Using the Micro CPU250 with Ethernet IP - Horner Automation Group Europe

0:10

Hello and welcome to today’s webinar.

0:14

Today we will look at using micro CPU 250 with Ethernet IP. Let us take a look at our agenda for today.

0:24

We are going to start with a quick review of the cpu 250 and then we are going to go into ethernet ip and then we are going to talk about ethernet ip device classes and then we have two main use cases we are going to go through today we are going to go through the use cases where you are using the cpu 250 as your main machine controller and you want to be able to publish data both directions over ethernet ip and then second use case we are going to talk about is using the CPU 250 as a very advanced Ethernet IP IO block and there will be demonstrations throughout and we will finish with a Q &A session.

1:11

The new CPU 250 is one of our new modular controllers that are part of the micro series that are great for simple and smart applications.

1:22

They can do a lot more than just simple applications but To date, the micro series are considered strictly of all-in-one controllers or controllers that include a display.

1:35

The CPU 200 and the CPU 250 shown on the screen at the right, those do not include a display.

1:43

And today we are going to be highlighting the CPU 250 because of all its great built-in IO.

1:50

Now these new modular controllers are loaded with capabilities, lots of connectivity options with ethernet, a USB-C for programming and microSD, lots of built-in I.O. for the CPU 250.

2:05

You can also add additional I.O. through standard OCS I.O.

2:10

blocks that you can add on the side of the unit and all the connectivity with all kinds of different protocols are supported.

2:18

And today we are focusing on Ethernet IP capabilities of the CPUs, now from a built-in I.O standpoint for the CPU 250.

2:29

It is packed full, and one of the highlights is the flexible I.O, which are A specific inputs.

2:36

They can either be digital or analog voltage or current, 512 or 24 volts.

2:43

The message for the CPU 250 IO is there are plenty of them and it is highly configurable.

2:50

And today, as we previously mentioned, one of the applications we are highlighting is using the CPU 250 as an Ethernet IP IO block.

3:02

Now let’s start with a quick review of Ethernet IP.

3:05

What is Ethernet IP?

3:07

It is one of the most popular industrial Ethernet protocols available today.

3:12

It is managed by ODVA organization that was created to manage device net but has been expanded to include Ethernet IP.

3:22

Now one of the reasons Ethernet IP is so popular is because of Rockwell which is one of the leaders in terms of market share for automation.

3:32

They are a big proponent of Ethernet IP and are promoting it.

3:36

Now one of the areas that we need to up the information on is Ethernet IP device classes.

3:42

because we have customers calling looking for Ethernet IP support, but they are not exactly sure of what they need.

3:50

So let’s talk about the four different device classes.

3:53

The first device class we are going to talk about is Ioscanner.

3:57

The purpose of the Ioscanner is to control the network and you have to have an Ioscanner on every network and our example here is a Rockwell PLC.

4:07

The next device class we will talk about is an explicit message client which is the device that can exchange messages typically tagged data over the network usually with IO scanner and as an example of that device would be HMI that is sitting on the network so the next class would be an explicit message server a device that is sending messages to the network like a barcode scanner And then finally, we have the IO adapter class or IO device, which is the most common class.

4:41

So for things like AC drives and temperature controllers and valve banks, these are devices that provide information to the network and they are looking to be controlled over the network or at least exchanged data over the network, but they are not controlling the network themselves.

5:00

Let’s take a look at all the different classes of Ethernet IP devices and how they are supported by Horner.

5:08

Let’s start with IO scanners, the device that controls the network.

5:13

Now if you are looking to the CPU250 to control Ethernet IP network that is possible but only if you add a third party product from a company like real-time automation and interface with device while that device is controlling the network.

5:31

Now let’s talk about using CPU 250 as an explicit message client.

5:38

This is a device that exchanges messages typically tagged data with the IO scanner which is usually a Rockwell PLC.

5:47

Now this can be a useful function but it is not all that popular and here is why most Horner customers are OEM machine builders that are using a Horner controller to control their machine and they sell their machine into the customer’s facility and the only way the static exchange will work is if you have control or access to the program that is running in the professor of the IO scanner or the Rockwell PLC and most of the time OEM machine builders do have that access that is their customer PLC for instance so while this is a connection that is supported by the CPU 250 it is not one that gets used that frequently so we are not going to spend that much time on that one today.

6:35

The one we are going to talk about is using the CPU 250 as an IO adapter in other words when you are using the CPU 250 to control your machine And you want to be able to exchange data over ethernet IP at your customers facility so your customer can monitor what is happening on the machine.

6:59

Or maybe your customer can send remote set points or remote control data that is very common and very capable.

7:07

A detailed workflow is when you are using the CPU 250 to control your machine and you exchange data or you want your customer to be able to exchange data from their Ethernet IP infrastructure to and from your machine and here is what you need to do.

