How to Control a VFD with a PLC – Part 1 (Configuring ControlLogix 5000 and HMS Anybus gateway)

How to Control a VFD with a PLC – Part 1 (Configuring ControlLogix 5000 and HMS Anybus gateway)


As you may have learned
in previous lessons, automation often requires
communication between heterogeneous systems from
different manufacturers. Each manufacturer offers a proprietary or
an open form of a communication protocol. It is the responsibility of the
Automation Engineer or Technician to configure devices and develop program
logic to communicate between systems. We have created a series of lessons
discussing the steps to configure and program communication between a Rockwell
ControlLogix PLC and a Siemens VFD. So stay tuned for the
sequence to this lesson. before we get started on today’s video if you love our videos, be sure to click the
like button below. then make sure to
click subscribe and the little bell to receive
notifications of new RealPars videos. This way you never
miss another one! In this lesson, we will discuss how a
Rockwell Automation ControlLogix 5000 PLC using ControlNet network
media and CIP protocol will overall communicate with a Siemens
Robicon VFD using Profibus protocol. However, these two systems
will need a device to help translate the two
heterogeneous protocols; this device is called a
“proxy” or “gateway”. In our example, we will use the Anybus
X-gateway AB7803 “PROFIBUS Master” to “ControlNet Adapter”
gateway from HMS. Part 1 of this lesson, will address the
configuration of the ControlLogix 5000 PAC to the HMS Anybus gateway. Part 2 of this lesson will address the
HMS Anybus PROFIBUS Master configuration and Part 3, will address the Siemens
Robicon PROFIBUS slave configuration. First, let’s review the overall
communication configuration we will perform to allow communication
between the “ControlLogix PLC” and “Siemens Robicon VFD” using the
“HMS Gateway” used in our example. The ControlLogix PLC will be controlling
a pump with a simple ON/OFF command and its velocity by setting a
speed set-point to the VFD. In response, the Siemens VFD will
return the actual speed reference and VFD status information
controlling the pump. This exchange of control data and status information is all
performed by the HMS gateway. The HMS Gateway also performs
an important responsibility as “PROFIBUS Master”,
controlling the Pump VFD. We have specific addressing
for each side of our network; On the left-hand side of the
network, the ‘CIP network’, the ‘ControlNet Master’ or ‘Scanner’
will be addressed as ‘Node 1’ and the ‘HMS Gateway’ will
be addressed as ‘Node 3’. On the right-hand
side of the network, the ‘HMS Gateway’ will be
the ‘Profibus Master’ and will have the address of ‘1’ . and the ‘Robicon VFD’ will have
the ‘Slave address’ as ‘3’ Please note, when beginning
a communication project, it is best to look at the big picture and create a spreadsheet with
all the tags and data types to be configured at each system And we want to point out that the
HMS Anybus gateway is not pass-thru but instead acts as a “translator” using
an internal shared common database. The communication is
asynchronous, in that, the gateway serves two
different communication loops, one for the ControlLogix
5000 ControlNet and one for the Siemens
Robicon PROFIBUS and the data is shared using an internal
Dual Port RAM to the HMS gateway. Ok, let’s get started with the
ControlLogix ControlNet communication to the HMS gateway. We will configure the ControlLogix
IO configuration first. We are assuming that the user is familiar with the basics of
Studio 5000 programming software. Now, I’ll launch the studio
5000 and create a new project. Next, I’ll select 1756-L71 processor,
name the project as “Pump”, hit “Next” and then hit
“Finish” as well. Next thing that I need to do here, under the “I/O configuration” folder, I right click on the 1756
Backplane, and select new Module. Then I’ll Locate the “1756-CNB ControlNet
Bridge” module and press “create”. In the next window, I’ll leave the “Major
Revision” number as it is and hit OK. Next, I will name the module as
“Pump Control”,and press OK. For this window, I will keep everything
as it is and click OK again. Next, I need to create a
