Rockwell Automation Allen-Bradley 45MLA User manual

Simple Package Measurement
Connected Components Building Block
Quick Start

Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines
for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell
Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Allen-Bradley, Rockwell Automation, Rockwell Software, MicroLogix, PanelView, PanelView Component, RSLogix 500, Stratix, and TechConnect are either trademarks or registered trademarks of Rockwell
Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage,
or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence
SHOCK HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.
BURN HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.

3Publication CC-QS012A-EN-P - September 2009 3
Where to Start
Follow the path below to complete your Simple Package Measurement application.
Chapter 1 45MLA Controller Integration
Chapter 2 System Validation and Application Tips
Connected Components
Building Blocks, publication
CC-QS001

4Publication CC-QS012A-EN-P - September 2009
Where to Start
Notes:

Publication CC-QS012A-EN-P - September 2009 5
Preface
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
45MLA Controller Integration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connect Your Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connect Your Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Set the 45MLA DIP Switches and Apply Power . . . . . . . . . . . 14
Configure IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2
SystemValidationandApplication
Tips
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overview of System Operation. . . . . . . . . . . . . . . . . . . . . . . 17
PanelView Application Screens. . . . . . . . . . . . . . . . . . . . . . . 18
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Array Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Current Object Size Screen . . . . . . . . . . . . . . . . . . . . . . . 20
Array Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Conveyor Control Screen (optional) . . . . . . . . . . . . . . . . 21
Program Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Application Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Finding Communication Faults . . . . . . . . . . . . . . . . . . . . 24
Adding Additional Arrays . . . . . . . . . . . . . . . . . . . . . . . . 24
Appendix A
Offset Values, Component
Versions, and Commands
Establishing an Offset Value. . . . . . . . . . . . . . . . . . . . . . . . . 25
Hardware, Firmware, and Software Component Versions . . . 25
Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table of Contents

6Publication CC-QS012A-EN-P - September 2009
Table of Contents
Notes:

Publication CC-QS012A-EN-P - September 2009 7
Preface
Introduction
This connected control building block quick start was created to aid
machine builders in implementing 45MLA Measuring Light Array
sensors with MicroLogix controllers and PanelView Component
terminals. This application demonstrates how an object’s three-
dimensional size can be determined by using three pairs of light
arrays.
The application uses three pairs of light arrays, one for each
dimension, each connected to its respective control interface that
resides on an RS485 network. The MicroLogix controller program
polls the controllers for array size and beam status information. The
PanelView Component terminal displays beam status and object
dimensions.
To assist in the design and installation of your system, application files
and other information are provided on the Connected Component
Building Blocks Overview CD, publication CC-QR001. The CD
provides bills of materials (BOM), CAD drawings for panel layout and
wiring, control programs, Human Machine Interface (HMI) screens,
and more. With these tools and the built-in best-practices design, the
system designer is free to focus on the design of their machine control
and not on design overhead tasks.
The beginning of each chapter contains the following information.
Read these sections carefully before beginning work in each chapter:
•Before You Begin - This section lists the steps that must be
completed and decisions that must be made before starting that
chapter. The chapters in this quick start do not have to be
completed in the order in which they appear, but this section
defines the minimum amount of preparation required before
completing the current chapter.
•What You Need - This section lists the tools that are required to
complete the steps in the current chapter. This includes, but is
not limited to, hardware and software.
•Follow These Steps - This illustrates the steps in the current
chapter and identifies which steps are required to complete the
examples.
IMPORTANT Use this Quick Start in conjunction with the Connected
Components Building Blocks Quick Start, publication CC-QS001.
Refer to Additional Resources on page 9 for a listing of other
related documents.

8Publication CC-QS012A-EN-P - September 2009
Preface
Conventions Used in This
Manual
This manual uses the following conventions.
Convention Meaning Example
Check or uncheck To activate or deactivate a checkbox. Check Disable Keying.
Click Click the left mouse button once while the cursor is positioned
on object or selection. Click Browse.
Double-click Click the left mouse button twice in quick succession while the
cursor is positioned on object or selection. Double-click the application icon.
Right-click Click the right mouse button once while the cursor is positioned
on object or selection. Right-click the 1768 Bus icon.
Select Using the mouse to highlight a specific option. Select the New Module folder.
Enter What you type. Enter your choice.
Press Pressing a specific key on the keyboard. Press Enter.
>Use this symbol to indicate the sub-menu name. Choose File>Menu>Options.

