L07 IO-Link Hands on Lab (CAM Demo Case) For Classroom Use Only!

Transcription

1 L07 IO-Link Hands on Lab (CAM Demo Case) For Classroom Use Only!

2 Important User Information This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation ) is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation should only be used as a learning tool by qualified professionals. The variety of uses for the hardware, software and firmware (hereinafter Products ) described in this Documentation, mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards in addition to any applicable technical documents. In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter Rockwell Automation ) be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of, or reliance on, this Documentation. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in the Documentation. Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for: properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell Automation or third-party provided instructions, warnings, recommendations and documentation; ensuring that only properly trained personnel use, operate and maintain the Products at all times; staying informed of all Product updates and alerts and implementing all updates and fixes; and all other factors affecting the Products that are outside of the direct control of Rockwell Automation. Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use the following notes to make you aware of safety considerations: 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. Identifies information that is critical for successful application and understanding of the product. 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 recognize the consequence Labels may be located on or inside the drive to alert people that dangerous voltage may be present. Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

3 L07 IO-Link Hands on Lab (CAM Demo Case) Contents Before you begin... 5 IO-Link Overview... 5 About this lab... 6 Tools & Prerequisites... 9 Section 1 Multiple Profiles (45CRM) CRM Overview About this Lab Section Scenario Steps Summary of Key Features Section 2 Multiple Profiles (42JT) JT Overview About this Lab Section Scenario Steps Section 3 Multiple Profiles and Trending (45LMS) LMS Overview About this Lab Section Scenario Steps Summary of Key Features Section 4 Multiple Profiles and Trending (42EF) EF Overview About this Lab Section Scenario Steps Summary of Key Features of 42

4 Section 5 Diagnosis About this Lab Section Steps Summary of Key Features Section 6 Descriptive Tags About this Lab Section Steps Summary of Key Features Section 7 Automatic Device Configuration (ADC) (Option 1) 42JT Overview About this Lab Section Steps (Option 2) 42EF Overview About this Lab Section Steps Summary of Key Features of 42

5 Before you Begin IO-Link Overview IO-Link is a worldwide standardized I/O technology for communications with sensors and actuators. It helps us solve the problem of clearing those final hurdles in the communication chain, allowing sensing devices to be connected on EtherNet/IP and therefore simplifying access to I/O data and configuration parameters. The standard interfaces that have been used on the sensor/actuator level up to now have not allowed the exchange of any data besides the actual process value. IO-Link makes transparent networking of all levels with one another - essential if we want to look at a machine as a whole - and optimizes the process and troubleshooting. The pillars of IO-Link are Simplified Installation, Simplified Integration, Consistent Engineering tools, Automated Parameter Settings and Advanced Diagnostics. A consistent communication concept right down to the lowest field level is key to using the features and technologies of state-of-the-art sensors and actuators, and making machines and systems more productive as a result. Being an integral part of the I/O module, the IO-Link master is installed in the control cabinet and can be configured through Studio 5000 Logix Designer. IO-Link is a point to point communication between sensor and IO-Link master (part of the I/O block). The IO-Link master is connected to the controller via EtherNet/IP. IO-Link is both forward and backward compatible with standard sensors a standard sensor connected to an IO-Link master works the same as if connected to a discrete input terminal, while an IO-Link sensor connected to a standard input terminal will act as a standard, discrete, PNP sensor. Furthermore, IO-Link utilizes the same standard, unshielded cordsets and patchcords as used with standard discrete sensors. Rockwell Automation is the only company with PLC, an IO-Link master, and IO-Link sensors. This enables the RA IO-Link solution to be differentiated, not just from traditional discrete and analog sensor connections, but even from competitive IO-Link solutions. RA Integrated Architecture technology enables Premier Integration of RA sensors via EtherNet/IP and IO-Link. As the company brings these solutions to market you will see additional technical collateral highlighting the capabilities and differentiation. In this lab we will focus on some of these main system features of the RA IO-Link solution further exhibited with RA IO-Link enabled devices. 5 of 42

6 About this Lab Figure 1 Key IO-Link Enabled Devices in the CAM Demo Case For all the lab sections in this document we will walk through various aspects of premier integration value-add features of particular types of Allen-Bradley IO-Link capable sensor(s) Portfolio and IP20 IO-Link master with associated with the CAM Demo Case. These devices highlighted above in Figure 1 are further described in more detail below: 45CRM Color Registration Mark Sensor (Catalog # 45CRM-4LHT1-D4) with these IO-Link Features: (CH0) 45CRM 1 Triggered (Output status): Provides indication when the target is detected. Teaching the sensor: Can be accomplished with IO-Link via the Add-on-Profile or by using the teach button on the sensor. Multiple profiles: Can be setup and stored to support multiple machine configurations. Multiple profiles enable setting up the sensor one time and having the capability to change products instantly without manual intervention. Location Indication: Helps the user to identify the location of the sensor on the machine by temporarily causing the LEDs to flash in a specific rhythm. Locking: options are available to lock local settings when operating in IO-Link mode, and therefore any user changes will not change the settings of the sensor. 6 of 42

