29,99 €
Mehr erfahren.
- Herausgeber: Packt Publishing
- Kategorie: Wissenschaft und neue Technologien
- Sprache: Englisch
Understanding programmable logic controller (PLC) programming with Rockwell Software’s Logix Designer and the Studio 5000 platform, which includes ControlLogix, CompactLogix, and SoftLogix, is key to building robust PLC solutions. RSLogix 5000/Studio 5000’s Logix Designer are user-friendly IEC 61131-3-compliant interfaces for programming the current generation of Rockwell Automation Controllers using Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), and Sequential Function Chart (SFC).
This second edition of Learning RSLogix 5000 Programming guides you through the technicalities and comes packed with the latest features of Studio 5000, industrial networking fundamentals, and industrial cybersecurity best practices. You’ll go through the essential hardware and software components of Logix, before learning all about the new L8 processor model and the latest Studio 5000 architecture to build effective integrated solutions. Entirely new for this edition, you’ll discover a chapter on cybersecurity concepts with RSLogix 5000. The book even gets you hands-on with building a robot bartender control system from start to finish.
By the end of this Logix 5000 book, you’ll have a clear understanding of the capabilities of the Logix platform and be able to confidently navigate Rockwell Automation Literature Library resources.
Das E-Book können Sie in Legimi-Apps oder einer beliebigen App lesen, die das folgende Format unterstützen:
Seitenzahl: 382
Veröffentlichungsjahr: 2020
Ähnliche
Learning RSLogix 5000 ProgrammingSecond Edition
Copyright © 2020 Packt Publishing
All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, without the prior written permission of the publisher, except in the case of brief quotations embedded in critical articles or reviews.
Every effort has been made in the preparation of this book to ensure the accuracy of the information presented. However, the information contained in this book is sold without warranty, either express or implied. Neither the author, nor Packt Publishing or its dealers and distributors, will be held liable for any damages caused or alleged to have been caused directly or indirectly by this book.
Packt Publishing has endeavored to provide trademark information about all of the companies and products mentioned in this book by the appropriate use of capitals. However, Packt Publishing cannot guarantee the accuracy of this information.
Commissioning Editor: Vijin BorichaAcquisition Editor: Rohit RajkumarContent Development Editor: Alokita AmannaSenior Editor: Arun NadarTechnical Editor:Dinesh PawarCopy Editor:Safis EditingProject Coordinator: Neil DmelloProofreader: Safis EditingIndexer: Rekha NairProduction Designer: Shankar Kalbhor
First published: August 2015 Second edition: July 2020
Production reference: 1020720
Published by Packt Publishing Ltd. Livery Place 35 Livery Street Birmingham B3 2PB, UK.
ISBN 978-1-78953-246-3
www.packt.com
Packt.com
Subscribe to our online digital library for full access to over 7,000 books and videos, as well as industry leading tools to help you plan your personal development and advance your career. For more information, please visit our website.
Why subscribe?
Spend less time learning and more time coding with practical eBooks and Videos from over 4,000 industry professionals
Improve your learning with Skill Plans built especially for you
Get a free eBook or video every month
Fully searchable for easy access to vital information
Copy and paste, print, and bookmark content
Did you know that Packt offers eBook versions of every book published, with PDF and ePub files available? You can upgrade to the eBook version at www.packt.com and as a print book customer, you are entitled to a discount on the eBook copy. Get in touch with us at [email protected] for more details.
At www.packt.com, you can also read a collection of free technical articles, sign up for a range of free newsletters, and receive exclusive discounts and offers on Packt books and eBooks.
Contributors
About the author
Austin Scott (GICSP, CISSP, OSCP) has nearly 20 years of industrial automation experience and is a principal industrial penetration tester at Dragos Inc., where he identifies cyber risks within industrial control networks. Prior to Dragos, Austin worked as part of the industrial cybersecurity team at Sempra, Shell, and as an industrial cybersecurity consultant at Accenture. Austin is a SANS Cybersecurity Difference Maker (2015) winner for his industrial cybersecurity contributions. In August 2018, Austin won the DEFCON ICS Village HACK THE PLAN(3)T competition and was awarded the DEFCON UBER black badge.