Publication CC-QS012A-EN-P - September 2009 9
Preface
Additional Resources
Resource Description
Connected Components Building Blocks Quick Start,
publication number CC-QS001 Provides information on how to select products and gain access to panel and wiring
information.
Connected Component Building Blocks Overview
CD, publication number CC-QR001 Provides files for the Connected Component Building Blocks.
Installation Instructions 45MLA Measuring Light
Array Sensors, publication number
10000035051(00)
Provides information on the installation and operation of the 45MLA Measuring
Light Array sensors.
45MLA Controller Installation Instructions,
publication number 10000035052 Provides information for installing the 45MLA Controller connections and DIP switch
settings.
45MLA Measuring Light Array Controller User
Manual, publication number 10000071139(00).Provides information for using the 45MLA Measuring Light Array Controller.
MicroLogix 1100 Programmable Controllers
Installation Instructions, publication number 1763-
IN001
Provides information for installing the MicroLogix 1100 programmable controller.
PanelView Component HMITerminals User Manual,
publication number 2711C-UM001 Provides information for using the PanelView Component HMI Terminals.
http://www.ab.com/sensors/ Provides access to the Allen-Bradley sensor website.
http://www.ab.com Provides access to the Allen-Bradley website.
http://www.rockwellautomation.com/
knowledgebase Provides access to self-service support.
http://www.rockwellautomation.com/components/
connected Provides access to the Connected Components website.

10 Publication CC-QS012A-EN-P - September 2009
Preface
Notes:

11Publication CC-QS012A-EN-P - September 2009 11
Chapter 1
45MLA Controller Integration
Introduction
This chapter provides step-by-step instructions for wiring and configuring the 45MLA Measuring
Light Array sensors and controllers for operation with the MicroLogix 1100 controller and
PanelView Component terminal.
Before You Begin
Review the Connected Components Building Blocks Quick Start, publication CC-QS001, verifying
that you have completed hardware design and installation as well as software installation.
What You Need
•Connected Components Building Blocks Overview CD, publication CC-QR001
•Personal computer
•PanelView Component terminal
•MicroLogix 1100 controller
•Standalone Stratix Ethernet switch (catalog number 1783-US05T or similar) to connect
your personal computer to the MicroLogix controller and the PanelView Component
terminal
•Ethernet patch cables (3)
•45MLA light arrays and controllers
•RS485-to-ML1100 communication cable, catalog number 1763-NC01

12 Publication CC-QS012A-EN-P - September 2009
Chapter 1 45MLA Controller Integration
Follow These Steps
Follow these steps to connect and set up your equipment.
Start
Connect Your Hardware,
page 13
Set the 45MLA DIP
Switches and Apply
Power, page 14
Configure IP Addresses,
page 14
Connect Your Wiring,
page 13

Publication CC-QS012A-EN-P - September 2009 13
45MLA Controller Integration Chapter 1
Connect Your Hardware
Using Ethernet patch cables, connect the PanelView Component terminal, MicroLogix 1100
controller, and personal computer to the Stratix Ethernet switch.
Connect Your Wiring
1. Connect 24V DC power and RS485 wiring to components according to this diagram.
24VDC
POWER
SUPPLY
MICROLOGIX
1100
CONTROLLER
RS 232/485
CONVERTER
45 MLA
CONTROLLER
1 5 6
1 2
45 MLA
CONTROLLER
1 5 6
1 2
45 MLA
CONTROLLER
1 5 6
1 2
A
B
+_
24V DC Power and RS 485 Communication Wiring
+_
+_+_+_
SHLD
COM
RS485 WIRING CONNECTIONS
RS485 CONVERTER 45MLA CONTROLLER J14 CONECTIONS
SIG COMMON
A
B
PIN 1
PIN 5
PIN 6
24vDC WIRING CONNECTIONS
POWER SUPPLY 45MLA CONTROLLER J2 CONECTIONS
+24 vdc
0 vdc PIN 2
PIN 1
J2 J2
J14
J14 J14
J2

14 Publication CC-QS012A-EN-P - September 2009
Chapter 1 45MLA Controller Integration
Set the 45MLA DIP Switches and Apply Power
1. Set the 45MLA DIP switches to the settings shown here.
2. Apply power to the MicroLogix controller.
3. Apply power to the PanelView Component terminal.
Configure IP Addresses
In the Connected Components Building Blocks Quick Start, publication CC-QS001, Chapter 3 -
Controller and HMI Integration details how to set the Ethernet IP addresses in the
MicroLogix 1100 controller and PanelView Component terminal. If you have not done this
already, follow those instructions to set the following static IP addresses in your devices.
•Set the personal computer IP address to 192.168.1.102.
•Set the PanelView Component terminal IP address to 192.168.1.200.
•Set the MicroLogix 1100 controller IP address to 192.168.1.101.
•Follow the instructions in the Load Your HMI Screens section of Chapter 3 to transfer your
HMI screens to the PanelView Component terminal.
•Follow the instructions in the Load Your Control Program section of Chapter 3 to transfer
your control program to the MicroLogix controller for use in your application.
Additional Resources
Refer to page 9 for a listing of product and information resources.
OFF
ON
S1
81
OFF
ON
S1
81
OFF
ON
S1
81
OFF
ON
S2
41
OFF
ON
S2
41
OFF
ON
S2
41
ADDRESS 1
HEIGHT
ADDRESS 0
WIDTH
ADDRESS 2
LENGTH
TERMINATION
RESISTOR
ON
(END OF NETWORK)