7 42JT VisiSight Photoelectric Sensor (Catalog # 42JT-D2LAT1-F4) with these IO-Link Features: (CH1) 42JT 2 Triggered (Output Status): Provides indication when the target is detected. Margin Low Alarm: Provides indication when the target signal is marginal and the sensor is about to fail. Uniquely Identifiable Serial Number: Helps ensure sensors are installed in proper locations during commissioning. Remote Teach Operations: Allows users to perform Static Teach, Precision Teach and Dynamic Teach Procedures. Lock/Unlock Pushbutton: Prevents unauthorized changes of parameters by locking the push button. 45LMS Laser Measurement Sensor (Catalog # 45LMS-D8LGC1-D4) with these IO-Link Features: (CH2) 45LMS 3 Triggered (Output status): Provides indication when the target is detected. Teaching the sensor: Can be accomplished with IO-Link via the Add-on-Profile or by using the teach button on the sensor. Multiple profiles: Can be setup and stored to support multiple machine configurations. Multiple profiles enable setting up the sensor one time and having the capability to change products instantly without manual intervention. Location indication: Helps the user to identify the location of the sensor on the machine by temporarily causing the LEDs to flash in a specific rhythm. Locking: Options are available to lock local settings when operating in IO-Link mode, and therefore any user changes will not change the settings of the sensor. 42EF RightSight Photoelectric Sensor (Catalog # 42EF-D2MPAK-F4) with these IO-Link Features: (CH3) 42EF 4 Triggered (Output status): Provides indication when the target is detected. Margin Low Alarm: Provides indication when the target signal is very marginal and the sensor is about to fail. Proximity Alarm: Indicates to the operator if there is a target in the background that may be in close proximity to the threshold. Signal Strength: Provides the raw signal strength value reflected by the target (diffuse) or the reflector (-Retro) Location Indication: Helps customers distinguish sensors in applications where you may need to identify in a large machine. Alignment Mode: Aids operator ensure optimal alignment of the sensor in diffuse and polarized retroreflective applications. Internal Temperature: Provides the sensor s internal temperature which helps customers determine if the sensor is operating close to its minimum and maximum temperature. Counter: When enabled this parameter counts the amount of times the target has been detected. Timer: Indicates the amount of time the output was present or absent which can be used to determine the how fast your system is operating. 7 of 42

8 871TM Inductive Proximity Sensor (Catalog # 871TM-M10NP18-D4) with these IO-Link Features: (CH0) 871TM 5 Triggered (Output status): Provides indication when the target is detected. Margin status: Provides indication when the target is detected beyond 80% of the specified operating range (i.e. the application may become unreliable/unstable). Timer functions: Enables the manipulation of the sensor s output signal (i.e., Delay On, Stretch On etc.). Switching mode polarity: Allows the device output type (i.e., N.O. or N.C.) to be changed for use in standard IO mode For all the lab sections we will walk through various aspects of premier integration value-add features of particular types of Allen-Bradley IO-Link capable sensors as depicted in Figure 2 below. The purpose of these lab sections, supplemented by the PowerPoint presentation, is to introduce and demonstrate the key features and associated benefits of IO-Link capable devices from both an operator and configurators point-of-view. Furthermore, the intent is to showcase the added benefits in regards to premier integration only available with IO-Link Allen-Bradley devices. Note that the 7 lab sections are estimated to take ~75 minutes in total Figure 2 Key Features for the CAM Demo Case IO-Link Lab 8 of 42

9 Tools & Prerequisites For this Hands-On lab, you will need the following hardware and software: IO-Link CAM Component Sales Force Demo (Drawing No. 14P005A-01) PC Workstation with containing Studio5000, v20 or later, with the IOL Master Add-On Profile (AOP) installed. The controller configuration files used in these lab sections are all pre-built and configured the same at every workstation IO-Link enabled sensors described in further detail in the section above 9 of 42

10 Section 1 Multiple Profiles (45CRM) 45CRM Overview The 45CRM sensor is a photoelectric contrast sensor that reliably detects registration marks on a web. This sensor features red, green, and blue (RGB) emitter LEDs. During the teach process the sensor determines which of the emitter LEDs maximizes the contrast between the registration mark and the web background. The extremely fast response time enables the control system to precisely align web material within the machine of any typical application scenario. Commented [KMG1]: Let s keep same if works. If KZ has time to change before day 1, we can update lab. Commented [KZ2]: To make the lab run better we probably want to update this screen. The evaluate and Run is confusing and has to be completed within a couple seconds. Can cause issues. We can combine these in the ladder program but it changes your program AND the lab manual. Thoughts? Should we rename the other boxes too to state save to controller? Figure 3 Multiple Profiles with 45CRM Sensor Option About this Lab Section This lab will be featuring the 45CRM color registration mark sensor showcasing the Allen-Bradley Premiere integration, or advanced level of integration, offering features and functionality not available with competitive offerings, such as Multiple Profiles. IO-Link capable sensors can store multiple sensor application profiles (i.e. configurations, recipes, etc.) in the PLC and then download those particular profiles to the sensor automatically with the push of a button on the HMI panel, thus enabling the sensor to be reconfigured very easily and very quickly. The multiple profile feature is a significant value-add IO-Link capability because this simplifies line changeover when a different web is used by the packaging machine (i.e. changing from one package to another). Multiple Profiles will be exhibiting both the dynamic and static teach methods that the 45CRM supports along with the key features as part of Allen-Bradley Premier Integration described in the section below. Scenario As depicted below in Figure 4, a machine is set up for packaging Skittles on first shift and Hot Tamales on second shift. The Skittles wrapper has a white registration mark on a red background. The Hot Tamales wrapper has a black registration mark on a 10 of 42

11 dark red background. This means that the operator must change the settings of the registration mark sensor between each shift. Traditionally this would require manually teaching the sensor IO-Link enables us to automate the process. The settings for each label are stored as profiles in the Logix controller. During line change-over, the controller will download the desired profile (with associated teach settings) to the 45CRM sensor. This could be done automatically or on demand simply by selecting the appropriate project profile number and then pushing the Write button on the HMI screen. 1 st Shift 2 nd Shift Figure 4 Skittles (1 st Shift) and Hot Tamales (2 nd Shift) Wrappers Because the printing and cutting of this web happen at different times, the cutting machine must know how the printing lands on the web. Otherwise it would not be possible to cut the web in the right spot. The key feature that enables the packaging machine to avoid this problem is the use of a registration mark on the label. This mark is of a contrasting color and is always printed on a linear section of the label that is otherwise a solid color. 11 of 42