7:28

First of all you are going to program your application into the CPU 250 like you normally would to control your machine.

7:36

Next after that is done you are going to get your pencil and you are going to design a map of data that want to share to Ethernet IP maybe temperatures and pressures and other status informations you want to broadcast to Ethernet IP and maybe they are some remote set points or remote control bits or something like that you want to be able to receive over Ethernet IP or you want your customer to be able to send you over Ethernet IP so that is what you’re going to do you are designing the map of data that you want to share both directions and then in seascape you are going to configure your CPU for Ethernet IP support and then in logic there you are going to have some logic that moves those variables that you want to make available over Ethernet IP that moves them into the right places so they can be broadcast and received with Ethernet IP and then you are going to publish what your data map looks like, and then after you ship your machine and it has been installed, your customer will be able to use your documentation and exchange data over Ethernet IP with your machine.

8:49

So that is the detailed workflow for the first use case.

8:53

Now the second use case is using CPU250 as an Ethernet IO block.

9:00

So the workflow is very similar but slightly different in this case.

9:04

So first of all when you are using it as an IO block the first step is to get Cscape out and to configure the CPU 250 IO to meet your application because remember this is a highly configurable IO and you have got those eight flexible IO points.

9:23

You have got some configurable ranges with your analog outputs you have got all kind of configuration so just configure it for your specific application.

9:33

application using Cscape and then again from Cscape add Ethernet IP support to it with a little bit of configuration there.

9:42

Still in Cscape you’re going to do a little bit of ladder logic to move the I, AI, Q and AQ data that has been allocated for the built-in IO over to the right places so they can be seen over Ethernet IP and then you’re going to be done with Cscape.

10:01

Then you’re to fire up the Rockwell software and add the CPU 250 as an IO block into your system you are going to set it up and you are going to test it.

10:13

Now in this scenario remember what we are doing is we are sending our input data from the CPU 250 out over Ethernet IP and the data we receive in from Ethernet we are going to map over to%Q and%AQ data.

10:31

So we have got a total of 19 words that we are producing that is our eyes and AIs and 26 words we are consuming that is our Qs and AQs and all that data is what has been allocated to the built-in IO of our CPU 250. Let’s take a look at what is happening on the bench.

10:54

So, here is our CPU 250. It is wired up to our I.O. Stimulator.

11:01

Now, this happens to be a first generation model. It works with exercising the I.O.

11:07

digital inputs and outputs analog.

11:10

And then over here, we have an old Battle Axe Rockwell Compact Logix, where we have got a flashing light because the I.O.

11:19

is not working quite right at this stage but For our purposes we are just testing the Ethernet IP and demonstrating that for you.

11:28

So this is an Ethernet IP IO scanner and this is how it is acting.

11:33

And then our CPU 250 as an Ethernet IP IO adapter.

11:39

Now in the use case that we are demonstrating we are going to turn the CPU 250 into an Ethernet IP IO block.

11:48

Now this is probably not your use case.

11:51

you are probably going to want to use the CPU 250 as a machine controller and you want to have some of your machine data available over Ethernet IP.

12:02

Well, despite the fact that your use case may be different, this demonstration will give you all you need to know so you can successfully implement Ethernet IP for your application.

12:14

So the first step we need to configure the IO and the CPU 250 for your specific application.

12:22

So we are going to go to hardware configuration and go to local IO tab.

12:27

Now the CPU 250 built-in IO is highly configurable and we need to configure it for your application.

12:36

So on the input side you might have high speed counting that needs to be configured.

12:41

We have configured some here so you would configure that Under Digital Input, on the Digital Output side, you may need to use a couple of high-speed outputs, maybe as a stepper, maybe for a PWM signal, maybe as an output that fires based on encoder position, so those would be configured here.

13:04

On the Flexible Input side, this is where all your analog inputs are configured, that you have, you might use them as digital inputs.

13:13

depends on the application so you would need to configure those here and on the analog output side you have got four milliamp and four voltage analog outputs that need to be configured for a signal type as well as the data range.

13:29

So all that configuration needs to happen now regardless of how you do the configuration for your application.

13:36

The way we have designed this application all the IQ, AI and AQ data for all that built-in IO will be available over Ethernet regardless of how you have configured your specific application IO requirements. So that was the first step.

13:55

The second step is to configure Ethernet IP and we are going to go back to the hardware configuration to do that.

14:03

So we are going to go under LAN 1 config and we are going to make our IP address and netmask are configured and we are going to make sure our Ethernet IP IO adapter is selected and highlighted and then we are going to hit configure selected protocol.

14:21

This is where we determine what data we are producing to Ethernet IP and what data we are consuming from Ethernet IP.

14:30

So from the standpoint of the data that we are producing this is considered Ethernet IP input data because this is the perspective of the Ethernet IP I.O. scanner.