About the reviewers
Gus Serino is currently an Industrial Control System (ICS) / Operational Technology (OT) cybersecurity consultant; the bulk of his career has focused on the engineering of industrial controls systems. Gus is a mechanical engineer who holds a professional engineering license in control systems and 20 years of experience in the design, implementation, management, and security of industrial controls systems. He has extensive experience in PLC programming, HMI development, ICS/OT networking, advanced troubleshooting, facility startup and testing, and implementing ICS cybersecurity controls. He holds an MA Water Treatment Operator's License, multiple GIAC Cyber Security certificates, is a member of the GIAC advisory board, and is passionate about controls systems and the security of critical infrastructure.
Javeria Parwani is an electronics engineer with 6 years of experience in the field of industrial automation. One of the few female engineers in this field, she has gained her experience by working in different parts of the world as an automation engineer, such as the UK, the Middle East, and Asia. She is a certified SCADA designer and a trained PLC engineer. As part of her job, she has delivered various projects for the Allen Bradley, Siemens, and Schneider PLCs. Having worked for many different industries, such as aerospace, manufacturing, district cooling, railways, and energy management, she has gained a great deal of experience.
Packt is searching for authors like you
If you're interested in becoming an author for Packt, please visit authors.packtpub.com and apply today. We have worked with thousands of developers and tech professionals, just like you, to help them share their insight with the global tech community. You can make a general application, apply for a specific hot topic that we are recruiting an author for, or submit your own idea.
Table of Contents
Title Page
Copyright and Credits
Learning RSLogix 5000 Programming Second Edition
Dedication
About Packt
Why subscribe?
Contributors
About the author
About the reviewers
Packt is searching for authors like you
Preface
Who this book is for
What this book covers
To get the most out of this book
Download the color images
Conventions used
Get in touch
Reviews
Section 1: Introduction to RSLogix
The History of Rockwell Automation Technologies
Controlling equipment with water, air, and power
The rise of pneumatics
Understanding electric relay logic
A brief history of Rockwell Automation
Program Data Quantizer II and the Programmable Matrix Controller
PLC-2 controllers
PLC-3 controllers
PLC-5 controllers
SLC-500 controllers
MicroLogix
ControlLogix controllers
Understanding Integrated Architecture
Summary
Further reading
Questions
Understanding ControlLogix
Technical requirements
Introducing ControlLogix controllers
ControlLogix Series 6 controllers (L6)
ControlLogix Series 7 controllers (L7)
ControlLogix Series 8 controllers (L8)
Selecting a ControlLogix controller
ControlLogix software and firmware
Key switches, lights, and character displays
Key switches
Lights
Character displays
The Rockwell Automation Compatibility and Download Center
Introducing GuardLogix safety controllers
Introducing extreme environment controllers
Understanding the ControlLogix operating cycle
Summary
Questions
Further reading
Understanding CompactLogix
Technical requirements
Introducing CompactLogix controllers
Navigating the CompactLogix controller family
CompactLogix deprecated controllers
Bulletin 1768 – L43 and L45
Bulletin 1769 – L23x
Bulletin 1769 – L3x modular controllers
CompactLogix 5370 controllers
Bulletin 1769 5370 – L1
Bulletin 1769 5370 – L2
Bulletin 1769 5370 – L3
CompactLogix 5380 controllers
Bulletin 1769 5380 – L3
CompactLogix GuardLogix
CompactLogix 5480 controllers
Identifying compatible products
Summary
Further reading
Questions
Understanding SoftLogix
Technical requirements
Learning about SoftLogix
Understanding SoftLogix controllers
Understanding the components of a SoftLogix solution
SoftLogix 5800 versus Logix Emulate 5000
Working with SoftLogix
Configuring the SoftLogix 5800 chassis monitor
Configuring the RSLinx virtual-backplane driver
Creating a Logix Designer SoftLogix project
Configuring the 1789-SIM module in the Logix Designer project
Simulating values using the 1789-SIM module