12 Steps (CH0) 45CRM 1. From the main IO-Link screen on the HMI, push and then subsequently to open the screen with controls for the IO-Link enabled 45CRM Color Registration Mark sensor as shown in Figure 3. Note that it is very common for registration mark sensors to be used on machines that package different products and therefore have different labels. With traditional registration mark sensors, the operator would have to use buttons on the sensor itself to teach it with each product changeover. 2. Confirm that the green indicator LED on the 45CRM is on, indicating that the sensor is communicating over IO- Link. Note that another way to confirm is by selecting the Diagnosis button and observing that status of the 45CRM row. For example, the Comms Loss Column should indicate in green that it is good. 3. Because of the nature of the CAM demo box, the 45CRM is not in an optimal position to operate because of the range. To be able to use the sensor, locate the two butterfly wing nuts to the left of where the sensor is mounted and loosen them so that you may bring the sensor out towards you and lower to the table. Tighten again when you have done so. 4. By observing the HMI, confirm that the mode is. If the Teach Mode is Dynamic, push to change it to static. Note that the Static Teach mode means that we separately teach the mark and the background. 5. Place the Skittles label target in front of the sensor. You should see a spot of light from the sensor s emitter on the label. Be sure that the label is approximately 20mm in front of the sensor emitter in order for the mark and background teaching to be successful. 6. Position the label so that the emitter s light spot is on the white color registration mark on the label. 7. On the HMI, push. 8. Confirm that the emitter LED is now white. The sensor turns on all the emitter LEDs during the teach process, causing the emitter to appear white. If the LED is still a single color (red, green, or blue), push the Teach Mark button again. 9. Move the label so that the emitter s light spot is on the red background color of the label. 10. On the HMI, push. 12 of 42

13 11. Push. The sensor internally compares the color it detected from the mark and the background, selects an LED color, and sets threshold. 12. Push to put the sensor back into run mode. 13. Slide the label back and forth under the sensor. The indicator LED should turn on when the sensor detects the mark and off when it detects the background. 14. On the HMI, use the and arrows to move the selector to Profile Push (under the arrows) to select Profile Next, push to upload the sensor s settings for the Skittles wrapper to Profile 1 on the Logix controller. 17. Position the Hot Tamales label target under the sensor so that the light spot is on the red background color. 18. Push so that the sensor mode is now. 19. Confirm that the teach state has changed to Dynamic to assure that teach process has been initiated. The sensor begins to actively monitor and remember the colors it detects. The sensor assumes that the color it sees when the Dynamic Teach is initiated is the background. 20. Starting with the sensor looking at the background (the rest of the wrapper), press and confirm that the emitter LED is now white. Start sliding the label back and forth under the sensor so that the light spot detects the mark and the background several times. Note that while using Dynamic Teach mode, it is important that the background and mark color are the only two colors that the sensor sees during the teach process. If it detects any other colors, the teach process will not properly work. 21. Push the button. 13 of 42

14 22. Next, push the button to put the sensor back into run mode. 23. Slide the label back and forth under the sensor. The indicator should turn on for the mark and off for the background color. 24. Use the arrow to move the selector to Profile Press the button (under the arrows) to select this profile. 26. Press the button to store the current sensor settings for the Hot Tamales label to Profile 2 on the Logix controller. 27. Position the Skittles label under the sensor. 28. Move the label back and forth under the sensor. Does the output indicator turn on? If so, does it turn on for the mark or the background? Note that the sensor is currently using the settings for the other label. 29. On the HMI, use the up arrow to move the selector to Profile Press the key to select Profile 1, the Skittles label. 31. Press the Write Profile to 45CRM button to write the Profile 1 settings stored in the Logix controller to the 45CRM sensor. Observe that the output LED will change color after about 2 seconds the delay. 14 of 42

15 32. Move the Skittles label back and forth under the sensor. Does the indicator LED turn on for the mark or the background? (The Write Profile process should have restored the settings for this label.) Note that the ability to store and write profiles dramatically simplifies the process of product changeover in applications where a sensor s settings must be adjusted for each different product, such as registration mark applications. Summary of Key Features Multiple Profiles - As shown in the CAM demo HMI home screen (Figure 3), IO-Link capable sensors can store multiple sensor application profiles (i.e. configurations, recipes, etc.) in the PLC and then download those particular profiles to the sensor automatically with the push of a button on the HMI panel. In this case, the taught values can be stored any of the one to five profiles in this lab. Note that additional profiles can be stored at other profile locations. These profiles can then be selected and written back to the 45CRM sensor, thus enabling the sensor to be reconfigured very easily and very quickly. The multiple profile feature is a significant value-add to IO-Link as it simplifies line changeover when a different web is used by the packaging machine (i.e. changing from one package to another). 15 of 42

16 Section 2 Multiple Profiles (42JT) Figure 5 Multiple Profiles with 42JT Sensor Option 42JT Overview The Allen-Bradley 42JT VisiSight photoelectric sensors feature a teach pushbutton and unique automatic PNP/NPN output that simplifies installation and reduces the number of catalog numbers to be stocked by up to 50%. The teachable push button enables adjusting the sensor to the optimal level of sensitivity for various types of applications. With the 42JT VisiSight, now available with IO-Link functionality, key sensor features such as location indication, margin bit indication, Emitter ON/OFF, etc. are now optimally contextualized for the application them at hand within the system architecture from the sensor to the PLC. About this Lab Section This lab will be featuring the 42JT VisiSight photoelectric sensor showcasing the Allen-Bradley Premiere integration, or advanced level of integration, offering features and functionality not available with competitive offerings, such as Multiple Profiles. IO-Link capable sensors can store multiple sensor application profiles (i.e. configurations, recipes, etc.) in the PLC and then download those particular profiles to the sensor automatically with the push of a button on the HMI panel, thus enabling the sensor to be reconfigured very easily and very quickly. The multiple profile feature is a significant value-add IO-Link capability because this simplifies line changeover when a different web is used by the packaging machine (i.e. changing from one package to another). Multiple Profiles is exhibited in this example by teaching the device Setpoint to various settings which are described in the section below. 16 of 42

17 Scenario The 42JT VisiSight family offers a wide range of sensing modes and a teach push button that simplifies sensitivity adjustment and offers light versus dark operate output selection. The unique Auto PNP/NPN output continuously monitors how the load is connected and automatically configures the output for proper operation and output light-emitting diode (LED) to indicate correct output status. The embedded IO-Link communication interface enables the sensor to provide more diagnostics information to help reduce downtime and increase productivity. In a hypothetical industrial application where products move along a production line equipped with a 42JT, which we will simulate today using our hands, the operator has the option of adjusting the sensor s function post-commissioning using commands on an HMI. 17 of 42

