to Knowledgebase answer

February 2015 TechConnect Genius Webinar

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