Summary
Questions
Further reading
Understanding Logix Emulate 5000
Technical requirements
Learning about Logix Emulate 5000
Working with Logix Emulate 5000
Configuring a Logix Emulate 5000 chassis monitor
Configuring the RSLinx virtual backplane driver
Creating a Logix Designer Emulate 5000 project
Configuring the 1789-SIM module in the Logix Designer project
Simulating values using the 1789-SIM module
Summary
Questions
Further reading
Section 2: Logix Programming Basics
Industrial Network Communications
Technical requirements
Understanding the key terms in industrial communications
Learning about modern network communication technologies
Primary network technologies
DeviceNet
ControlNet
EtherNet/IP
Understanding legacy network technologies
Data Highway Plus
RIO
SERCOS
SynchLink
DH-485 and DF1
Comparing network communication technologies
Working with EtherNet/IP Capacity Tool
Using EtherNet/IP Capacity Tool
Using RSLinx Classic and FactoryTalk Linx
Using BOOTP/DHCP
RSLinx communication using ControlLogix and a USB connection
Using Rockwell Automation Integrate Architecture Builder
Networking safety systems
Summary
Questions
Further reading
Configuring Logix Modules
Technical requirements
Understanding the module terminology
Learning about the module types
Analog modules
Digital modules
Communication modules
Controller processor modules
Motion control modules
Specialty modules
Introducing Logix terminal blocks
Configuring a ControlLogix module
Reading Logix module catalog numbers
Learning about the module special features
Addressing module I/O
Exploring module addresses
Buffering module I/O data
Configuring remote racks with RSNetWorx
Summary
Questions
Further reading
Writing Ladder Logic
Technical requirements
Ladder Logic overview
Understanding IEC 61131-3
Understanding IEC programming logic
AND logic in Ladder
OR logic in Ladder
NOT logic in Ladder
Programming Ladder Logic
Buffering module I/O data
Defining tags
Buffering base tags
Creating the pump control logic
Implementing maintenance manual override
Buffering using program parameters
Summary
Questions
Further reading
Writing Function Block
Technical requirements
Understanding language compilation in Logix
Introducing Function Block
Function Block versus Ladder Logic
Function Block sheets
Function Block elements
Function Block wiring
Understanding Function Block logic
AND logic in Function Block
OR logic in Function Block
NOT logic in Function Block
Creating a Function Block program
Online monitoring and editing
The FBD properties
Adding and naming sheets to a routine
Adding a textbox to a Function Block routine
Hiding and showing function block pins
Assigning a constant value to a function block
Summary
Questions
Further reading
Writing Structured Text
Technical requirements
Applying ST programming
Typical uses of ST
Exploring the ST editor
New features in Studio 5000 version 31
Writing structured routines
A simple ST routine
Breaking down the simple ST routine
Using ST operators
The assignment operator
The non-retentive assignment operator
Retentive versus non-retentive assignment operators
Buffering ST I/O module values
Relational operators
Logical operators
Arithmetic operators
Using expressions
Understanding instructions
Arithmetic instructions
Using the OSRI instruction
Understanding the ST constructs
The IF_THEN construct
The CASE_OF construct
The FOR_DO construct
The WHILE_DO construct
The REPEAT_UNTIL construct
Summary
Questions
Further reading
Building Sequential Function Charts
Technical requirements
Introducing SFCs
Applying SFCs
Using the SFC editor
Defining the SFC steps
Defining the SFC actions
Defining SFC transitions and branches
Defining the SFC Stop element
Building a backwash SFC routine
Summary
Questions
Further reading
Section 3: Advanced Logix Programming
Using Tasks and Programs for Project Organization
Technical requirements
Introducing project organization in Logix
Understanding the organizational units in Logix
Learning about controller tasks
Learning about controller programs
Learning about controller routines
Learning about the controller task types
Learning about continuous tasks
Learning about periodic tasks
Learning about event tasks
Applying the best practices of Logix task usage
Creating a task
Inhibiting programs and tasks
Setting task priorities