18 Steps 1. Using the HMI, Navigate to the ADC page. Press. This clears any information related to this sensor out of the Logix controller. (CH1) Setpoint will now display Press to return to the main screen. From the main IO-Link screen on the HMI, press the button and then subsequently as it appears in Figure 5. to open the screen with controls for the IO-Link enabled 42JT The controller uses IO-Link to read the information out of the sensor and then displays these details on the HMI. All of these details are stored on the sensor in configuration parameters accessible via IO-Link. Some of these parameters are read only the controller cannot overwrite this information. Other parameters offer read/write access. All parameters displayed here are read/write. If a parameter can be written, it is possible to modify it from the controller. 3. Confirm that the green indicator LED on the 42JT is flashing, indicating that the sensor is communicating over IO-Link. Note that another way to confirm is by selecting the Diagnosis button and observing that status of the 42JT row. For example, the Comms Loss Column should indicate in green that it is good. 4. Request that the controller read the device parameters by selecting. The resulting table should appear as shown below. Since the project values should still be set, nothing should change. 5. Using your hand, find the approximate distance from the sensor face that results in the sensor being triggered. The amber LED on the 42JT will turn on and the box in the lower left corner of the HMI will change to which represents triggered. 6. Note the current Setpoint displayed on the HMI (200) the range is from 20 to On the 42JT Diffuse sensor, a high Setpoint corresponds to a threshold requiring a high amount of reflected light, which in turn represents a very short range; in order to reflect more light than the threshold/setpoint value, the target must be very close to the sensor. Think of the margin curve for a diffuse sensor shown in Figure of 42

19 Sensor Triggered Setpoint (Threshold) Not Triggered Figure 6 42JT Diffuse Margin Curve 7. To demonstrate the range sensitivity, you will change the Setpoint. Press the number field next to the Write Setpoint button. A number entry field pops open. 8. Key in 300 and press. This Setpoint corresponds to a high light level threshold for actuation. Press. The controller writes this value to the Setpoint parameter of the sensor. 9. Confirm that the Setpoint of the sensor has been updated by observing the value shown under the Sensor Configuration label. 10. Observe the position of your hand now required to trigger the sensor. Did it change? Is this the result you expected based on the graph? Your hand should now trigger the 42JT when held farther away versus when the Setpoint was of 42

20 11. Next, we will focus on the polarity of the sensor. Press (Light Operate) in the next row. It will toggle to (Dark Operate). 12. With selected, press to write this parameter to the sensor. The light operate (L.O.) setting means that output turns ON when the light between the emitter and the receiver is blocked. If the application requires the output to turn OFF when the target is blocking the light between the emitter and receiver, the setting can be changed to dark operate (D.O.). 13. On the row labeled Emitter (On/Off), press the button. It toggles to. 14. With selected, press to write this parameter to the sensor. The sensor s emitter turns off. This capability can be useful for testing the sensor. 15. Unscrew the 42JT from its patchcord and move it to the patchcord labeled CH1 Generic. This cord is connected to the second IOL master and is configured for a generic IO-Link device in the AOP. In other words, any IO-Link sensor can be plugged into this port. 16. Again, find the distance now required to trigger the sensor with your hand. Did it change? The configured Setpoint is maintained when the sensor loses power, so the Setpoint has not changed. 17. Is the sensor operation Light Operate or Dark Operate? This parameter is also maintained when the sensor loses power, so the sensor is still Dark Operate. While the Setpoint and L.O. / D.O. settings are maintained, notice that the emitter is on even though we have turned it off before disconnecting it above. Because disabling the emitter is used only for testing and is always an exception condition, this setting is not maintained through a power loss. The emitter will always turn on when the sensor is first powered up, regardless of its previous setting. 18. Return the 42JT to its home patchcord. 20 of 42

21 Section 3 Multiple Profiles and Trending (45LMS) Figure 7 Multiple Profiles with the 45LMS Sensor 45LMS Overview The Allen-Bradley 45LMS is a distance laser measurement sensor for measuring various distances ranging from 8m (26.2 ft.) as diffuse and 50m (164ft) as retro reflective, which are now available with IO-Link. This IO-Link capability will not affect how the sensor operates in existing applications. In applications where the user chooses to add an AB IO-Link master, they will have access to additional sensor functionality including (internal) temperature, location indication, margin bit indication, etc. This information is optimally extracted and contextualized as needed for the application need, all within the system architecture from the sensor to the Logix controller. About this Lab Section This lab will be featuring the 45LMS distance laser measurement sensor showcasing the Allen-Bradley Premiere integration, or advanced level of integration, offering features and functionality not available with competitive offerings, such as Multiple Profiles. IO-Link capable sensors can store multiple sensor application profiles (i.e. configurations, recipes, etc.) in the PLC and then download those particular profiles to the sensor automatically with the push of a button on the HMI panel, thus enabling the sensor to be reconfigured very easily and very quickly. The multiple profile feature is a significant value-add IO-Link capability because this simplifies line changeover when a different web is used by the packaging machine (i.e. changing from one package to another). Multiple Profiles is exhibited in this example by teaching the device near and far Setpoints to various settings which are described in the section below. Additionally, the trending feature is a significant value-add IO-Link capability because it enables the plant floor operator to have an easily accessible and understandable log as to when events occurred. For plant supervisors, the ability to leverage historical and instantaneous data will prove valuable when considering how to improve existing operations and drilling down through run-time data remotely. 21 of 42

22 Scenario The 45LMS Laser Measurement Sensor offers an IO-Link interface that enables consistent communication for diagnosing and parameterizing through to the sensor level and makes the intelligence that is already integrated in every 45LMS sensor fully available to the user. This provides advantages in the service area (fault elimination, maintenance, and device replacement), during commissioning (cloning, identification, configuration, and localization) and during operation (job changeover, continuous parameter monitoring, and online diagnosis). In a hypothetical industrial application where products move along a production line equipped with a 45LMS, which we will simulate today using our hands, the operator has the option of adjusting the sensor s function post-commissioning using commands on an HMI. We will explore this capability and further look into the benefits of IO-Link specifically surrounding Automatic Device Configuration and trending. 22 of 42