15Publication CC-QS012A-EN-P - September 2009 15
Chapter 2
System Validation and Application Tips
Introduction
In this chapter, you will run and validate the operation of the 45MLA Measuring Light Arrays with
the MicroLogix controller and PanelView Component terminal HMI.
Before You Begin
•Verify that you have completed all of the steps in Chapter 1 of this document.
•Review the MicroLogix 1100 Programmable Controllers User Manual, publication
1763-UM001.
•Review the PanelView Component HMI Terminals User Manual, publication
2711C-UM001.
•Review the 45MLA Measuring Light Array Sensors Installation Instructions, publication
45MLA-IN001.
What You Need
•Connected Component Building Blocks Overview CD, publication CC-QR001
•Personal computer
•PanelView Component terminal
•45MLA light arrays and controllers
•MicroLogix 1100 controller

16 Publication CC-QS012A-EN-P - September 2009
Chapter 2 System Validation and Application Tips
Follow These Steps
Follow these steps to understand the operation of the 45MLA Measuring Light Array system,
however, you can just go through Chapter 1 and then let the system run with the defaults.
Start
Overview of System Operation,
page 17
PanelView Application Screens,
page 18
Application Tips, page 24
Program Operation, page 22

Publication CC-QS012A-EN-P - September 2009 17
System Validation and Application Tips Chapter 2
Overview of System Operation
This application determines an object’s three-dimensional size by using three pairs of 45MLA light
arrays, one for each dimension, each connected to its respective control interface. The MicroLogix
1100 controller sequentially polls the three slave 45MLA controllers on the RS485 network for
array size and beam status information. The PanelView Component terminal displays each beam
status and the object dimensions.
In this example, we are using command 20. Command 20 requests information on the total
number of beams broken, as well as the first and last interrupted beams and array size.
You can use other command instructions to poll additional data from the array controllers. Details
of these other commands are in the 45MLA Measuring Light Array Controller User Manual,
publication 10000071139(00).
User interaction is via a PanelView Component terminal HMI. The HMI application has screens,
details of which are below.
This Building Block application was developed for a conveyor line, with the MicroLogix
controller interfacing with 22ZC zone controllers. The MicroLogix code and HMI screens are
provided, however they are not required to read data from the array controllers.

18 Publication CC-QS012A-EN-P - September 2009
Chapter 2 System Validation and Application Tips
PanelView Application Screens
Home Screen
Press Enter to go to the application’s Main Menu.
Main Menu
The Main Menu screen allows navigation between the four additional screens in the application:
Array Setup, Current Object Size, Array Status, and Conveyor Control. These are explained in
sections below.
Additionally, there are two buttons for Goto Config
and Reset RS485 Comms.
•Press Go to Config to access the HMI's
configuration.
•Press Reset RS485 Comms to clear the
MicroLogix serial-port communication
buffer.

Publication CC-QS012A-EN-P - September 2009 19
System Validation and Application Tips Chapter 2
Array Setup Screen
On the Main Menu screen, press ARRAY SETUP.
The specific arrays are listed as text boxes in the
left column, each with an enable/disable toggle
button and an offset distance button to its right.
You can select which arrays are operational by
pressing its ENABLE/DISABLE toggle button.
The offset feature, in the right column, lets you
add an offset distance to the array dimension that
is measured. For example, this screen shows that
the height array has an offset of 120 mm, the
distance between the conveyor and the lowest
beam if measuring height above the conveyor.
Follow this procedure to enter an offset for an array.
1. Press the appropriate OFFSET button for that array.
This displays the numerical input pad.
2. Enter the offset desired in millimeters.
Information for calculating the offset can be found in Establishing an Offset Value on
page 25.
3. Press Enter.
To set RS485 communications, you can toggle between Auto and Manual polling of the 45MLA
controllers by pressing the RS485 COMS button in the upper left of the screen. The button text
toggles between RS485 COMS IN AUTO and RS485 COMS IN MANUAL, showing the current
operation.
To set beam spacing, press BEAM SPACING at the bottom of the screen. This toggles the beam
spacing multiplier in the MicroLogix controller to either 10 mm or 25 mm based on the array
model used in the application.

20 Publication CC-QS012A-EN-P - September 2009
Chapter 2 System Validation and Application Tips
Current Object Size Screen
On the Main Menu screen, press CURRENT OBJECT SIZE.
This screen provides a real-time animation of the arrays’ status. Height, width, and length
dimensions are displayed.
This graphic shows no object present, so the
array is clear.
This graphic shows a box is present, so the height
array indicates that measurement.
The PanelView graphic includes only the height
array in the picture. However, numeric values for
all three dimensions are displayed when all three
pairs of light arrays are installed.
Array Status Screen
On the Main Menu screen, press ARRAY STATUS.
Raw data returned from the individual array
controllers is displayed in table format.