Tuning a Logix controller
System overhead time slice
Setting the system overhead time slice
Monitoring task execution time and overlap
Task watchdog time
The Logix5000 Task Monitor tool
Summary
Questions
Further reading
Faults and Troubleshooting in Logix
Technical requirements
Troubleshooting Logix solutions
Troubleshooting Logix faults
Understanding the fault categories
Clearing a fault
Fault handling and recovery
Programmatically clearing faults
The GSV and SSV instructions
Learning about UDTs
Trapping a fault
Understanding FactoryTalk TeamONE
Summary
Questions
Further reading
Understanding Cybersecurity Practices in Logix
Technical requirements
The Rockwell Industrial Security Advisory Index
Reviewing the Industrial Security Advisory Index
Introducing RSLogix security features
FactoryTalk Security system
Source Key protection or License protection
The Logix CPU Security Tool
FactoryTalk AssetCentre
Understanding Converged Plantwide Ethernet architectures
Introducing Common Industrial Protocol (CIP) Security for EtherNet/IP
Implementing CIP Security
Summary
Questions
Further reading
Building a Robot Bartender in Logix
Technical requirements
Building and housing a robot bartender
Tools you will need for this project
Housing the bartender
Acquiring ControlLogix parts for this project
Purchasing a ControlLogix 1756-PA75 rack power supply
Selecting a ControlLogix chassis
Selecting a ControlLogix CPU
Selecting a ControlLogix EtherNet/IP card
Selecting a ControlLogix digital output module
Understanding the ControlLogix digital output module features
Working with electronically fused digital outputs
Isolated output modules
Sinking versus sourcing modules
Fast output modules
Selecting a ControlLogix digital input module
Understanding the ControlLogix digital input module features
Diagnostic input modules
Using RTBs
Commonly used RTBs
In-panel I/O wiring system modules and cables
Estimating a robot bartender project budget
ControlLogix equipment budget
Robot bartender process equipment
Selecting the robot bartender bottles and recipes
Building a ControlLogix rack
Powering up your ControlLogix rack
Creating a power cable for the 1756-PA75 power supply
Testing communications with your rack
Starting your RSLogix project
Wiring the ControlLogix digital output cards
Creating a power cable for the 12 V power supply
Connecting the power supply to the ControlLogix power supply
Wiring the 12 V dosing pumps to the digital output card
Testing the digital outputs
Wiring ControlLogix digital input cards
Testing the digital inputs
Writing the robot bartender ladder logic
Building the robot bartender routine structure
The pump timer ladder logic
Duplicating the pump timer ladder logic
Writing robot bartender recipes in Ladder Logic
Writing a recipe for the Old Fashioned ladder logic
Robot Bartender recipes
Summary
Questions
Further reading
Assessments
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Chapter 14
Chapter 15
Other Book You May Enjoy
Leave a review - let other readers know what you think
Preface
In 1997, Rockwell Automation launched its current generation control platform, Logix. Logix represented decades of technical advancement in automationfor robust, large-scale solutions. The RSLogix 5000 programming software (from version 21 and above, it is referred to as Logix Designer within the Studio 5000 software package) provides a unified IEC61131-3 control platform featuring user-friendly interfaces and workflows. Ultimately, the Logix platform reduces programming complexity, eases troubleshooting, and increases plant reliability.
RSLogix 5000 provides intuitive access to real-time information, easy-to-follow runtime logic animations, and a comprehensive suite of online change capabilities. Rockwell's market share is second only to Emerson in North America. Moreover, due to Rockwell Automation's continued success and the glacial speed at which most plants switch platforms, it will be the market leader for the foreseeable future. Globally, Rockwell Automation is the fifth-largest automation manufacturer (behind Siemens, ABB, Emerson, and Schneider). Rockwell Automation's total global install base is well over 2 million programmable controllers. Needless to say, as an automation professional, learning the Logix platform suite is an excellent investment of your time.