23 Steps (CH2) 45LMS 1. From the main IO-Link screen on the HMI, press the button and then subsequently to open the screen with controls for the IO-Link enabled 45LMS as it appears in Figure 7. The controller uses IO-Link to read the information out of the sensor and then displays these details on the HMI. All of these details are stored on the sensor in configuration parameters accessible via IO-Link. Some of these parameters are read only the controller cannot overwrite this information. Other parameters offer read/write access. Both Setpoints are read/write whereas the distance is read only. If a parameter can be written, it is possible to modify it from the controller. 2. Confirm that the green indicator LED on the 45LMS is flashing, indicating that the sensor is communicating over IO-Link. Note that another way to confirm is by selecting the Diagnosis button and observing that status of the 45LMS row. For example, the Comms Loss Column should indicate in green that it is good. 3. Observe the current Setpoints in the top row. They should be 300 for near and 450 for far as shown in Figure 7. Press to ensure the top displayed values represent the project settings on 300 and Using your hand, find the approximate distance from the sensor face that results in the sensor being triggered. The amber LED on the 45LMS will turn on and the box in the lower left corner of the HMI will change to which represents triggered. Note that there are two Setpoints. Here, the Setpoints act as a window boundaries between which the sensor will read triggered. The 45LMS has several modes that can be selected, for example a hysteresis mode application where the sensor will read as triggered within a range from each Setpoint. In this application, you should notice your hand will trigger the 45LMS from approximately or rather mm. 5. To demonstrate the range sensitivity, you will change the Setpoint. Press the number field above the first set of Read/Write Setpoint buttons. A number entry field pops open. 23 of 42

24 Near Setpoint Entry Far Setpoint Entry 6. Key in 100 and press. This Setpoint corresponds to a lower distance. Press. The controller writes this value to the Near Setpoint parameter of the sensor. 7. Repeat this process for the Far Setpoint this time entering 700. Take note that for this application, the Setpoint values have been restricted to and respectively. By design, the near Setpoint cannot be greater than the far Setpoint; the inverse is also true. Here, the HMI has been designed specifically to prevent this. Try entering a value outside the indicated range you will notice it is not possible. Note that the distance is displayed in millimeters. 8. Confirm that the Setpoint of the sensor has been updated by pressing for both new Setpoints and observing the updated values in the top fields. 9. Observe the positions of your hand now required to trigger the sensor at the near and far Setpoints. Did it change? Is this the result you expected? 24 of 42

25 Figure 8 Trending (45LMS Distance) 10. From the main IO-Link screen, access and you will be brought initially to the 45LMS. 11. This trending chart has been specifically formatted for a fixed y-axis range of mm is the lower sensing limit for this 45LMS. Charts can also be dynamic and scale according to data, show actual values, and display multiple parameters as will be seen on the 42EF chart in the following section. 12. Feel free to move the 45LMS device around to change the distance measurements on the display. Summary of Key Features Trending As shown in the CAM demo HMI home screen, IO-Link this allows for smarter machines (dirty lens, misaligned sensor or reflector, overheating, etc.), real-time monitoring features of interest, margin, temperature, location indication, etc. 25 of 42

26 Section 4 Multiple Profiles and Trending (42EF) 42EF Overview The Allen-Bradley 42EF RightSight photoelectric sensor is a flagship product of the sensor portfolio. The highest volume models are now available with IO-Link, and other models will add this functionality over the next year. This IO-Link capability will not affect how the sensor operates in existing applications. In application where the user chooses to add an AB IO-Link master, they will have access to additional sensor functionality including (internal) temperature, location indication, margin bit indication, proximity bit indication, etc. This information is optimally extracted and contextualized as needed for the application need, all within the system architecture from the sensor to the Logix controller. Figure 9 Multiple Profiles with the 42EF Sensor About this Lab Section This lab will be featuring the 42EF RightSight photoelectric sensor showcasing the Allen-Bradley Premiere integration, or advanced level of integration, offering features and functionality not available with competitive offerings, such as Multiple Profiles. IO-Link capable sensors can store multiple sensor application profiles (i.e. configurations, recipes, etc.) in the PLC and then download those particular profiles to the sensor automatically with the push of a button on the HMI panel, thus enabling the sensor to be reconfigured very easily and very quickly. The multiple profile feature is a significant value-add IO-Link capability because this simplifies line changeover when a different web is used by the packaging machine (i.e. changing from one package to another). Multiple Profiles is exhibited in this example by teaching the device Setpoint to various settings which are described in the section below. Additionally, the trending feature is a significant value-add IO-Link capability because it enables the plant floor operator to have an easily accessible and understandable log as to when events occurred. For plant supervisors, the ability to leverage historical and instantaneous data will prove valuable when considering how to improve existing operations and drilling down through run-time data remotely. 26 of 42

27 Scenario The 42EF RightSight photoelectric sensor offers an IO-Link interface that enables consistent communication for diagnosing and parameterizing through to the sensor level and makes the intelligence that is already integrated in every 42EF sensor fully available to the user. This provides advantages in the service area (fault elimination, maintenance, and device replacement), during commissioning (cloning, identification, configuration, and localization) and during operation (job changeover, continuous parameter monitoring, and online diagnosis). In a hypothetical industrial application where products move along a production line equipped with a 42EF, which we will simulate today using our hands, the operator has the option of adjusting the sensor s function post-commissioning using commands on an HMI. We will explore this capability and further look into the benefits of IO-Link specifically surrounding Automatic Device Configuration. 27 of 42

28 Steps 1. From the main IO-Link screen on the HMI, press the button and then subsequently to open the screen with controls for the IO-Link enabled 42EF as it appears in Figure 9. The controller uses IO-Link to read the information out of the sensor and then displays these details on the HMI. All of these details are stored on the sensor in configuration parameters accessible via IO-Link. Some of these parameters are read only the controller cannot overwrite this information. Other parameters offer read/write access. The Setpoint is read/write in addition to location indication and LED status, whereas all other values are read only. If a parameter can be written, it is possible to modify it from the controller. 2. Confirm that the green indicator LED on the 42EF is flashing, indicating that the sensor is communicating over IO-Link. Note that another way to confirm is by selecting the Diagnosis button and observing that status of the 42EF row. For example, the Comms Loss Column should indicate in green that it is good. (CH3) 42EF 3. Request that the controller read the device parameters shown in the brown outline by selecting. Alternatively, will refresh all the parameters shown. While each parameter will be unique based on your unit, it is important to confirm the Setpoint of If 3000 is not displayed, follow the steps below to learn how to change the Setpoint. 4. Using your hand, find the approximate distance from the sensor face that results in the sensor being triggered. The amber LED on the 42EF will turn on and the box in the center left of the HMI will change to represents triggered. which 5. Note the current Setpoint displayed on the HMI the range is from 505 to On the 42EF Diffuse sensor, a high Setpoint corresponds to a threshold requiring a high amount of reflected light, which in turn represents a very short range; in order to reflect more light than the threshold/setpoint value, the target must be very close to the sensor. Think of the margin curve for a diffuse sensor. You should note that the sensor reads triggered when your hand is held up to 200mm or 8 away. To demonstrate the range sensitivity, you will change the Setpoint. Press screen. A number entry field opens. on the right side of the 28 of 42