ControlNet communication module. To do this, under the “I/O
configuration” folder, I’ll right click over 1756-CNB/E Pump
Control and select “New Module”. On the left side of the “Catalog” Tab, I’ll uncheck the “module type category
filters” and select the “communication”. Then I’ll scroll down a bit until I’ll
find the “Generic ControlNet Module”, and then I’ll press create. Let’s name this module as “Robicon
VFD”, with the Node address of 2. I will also set up the “Connection
Parameters” with “Input Instance” of 100, “Input Size” of 16,
“Output Instance” of 150, Output Size” of 16 and
Configuration Instance of 1. After everything is done,I’ll click ok. For this window, I’ll leave everything
as it is and click OK again. After the “ControlNet
Generic Module” is created, Studio 5000 software
automatically creates “Input” and “Output Controller” Tags
for the RobiconVFD IO . From the spreadsheet we will
use RobiconVFD:I.Data[2] as the “VFD status” word
and RobiconVFD:I.Data[6] as the “VFD speed reference” and Robicon:I.Data[7] as
the “Pump Amps” reference. In the Studio 5000
programming environment I have created a routine and configured
the PLC program logic in there. In the first rung, rung zero, I have
set the logic to move the input data from the VFD to Studio
5000 controller tags with alias tag names to easily identify
the input data by its VFD origin. If I scroll down to the
next rungs, rungs 1 and 2, you can see the “ZSW1”
input status word-bits. These bits are used as permissive
to indicate the Pump is ON and or if the Pump is Faulted
using the “PumpInFwd” and “PumpFaulted” tags respectively. In rung 3, you can see
“ControlLogix output VFD control”, “STW1” word-bits will be forced “True” or
“False” based on the VFD requirements. And the output bits in the
“STW1” VFD control word are moved to the
ControlNet relevant word, RobiconVFD:O.Data[0] and the
Speed Setpoint,“N_set_A” tag is also moved to its ControlNet
relevant word,RobiconVFD:O.Data[1] . At this point, ControlLogix
ControlNet module will “Read” and “Write” the ControlLogix
processor data to and from the HMS Gateway for translation into
the PROFIBUS language to be processed in milliseconds and communicated to the
Siemens VFD for pump control. As we mentioned earlier, the HMS gateway provides a kind of
translation for Siemens Robicon VFD and the ControlLogix 5000 systems. In our example, in Network 1, HMS Gateway is the ControlNet
Slave to the ControlLogix and Network 2, is the PROFIBUS
Master to the Siemens VFD. Generally, the gateway requires very little
effort to get it up and running. However, since all
networks are different, certain settings may need to be adjusted
slightly to fit a particular application. This is achieved through the
Gateway Configuration Interface, which features a text-based
user interface that can be accessed using standard
terminal emulation software such as the Microsoft Hyper Terminal. From the physical point of view, the gateway is using a
standard RS232 interface. Once connected, Start
“Hyper Terminal” software and configure it to the correct physical
COM port set up on your Laptop. After you connected, the
Main Menu will be displayed displaying multiple choices
with a corresponding number. I selected number 4, for the
Fieldbus system configuration and set the I/O data size for each network. We also instructed the HMS
gateway to clear the data if and when the gateway where to
go offline as a safety precaution. This completes the HMS ControlNet
slave configuration setup. This concludes the video, ControlLogix PLC
and Siemens VFD Communication Part 1. Stay connected with RealPars
for Part 2 and Part 3 lessons. In Part 2, we will
discuss how to configure the HMS Gateway PROFIBUS Master
communication to the Siemens Robicon VFD. I hope you have enjoyed learning what will
support you in your upcoming project. If you would like to get additional
training on a similar subject, please let us know in
the comment section. If you enjoyed this video,
please press the like button. Please check back with us soon for
more automation control topics. Want to learn PLC programming
in an easy to understand format and take your career
to the next level? Head on over to realpars.com