Rockwell Automation has provided a wealth of knowledge in their web-based Literature Library, which is the ultimate source of all Logix platform knowledge. Rockwell has created a library of over 10,000 documents that are often difficult to navigate for beginners. Learning RSLogix 5000 Programming, Second Edition is in no way a replacement for this resource (this book would need to be 100,000 pages longer) but provides newcomers with a solid foundation in the Logix platform features and Rockwell Automation terminology. By the end of each chapter, links to the relevant Literature Library resources are provided to allow you to dive deeper into the topics covered. The final chapter of this book crystalizes what has been learned in a working control-system example that you can build at home. The final project of this book details all the steps required to create a Rockwell-powered robot bartender from the ground up. By the end of this book, you will have a clear understanding of the capabilities of the Logix platform and be able to quickly navigate the Rockwell Automation Literature Library resources. Moreover, you will have the unique experience of purchasing, building, wiring, and programming a control system from end to end.Learning RSLogix 5000, Second Edition provides a gentle introduction to RSLogix 5000/Studio 5000 and the Logix platform. If you are new to Programming Logic Controller (PLC) programming or have experience with programming other PLC platforms, then this book will provide you with the knowledge of the Rockwell family of controllers and teach you how to become proficient at implementing Logix solutions from the ground up.
Who this book is for
The purpose of this book is toexplore the hardware, software, andprogrammingof theLogixplatformso that electricians, instrumentation technicians, automation professionals, industrial control system network defenders, and students who are familiar withautomationcan get up to speed with a minimal investment of time. I intentionallyfocus on the essential requirements for selecting, configuring, and programming a modernLogixapplication to get you working with the platform as quickly as possible. Onceyouhave a solid foundation in the Rockwell Automation Integrated Architecture system,you will be able to further your knowledge of any topic using the online Literature Library.
What this book covers
Chapter 1, History of the Rockwell Automation Technologies,provides a history of industrial control systems and the Rockwell Automation ecosystem. It is important to understand the legacy systems provided by Rockwell Automation because some of them can still be found operating in the field today. Also, it is important to understand the overall Rockwell Automation offering, terminology, and how the platforms we focus on in the book fit into that world. Rockwell Automation's Integrated Architecture system is outlined, as is where ControlLogix fits into their larger strategy.
Chapter 2, Understanding ControlLogix, introduces the flagship controllers available within Rockwell Automation's Integrated Architecture system. We cover the controller solutions available within the Integrated Architecture system and learn how to make solution architecture decisions. We explore the physical features and diagnostic information available on the ControlLogix cards and investigate the evolution of the platform's firmware. Finally, we learn the differences between the traditional synchronous PLC scan and the Logix asynchronous operating cycle.
Chapter 3, Understanding CompactLogix, introduces the full line of CompactLogix controllers available within Rockwell's Integrated Architecture system. We learn about the CompactLogix 5480 hybrid controllers, and their unique position in the industrial marketplace. We gain an understanding of the controller solutions available within Integrated Architecture and learn to make CompactLogix architecture decisions. We also learn how to use Rockwell's online resources to identify the modules that are compatible with our solution.
Chapter 4, Understanding SoftLogix, teaches us about the SoftLogix 5800 controllers, which enable us to create a PC-based Logix controller rack. We learn how to create a virtual rack that houses our virtual controllers and virtual communication modules. We also learn that SoftLogix is another component of Rockwell Automation's Integrated Architecture system and can interface with the other Logix controllers, communication modules, and I/O modules. We also learn that by taking advantage of the computing power of modern PCs, the SoftLogix controllers are capable of processing larger volumes of data and at a higher speed than even the most powerful Logix controller.