29 6. Key in 8000 and press. This Setpoint corresponds to the controller automatically writes this value to the Setpoint parameter of the sensor. Commented [JMH3]: Update image 7. Confirm that the Setpoint of the sensor has been updated by observing the value shown above the button. 8. Observe the position of your hand now required to trigger the sensor. Did it change? Is this the result you expected? Your hand should now trigger the 42EF when held closer versus when the Setpoint was 3000 roughly when held against the left side of the case to up to 75mm away. 9. Next, we will focus on the different LED settings of the sensor by pressing. 10. Notice it changed to. What is the sensor doing now versus previously? 11. Disable the location indication and now, press and it will change to and disable the lights on the sensor. 12. Now having triggered the sensor several times, notice the count at the top right corner of the display. Press. Did the number change? 29 of 42

30 13. With LED s enabled, unscrew the 42EF from its patchcord and move it to the patchcord labeled CH1 Generic. This cord is connected to the second IOL master and is configured for a generic IO-Link device in the AOP. In other words, any IO-Link sensor can be plugged into this port. 14. Again, find the distance now required to trigger the sensor with your hand by observing the orange LED on the 42EF. Did it change? Commented [JMH4]: Update The configured Setpoint is maintained in this situation still 8000 from the most recent setting. 15. Conversely, see what happens when you return the 42EF to its home patchcord. Is the Setpoint still 8000 or has it changed? The sensor will now behave as it did at the beginning of this section with a Setpoint of This is because of an IO-Link exclusive feature known as Automatic Device Configuration, or ADC. In a real application, if a sensor were to become damaged or destroyed, the user would have to make manual adjustments for it to work in the application after replacement. For example, the user would almost always want to adjust the sensitivity (changing the Setpoint). Most IO-Link sensors on the market still work this same way when the sensor is replaced, it must be manually adjusted for the application. Even though IO-Link enables this process to potentially be executed remotely, it is still a manual process. By comparison, many AB sensors with IO-Link enable Automatic Device Configuration (ADC). With this functionality, if a sensor is replaced with a sensor of the same family, the system automatically configures it for the application in the same way that the original was configured. This dramatically reduces the required knowledge of specific sensor operation by maintenance staff of a manufacturing facility. No more frantically trying to find a user manual for a sensor to figure out how to teach it in the middle of the night. ADC is an optional feature that can be enabled or disabled based on its appropriateness for an application. Figure 10 Trending (42EF Triggered, Proximity Alarm, Margin Low Alarm) 30 of 42

31 16. From the main IO-Link screen, access and you will be brought initially to the 45LMS. 17. Next select the (CH1) 42EF icon to view the 42EF trending information. 18. You ll notice that versus the 45LMS, the 42EF has two additional trending lines. Here, you can see the Margin and Proximity status in addition to the triggered status. The plots all operate on an independent y-axis and you can see from the above image where the bit is on (1) versus off (0). Also, remember from the previous diagnostics section that proximity alarm will only be on if the sensor is not triggered. Summary of Key Features Location Indication - The Location Indicator button is another value-add IO-Link capability where-in when the user activates this function they will immediately see the physical IO-Link 42EF device LEDs flash. This is value-add in the scenario when a Low Margin Alarm happens and a secondary operator response would be to go find the physical device on the machine application to easily and quickly mitigate the issue where the device is located. Refer to the multiple use cases in the PowerPoint presentation of this lab for further understanding of this feature value. Serial Number - The user can see the Serial Number of each of the two 42EF sensors which uniquely identify and distinguish the devices between each other beyond their common shared device identification value (DID) or device catalog numbers. Typically this would not be shown on the HMI, but the value is more prevalent when accessing the system remotely and needing more information. Imagine a scenario where a Product Advisory has been issued for a certain catalog number and date code. Historically, the user would have to check the catalog number and date code physically printed on the sensor (or more likely, the user would just return all the sensors and say you figure it out ). Because this information is available via IO-Link (the date code is built into the serial number), it is possible to check the information remotely rather than physically looking at the sensor itself. Refer to the BOM OEM to End-User use case in the PowerPoint presentation of this lab for further understanding of this feature value. Trending As shown in the CAM demo HMI home screen and in Figure 10, In IO-Link this allows for smarter machines (dirty lens, misaligned sensor or reflector, overheating, etc.), real-time monitoring features of interest, margin, temperature, location indication, etc. 31 of 42

32 Section 5 Diagnosis Figure 11 Diagnostics About this Lab Section Sensor Health The loss of communications notification, or Comms Loss indication notification with only the IO- Link capable device allows the operator to see right away on the HMI screen that communications was lost with that specific device as soon as the device is removed from the cable or cable removed from the device. Conversely, with the standard I/O there is no Comms Loss indication when a sensor or cable is unplugged. Real-Time Diagnostics The user gets advanced information, such as Low Margin Alarm and Comms Loss remotely, either on a local HMI or even in a remote location through a connection to the controller. 32 of 42