32 Comments

  • Karamürselli Deli Hamdi says:

    How can I programming DCS Honeywell c300 with function block ?

  • Alexandr Kostik says:

    Thanks !

  • Linton Thomas says:

    Wonderful video, do u have info on programming dpu"s?

  • Renegade Flower says:

    Very useful video. You still have a couple of part 2s videos to come. We are still waiting for part 2 of encoder. Thanks.

  • EMMANUEL SANUSI says:

    Thank you Realpar

  • Jagraj Singh says:

    If we use same protocol at both sides plc and vfd then Gateway is necessary or not ??

  • Krishna Gupta says:

    How can i communicate with siemen drive micromaster 440 with simotion software please help

  • Erick Ontiveros Lara says:

    Great! Just what I needed. This'll surely help me complement the lessons of Profibus device ACT 350 weight scale configuration on the library! Thanks!

  • PRO GAMER says:

    Good

  • Ayyaz Bagnikar says:

    Us there any single Gateway which convert large number of different communication protocol to Ethernet protocol or only one protocol …..

  • theghostmachine says:

    Thank you

  • Melquíades Delgado Ramírez says:

    Excellent video, illustrating the responsibilities of the automation engineers and technicians

  • Shaine MacDonald says:

    Heterogeneous = diverse!

  • Max R says:

    👍🏼👍🏼👍🏼👍🏼👍🏼👍🏼👍🏼

  • Ardent Dfender says:

    I really learned a bit watching this. Though it’s not everyday we do VFD setups this was useful in fundamental understanding of what’s required. I’m not a programmer, but more like a junior programmer who works with a very good Senoir programmer at work and have a lot of experience by virtue of having done quite a many major PLC Upgrades with our Senoir Engineer at numerous power plants. Last VFD we did was a year ago on an recommissioning and plant upgrade and that was all Ethernet for the RA Power Flex VFD’s. Mostly I do Rockwell FactoryTalk HMI design and some tagging of program along with helping on all else. But I do learn by watching how programing is done. I find these videos extremely useful in that they are well explained, very understandable and that the person doing the video speaks in an understandable way and go step by step in explaining. Just like showing how you open Studio 5000 and start the pump project step by step in explaining the VFD setup. Things like that are quite useful to see and have explained in the video explanation of the VFD setup and that’s appreciated. I hope the feedback helps.

  • Pedro Alberto Pérez Puerta says:

    Wonderful video. Keep on issuing videos like that!

  • Anderson Marinho Rodrigues says:

    Thank you so much for this job that you have been doing for us.

  • Jagraj Singh says:

    Wht is the ladder daigram program for control the vfd speed??

  • muhammed a.elS says:

    Your website links dont work

  • rulo antony says:

    Congratulations for the videos, I think you guys are great¡¡¡ Can you make a video explaining difference between HMI and INDUSTRIAL PC?? that would be great¡¡ greetings from Mexico

  • mouiz imran says:

    Hi, RealPars Team,
    Great work, your educational videos are really good. thanks for that.
    Kindly make a video about PLC I/O Modules regarding wiring
    Especially AI – There are 2 wire, 3 wire, 4 wire connection how it is done

  • Mahdi Abbaszadeh says:

    Thank you very much. please make a video about how to choose a power supply for a PLC. Thanks again.

  • Ravi Mishra says:

    Hello sir,
    Can you please make a video of programming and wiring connection of multifunction meter with plc,
    How to read data from MFM.

  • Andrés Gallardo says:

    Really nice instructing videos guys! you should show more Rockwell PLC's rather than Siemens.

  • Minnatullah Rahmani says:

    Appreciate your great efforts!

  • Rafid Alani says:

    Hi,
    I am a follower of your channel, I like your channel and the wonderful way you explain the topics, wondering if
    you can help in this issue even that your channel is specialized in plcs.
    Can you please help in explaining LV Capacitor Bank step by step but the
    most important is;
    1- the calculation of reactors in base of the harmonics in an industry
    using VFD controlled motors for example or any wave distorting source,
    with an example using power factor meter that gives the harmonics in the
    facility and how to deal with those harmonics.
    And which are the cases that we don't need to use reactors in series
    with the capacitors, that if we are using Capacitor duty Contactors to
    limit the Inrush current.
    2- discharging resistors issue, how to calculate them and how to connect
    them exactly? Is the connection made via timer relay? With a diagram,
    if possible. I found diagrams on the net showing the resistors
    connected directly on the Capacitors terminals without any timing relays
    and that did not convince me, the proper time permissible to discharge
    in case of on off loads like motors used to cut marble or variable
    mechanical load that changes the pf in the way that we need to cut the
    Capacitors out for some moments.
    Thank you in advance.

    My best regards and respect.

  • Ardent Dfender says:

    Having watched this video again just going thru the playlists I noticed every time but something watching this again I’m curious of. What happened to the missing Node 2 as well Address 2. They aren’t on the board. I’m curious.
    Also programing of the Gateway Module or A Gateway module could be a video all in itself.

    Oh and in another note to the RealPars guys here putting up with my comments, I’m now officially subscribed as a member on the website with a year subscription and enjoying it. Just gotta update my name so it’s the same. Cheers

  • Farsad Islam says:

    👍👍 Thanks. You've covered a very important topic, pairing two heterogeneous fieldbus system. Nice flow of information with explanation.

  • Farsad Islam says:

    Is it possible to pair more than one heterogeneous slaves through one gateway? I mean, say, I've three Profibus slaves to be paired to a ControlNet master. Can I do this with just one gateway?

    Although, manufacturers usually keep provision in their products for different Fieldbus interface cards and this makes things a lot easier.

  • Jay Jaraba says:

    Wow

  • Mohamed Menarni says:

    I like your channel it's more useful. thank you very very much for your effort .

  • Ismayil Boojelben says:

    It would be perfect to see future videos about OPC, HMI programming, Alarms programming and cybersecurity. You are great!

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