Chapter 5, Understanding the Logix Emulate 5000, teaches us how to leverage a virtual Logix controller and rack to facilitate debugging Logix program code using features such as breakpoints and tracepoints. In this chapter, we create a virtual test rack using similar modules to a physical rack and create a simple test. We learn the critical differences between Emulate 5000 and SoftLogix 5800. We learn how to create a RSLogix Emulate 5000 solution containing modules that are configured in a virtual Logix rack to mimic the end solution.
Chapter 6, Industrial Network Communications, introduces the various communication technologies available for the Logix platform. The focus of this book is the current state of Rockwell Automation's ControlLogix and CompactLogix controllers; however, we will touch on some legacy communication protocols that you may still find running in the field today. Communications allow us to interface with controllers, racks, and devices on our network. Establishing communications is an important step that enables us to connect with a device and transfer configuration changes and programs. In completing this chapter, you will be familiar with all the Rockwell Automation communication technologies that have been used in the past and that are actively used in the field today.
Chapter 7, Configuring Logix Modules, enumerates the available modules for the Logix platform, how to configure them, and their usage in a Logix project. We will also include methods for identifying module features by their Logix module catalog numbers and introduce the address tree that a typical I/O module creates. After completing this chapter, you will be able to select and add I/O modules to your projects, modify the module configurations, and reference their real-time values using the recommended best practices.
Chapter 8, Writing Ladder Logic, looks at the history of ladder logic and the development of the IEC standard programming languages. Then, it jumps into ladder logic programming by creating a simple pump control program. We demonstrate how to buffer inputs and outputs in our ladder logic code and discuss the importance of this process. At the end of the chapter, you will be able to read and write IEC ladder logic for the Logix platform and for multiple other vendors that support IEC standard programming languages.
Chapter 9, Writing Function Blocks, explores the origins of Function Block Diagrams (FBDs) in systems engineering and introduces the basic concepts of IEC FBD programming. We learn how to create FBDs by dragging and dropping elements into a sheet in a routine. The way Logix compiles IEC languages down to bytecode is also explored in this chapter. We learn how to wire input and output references to Function Block pins and identify digital and analog connections before monitoring their values online. By the end of the chapter, you will understand how to read and write Function Blocks and be able to apply this knowledge to Rockwell products or products from other industrial automation vendors that conform with the IEC standards.
Chapter 10, Writing Structured Text, introduces you to the best uses for Structured Text (ST) within an automation solution. We start by exploring the ST editing environment and then introduce some of the new editing features available in Studio 5000 version 31 and higher. We create a simple ST routine and learn about the powerful syntax of ST code. Then we explore the full range of operators, expressions, instructions, and constructs available in the ST language. You will gain a solid foundation to help you read and write ST code within Logix and within other products that implement the IEC standard ST language.
Chapter 11, Building Sequential Function Charts, introduces you to Sequential Function Charts (SFCs) and typical usages within an automation solution. The core elements that make up an SFC are covered, and you will create a simple backwash process routine. We will learn how the usage of SFC varies from industry to industry. You are also shown that there are certain cases where leveraging the IEC SFC construct can greatly simplify the creation and debugging of a program. As with the previous IEC languages covered in this book, we will learn that selecting the appropriate language for your application is like selecting the correct tool to solve the problem you are facing. Although some programmers will only ever write in ladder logic, we learn that there are many advantages of using the full range of IEC languages where appropriate.
Chapter 12, Using Tasks and Programs for Project Organization, investigates the project organizational units used throughout this book. It details the way a Logix controller executes tasks and how the CPU divides its time based on priority. It introduces the overhead time slice and emphasizes its importance when optimizing a Logix application. Finally, it investigates methods within the Logix platform to monitor and troubleshoot performance issues. By the end of the chapter, you will be able to troubleshoot and optimize Logix project performance on larger solutions.