14:43

So the input data from the perspective of the scanner in our case is 19 reads of present I and present AI data that is allocated to the built-in I.O. Now where is that data coming from?

14:58

Well it is coming from I and AI but we have to put it in this array here and we have got 19 word array where the I and AI data elsewhere in the program is going to be pushed into and then that data is going to be broadcast over ethernet IP.

15:17

Now coming back the other direction is going to be 26 words of ethernet IP output data from the perspective of the scanner that is going to go into this array of 26 words and then elsewhere in the program we are going to take this data and push it into%Q and%AQ data to get the data going that direction and then finally we have one word of Ethernet IP status. What does that do for us?

15:49

Well the lower byte of the status word if it is a non-zero tells us there is at least one Ethernet IP IOS scanner that is controlling the IO so as long as that we have at least one IO connection we know the IO is being controlled and we can allow the normal operation of the unit.

16:11

If the IO is not being controlled then we are probably going to want to turn on our present queue and present AQ data all to zero. So that is the Ethernet IP configuration. That was step two.

16:25

Step three now is to move the data around appropriately.

16:30

So let’s start with percent I and percent AI data that we want to broadcast to Ethernet IP or to publish to Ethernet IP.

16:40

So the first three words of the array that is going to be published to Ethernet IP consists of present I1 to present I48.

16:51

Those three words of percent I data that are being allocated to the built-in IO that the first three words in the array.

17:00

The last 16 words in the array come from present AI 1 to present AI 16.

17:07

So this is the data that we are publishing to Ethernet IP.

17:11

Now in terms of consuming from Ethernet IP, here is the array of 26 total words that is receiving the data we are consuming from Ethernet IP.

17:22

The first 2 words or 32 bits of the data that we are pushing into%Q1 to%Q32, the last 24 words we are pushing into%AQ1 to%AQ24.

17:38

Now you will notice we have an ETHER OR logic going on here, so that is where we determine that ETHER OR is going to depend on whether we are being controlled right now by Ethernet IP Scanner.

17:52

How do we detect that? Well we look at the lower byte of the Ethernet IP status.

17:58

If it is greater than zero we know we are being controlled and therefore everything’s okay.

18:05

If everything’s okay we are going to go ahead and push that data we receive over Ethernet into our%Q and%AQ registers so that we can control the IO.

18:19

If we are not being controlled that data is old so we are going to put zeros in all the%Qs and%AQs that have been allocated for the built-in IO.

18:31

So this is the logic that we have got here for step 3 and the next step is to fire up the Rockwell software.

18:39

Now that we have configured the CPU 250 for Ethernet Let’s see how quickly we can get it added to Ethernet IP network.

18:50

So here we are with our compact Logix from Ethernet.

18:54

We are going to go ahead and right click, hit new module and this is where we are going to add the CPU 250.

19:03

Now we need to search under generic module.

19:07

We want to give it a logical name.

19:09

This will be the basis for all the automatically created tags.

19:14

We are going to call it CPU 250.

19:18

The mapping works much better if you use integer as your basis for your data.

19:24

We will type in the IP address for the CPU 250 here.

19:29

The input instance is always 100, the output instance is always 101, and the configuration instance is always 3.

19:39

Now for our specific configuration we have 19 input words from CPU 250 to the Ethernet IP.

19:48

We have 26 input words going the other direction and 0 configuration words.

19:55

We hit OK and go from here so let’s go ahead and go online because right now we are offline so we have to connect to the controller.

20:05

We need to download the changes we just made.

20:08

We will hit download here.

20:11

Done downloading.

20:12

Change the controller mode back to run.

20:15

Press yes, we will.

20:17

So let’s see where we are at.

20:19

So the CPU 250 is now running and we have some additional tags that have been added here automatically.

20:28

So let’s take a look at the input tags.

20:31

Let’s expand those here and look at this.

20:34

We have live data so you can see data that is changing here.

20:40

So let’s flip a couple of switches on our IO Stimulator here so we can see those changing.

20:46

Remember the%i digital inputs are mapped to the first word here.

20:52

Here are our two analog inputs, let’s go ahead and exercise the first one.

20:58

you can see it is going up quite a bit over 20 ,000 the second one we will make is go lower we can see it go below that is all updating nice and quickly and then the number here represents our encoder so let’s count up we have got live data that all looks good now that is on the input side of things now let’s take a look at the output data let’s expand that here here we have all zeros Remember, this data is going the other direction.

21:32

Let’s change this to value of 255.

21:36

Remember, this is where our first 8 cues are mapped.

21:40

We will hit enter.

21:42

And now, if we switch over to our overhead view, we can see that all our LEDs are on.

21:50

So if we do the binary math, a value of 255 will turn on all those LEDs.

21:57

Now on the software we are going to change that to a value of 128 and when we do that all the LEDs but one should go off.