33 Steps 1. Using the HMI, Navigate to the ADC page. Press. This clears any information related to the 42JT and 42EF sensor out of the HMI view. (CH1) and (CH3) Setpoints will now display Press to return to the main screen. From the main IO-Link screen on the HMI, press the button and subsequently. Select and note the Setpoint and other parameters in the table. (CH1) 42JT (CH2) 45LMS 3. Continue by selecting and selecting for both Setpoints. Again, note the Near and Far Setpoints shown. (CH3) 42EF 4. Finally, select and to refresh the parameters displayed on the screen. Again, note the Near and Far Setpoints shown. 5. Now that we ve refreshed and observed the parameters, return to the main screen by pressing. From here, select to be brought to the sensor health overview as shown in Figure The last column of the display signifies the current state of communication between the sensor and controller. Take the 42JT and remove it from its cord and note what happens when it is unscrewed. You ll notice the indication in the Comms Loss column has changed from to for the 42JT. 7. Reattach the 42JT and verify the screen is in its original state. 8. Now, locate the terminal block beneath the 1 st 1734-IOL Master. Pull the clasp that secures the 1734-IOL Master to the terminal block down and away toward you to disconnect power and communications to the sensors. Note how the display appears now: 33 of 42

34 In the Add On Profile, the Comms Loss parameter is represented by a single bit that can be on (1) or off (0). All Allen Bradley IO-Link enabled sensors are enabled with this feature. Though seemingly simple, a Comms loss alarm can instantly inform plant floor operators of a problem rather than discovering later eliminating the need to sift through data to determine when the fault occurred and how many manufactured products now have to be sent to quality because of a simple Comms fail. Since the future of The Connected Enterprise is in actionable data delivered where and when it matters, every piece of data matters as shown above. A single Comms fail might suggest a bad connection or failed sensor whereas all 4 channels failing concurrently might prompt the user to examine the IOL master or the power supply. Carefully reconnect the terminal block by aligning the bottom first and then pushing into place on top, clasping the clip back to the IOL Master. Verify the screen is in its original state. 9. Another part of sensor health and diagnostics is margin supported on the 42JT, 45LMS, 42EF, and 871TM and proximity alarm supported on the 42EF. In this project, the margin and proximity status will only be displayed if the sensor also reads triggered. Confirm this by triggering the 42EF, holding your hand in front of the sensor, and noticing the margin status appear. 10. To simulate a margin alarm, locate the 42EF sensor and slowly begin to obscure the sensor s field of vision by sliding your finger down across the face of the sensor until it is covering about half the lens. You will notice that the margin has changed from to in the 42EF row. You can also simulate this by holding your hand approximately 1 away from the face of the sensor given the condition of the default Setpoint of 3000 for this project. 34 of 42

35 11. Next, move your hand a few more inches away from the sensor. You will notice that as you do, the Proximity Alarm status will change from being blank to Alarm is triggered? in the 42EF row. What else changes when the Proximity You will notice in your analysis that when the proximity alarm is ON, both triggered and margin are off. This is confirmed with the Orange LED on the 42EF going off when the HMI indicates the proximity alarm is ON. The margin indication is designed to inform the operator when the ability to see the target at the programmed Setpoint has become diminished as a consequence of a low signal strength. This can be caused by either obstruction on the sensor itself or from the target drifting farther from the sensor. Similarly, this could apply to a sensor mounted on a bracket that became twisted and consequently was not detecting targets as effectively. The proximity alarm is also a function of the received signal strength and instead informs the user that something is present just outside the Setpoint. 12. The 45LMS margin will most likely be displaying since the light path is unimpeded. In this project, similar to the 42EF, the margin can be in multiple states dependent on the received signal strength. The easiest way to trigger the margin on the 45LMS is to take your phone and hold it approximately 1 from the face of the sensor with the glass facing towards the sensor. Margin detection is most beneficial in dirty applications where particulates from a cutting application or weld slag, for example, have the possibility of debris accumulating on the sensor, impeding its ability to clearly see the target. When left unchecked, the sensor could be left blind and unable to meet the needs of the application. The margin alarm gives operators early notice of a sensor that requires attention. You should see 4 states programmed for this application: and. 13. Feel free to continue to observe the changes that occur when triggering the sensors, including finding the margin alarm for the 42JT and noting the different triggered/setpoint values for the 45LMS. Summary of Key Features Diagnostics - As shown in Figure 11 of the HMI screen, the user can see the Triggered bit indication as which is a visual representation as to when the taught target becomes present, or is in the sensor s field of view as previously taught in that project profile set-up. This allows for smarter machines (dirty lens, misaligned sensor or reflector, overheating, etc.), real-time monitoring features of interest, monitor sensor margin and temperature, etc. As shown in Figure 12 below, the loss of communications notification, or Comms Loss indication notification with only the IO- Link capable device allows the operator to see right away on the HMI screen that communications was lost with that specific device as soon as the patchcord is removed from the device. Conversely, with the standard I/O there is no Comms Loss indication when that devices cord is removed. Figure 12 Diagnostics Communications Loss 35 of 42

36 Section 6 Descriptive Tags Figure 13 Descriptive Tags View About this Lab Section This section will show the differences between the All-Bradley Premiere Integration with competitive IO-Link solutions, specifically surrounding the Allen Bradley AOP. Rockwell Automation has the full integrated solution over the competition, offering PLCs, Sensors, and now a Point IO Master Module to harness the capabilities of IO Link. When an AB IO-Link sensor is operating with the 1734-IOL Master, the controller has access to descriptive tag names that provide contextualized, easy to understand information. 36 of 42

37 Steps 1. Be sure that you have selected the button from the CAM demo HMI home screen to assure that you are in the Descriptive Tags view as it appears in Figure What you see is a live snapshot into the Controller Tag view of Studio 5000 that has been captured for the HMI. You will explore this section a little later in the AOP Lab following this if you so choose. While communicating over Ethernet I/P and using existing digital point I/O cards is seamless and fast, the data received is generic and lacking context. Enabled by the 1734-IOL point IO master and our Add-On Profile, descriptive tag names are automatically injected. This not only makes programming the sensors with ladder logic that much easier, but provides data that can be understood at a glance to anyone. 3. Feel free to move the sensors around to trigger the sensors and notice how the bits change from 0 to 1. Summary of Key Features Descriptive Tags As shown in the CAM demo HMI home screen and in Figure 13 above and in Figure 14 below, the user will see the sensor s process data naming as it typically looks with competitive IO-Link capable devices. For example, the supported process data only is named as Data rather than the Descriptive Tag Naming as part of the Allen-Bradley Premier Integration with IO-Link capable devices.. Figure 14 Descriptive Tag Names 37 of 42

38 Section 7 Automatic Device Configuration (ADC) Figure 15 ADC with 42JT Sensor (Option 1) 42JT Overview (Option 1) The Allen-Bradley 42JT VisiSight photoelectric sensors feature a teach pushbutton and unique automatic PNP/NPN output that simplifies installation and reduces the number of catalog numbers to be stocked by up to 50%. The teachable push button enables adjusting the sensor to the optimal level of sensitivity for various types of applications. With the 42JT VisiSight, now available with IO-Link functionality, key sensor features such as location indication, margin bit indication, Emitter ON/OFF, etc. are now optimally contextualized for the application them at hand within the system architecture from the sensor to the PLC. About this Lab Section (Option 1) This lab will be featuring the diffuse 42JT sensor showcasing the Allen-Bradley Premiere Integration, or advanced level of integration, offering features and functionality not available with competitive offerings, such as Automatic Device Configuration (ADC). ADC is described as where sensor configurations can be stored in the IO-Link master and Logix controller and downloaded to new / replacement sensors (with the same catalog number) without the need to reteach or reprogram the sensor again. 38 of 42

39 Steps (Option 1) Be sure that you have selected the you are in the ADC page as shown in Figure 15. button from the CAM demo HMI home screen to assure that 1. Using the HMI, Navigate to the ADC page. Press. This clears any information related to this sensor out of the Logix controller. (CH1) Set Point will now display Next, press in the Step 1 row. This will read in the Setpoint value that is currently stored for the project. 3. Note the distance, using your hand, at which the sensor reads triggered. The orange LED on the sensor will illuminate when true. 4. Now, disconnect the 42JT sensor from the patchcord and reconnect to the Generic Device (CH1) patchcord on the 2 nd IOL master. 5. Press in the Step 2 row. This can also be done from the Generic Channel page off the home screen. 6. Select in the Step 3 row order to view the 42JT default set point value as read on the Generic Device channel. Note that the default Setpoint value on the 42JT is Again, using your hand, determine the distance at which the sensor indicated triggered by observing the orange LED. 8. Next, reattach the 42JT sensor to its native channel with the CH1 patchcord for the 1 st IOL master and press in the Step 4 row. Note that the Setpoint for the 42JT is now 900, which matches the project set point value. Automatic Device Configuration adds significant value when considering sensor implementation and long-term use. Historically, replacing a damaged sensor could involve tracking down the user who commissioned it and scouring their harddrive for the original configuration file that may or may not exist in which case the sensor would need to be re-taught manually. Rockwell believes that the controller holds the answer in any situation; from replacement to power cycle. Each time a sensor is connected, the controller will push down the programmed configuration automatically. Enabled by IO-Link, replacing a damaged sensor is easier than ever. 9. For the final step, select at the upper-right of the screen to return back to the HMI home screen. 39 of 42

40 Figure 16 ADC with 42EF Sensor (Option 2) 42EF Overview (Option 2) The Allen-Bradley 42EF RightSight photoelectric sensor is a flagship product of the sensor portfolio. The highest volume models will soon be available with IO-Link, and other models will add this functionality over the next year. This IO-Link capability will not affect how the sensor operates in existing applications. In application where the user chooses to add an AB IO-Link master, they will have access to additional sensor functionality including (internal) temperature, location indication, margin bit indication, proximity bit indication, etc. This information is optimally extracted and contextualized as needed for the application need, all within the system architecture from the sensor to the Logix controller. About this Lab Section (Option 2) This lab will be featuring the diffuse 42EF sensor showcasing the Allen-Bradley Premiere Integration, or advanced level of integration, offering features and functionality not available with competitive offerings, such as Automatic Device Configuration (ADC). ADC is described as where sensor configurations can be stored in the IO-Link master and Logix controller and downloaded to new / replacement sensors (with the same catalog number) without the need to reteach or reprogram the sensor again. 40 of 42

41 Steps (Option 2) Be sure that you have selected the you are in the ADC page as shown in Figure - 2. button from the CAM demo HMI home screen to assure that 1. Using the HMI, Navigate to the ADC page. Press. This clears any information related to this sensor out of the Logix controller. (CH3) Set Point will now display Next, press in the Step 1 row. This will read in the Setpoint value that is currently stored for the project. 3. Note the distance, using your hand, at which the sensor reads triggered. The orange LED on the sensor will illuminate when true. 4. Now, disconnect the 42EF sensor from the patchcord and reconnect to the Generic Device (CH1) patchcord on the 2 nd IOL master. 5. Press in the Step 2 row. This can also be done from the Generic Channel page off the home screen. 6. Select in the Step 3 row order to view the 42EF default set point value as read on the Generic Device channel. Note that the default Setpoint value on the 42EF is Again, using your hand, determine the distance at which the sensor indicated triggered by observing the orange LED. 8. Next, reattach the 42JT sensor to its native channel with the CH1 patchcord for the 1 st IOL master and press in the Step 4 row. Note that the Setpoint for the 42EF is now 3000, which matches the project set point value. Automatic Device Configuration adds significant value when considering sensor implementation and long-term use. Historically, replacing a damaged sensor could involve tracking down the user who commissioned it and scouring their hard-drive for the original configuration file that may or may not exist in which case the sensor would need to be retaught manually. Rockwell believes that the controller holds the answer in any situation; from replacement to power cycle. Each time a sensor is connected, the controller will push down the programmed configuration automatically. Enabled by IO-Link, replacing a damaged sensor is easier than ever. 41 of 42

42 Summary of Key Features Automatic Device Configuration (ADC) As shown in the CAM demo HMI home screen and in Figures 15&16 and in Figure 17 below, the sensor configurations can be stored in the IO-Link master and Logix controller and downloaded to new/replacement sensors (of the same catalog number) without the need for re-teaching/re-programming allowing easy building of multiple machines (simple project download), easy sensor replacement, agnostic to cable, connection types, and easy tool change-ups. Figure 17 Automatic Device Configuration (ADC) ***Congratulations! You have completed this lab.*** Rockwell Automation, Allen-Bradley, Rockwell Software, Studio 5000, Logix Designer, CompactLogix, and RightSight are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Copyright 2015 Rockwell Automation, Inc. All rights reserved. 42 of 42