Chapter 13, Faults and Troubleshooting in Logix, provides recommendations for improving your troubleshooting capabilities in the Logix platform. It teaches us how to identify and troubleshoot the various types of faults that can occur in a Logix solution. In this chapter, we will use ladder logic to trigger a major fault, and then learn how to trap the major fault and prevent the controller from stopping when it occurs. Finally, we will highlight the FactoryTalk TeamONE app provided by Rockwell Automation for troubleshooting the Logix issues while in the field from a mobile device. By the end of the chapter, you will be comfortable investigating issues and will know where to find additional support if required.
Chapter 14, Understanding Cybersecurity Practices in Logix, introduces some of the industrial control system cybersecurity resources provided by Rockwell Automation and the tools that can be used to prevent unauthorized views or edits of projects. Rockwell has invested heavily in its cybersecurity practice over the past decade and has come to the table with numerous products, services, and guidance to help protect their customers from cyber threats. By the end of the chapter, you will be familiar with the Rockwell cybersecurity solution landscape and the features that can be enabled in a Logix solution to protect the process and code base.
Chapter 15, Building a Robot Bartender in Logix, combines the skills we have learned throughout this book into a sample application. This chapter steps through building a complete robot bartender control system from scratch, including configuring the modules, writing the code, and downloading it into our PLC. At the end of this chapter, you will understand how to select the components required for a simple ControlLogix industrial control solution. You will also learn how to wire digital input and output cards for a small control system project. After completing this project, you will gain a deeper understanding of the entire industrial control system building, tuning, and troubleshooting process and will be able to apply this knowledge to real-world control environments.
To get the most out of this book
To get the most out of this book, you should create a Rockwell Support account by visiting the following URL:
https://www.rockwellautomation.com/account/create-account
The account is free, and the material we will be reviewing in this chapter is publicly available to anyone who has registered with Rockwell Automation.
You will also need a copy of RSLogix or Studio 5000 to program your project. You can either purchase this from your local distributor or request a time-limited trial version. You can find a local distributor for Rockwell products at the following URL:
https://locator.rockwellautomation.com/
Software/hardware covered in the book
OS requirements
Rockwell Automation Studio 5000 Logix Designer v20 - v32
Windows® 7 Professional (64-bit) with Service Pack 1
Windows 8.1 Professional (64-bit) with April 2014 Update Roll-up
Windows 10 Professional (64-bit) version 1607
Windows Server 2008 R2 Standard Edition with Service Pack 1
Microsoft Windows 8.1 Professional (64-bit)
Windows Server 2012 Standard Edition
Windows Server 2016
Rockwell Automation RSLogix 5000 v10 - v19
Microsoft Windows XP Professional with Service Pack 2
Microsoft Windows Server 2003 R2 Standard Edition with Service Pack 1
Microsoft Windows 2000 Professional with Service Pack 4
Microsoft Windows XP Home
Microsoft Windows Server 2003 Standard Edition with Service Pack 1
Microsoft Windows 2000 Professional with Service Pack 1, 2, or 3
ControlLogix CPUs
1756-L55 ControlLogix 5555
1756-L61 ControlLogix 5561
1756-L62 ControlLogix 5562
1756-L63 ControlLogix 5563
1756-L71 ControlLogix 5571
1756-L72 ControlLogix 5571
1756-L73 ControlLogix 5571
1756-L81 ControlLogix 5581
1756-L82 ControlLogix 5582
1756-L83 ControlLogix 5583
1756-L84 ControlLogix 5584
1756-L85 ControlLogix 5585
CompactLogix CPUs
Any CompactLogix controller CPU
To complete the robot bartender build in the last chapter of this book, you will also need to have several tools and purchase some Rockwell Automation equipment. The tools and parts are listed in the final chapter of the book, Chapter 15, Building a Robot Bartender in Logix.
Download the color images
We also provide a PDF file that has color images of the screenshots/diagrams used in this book. You can download it here:http://www.packtpub.com/sites/default/files/downloads/9781789532463_ColorImages.pdf.
Conventions used
There are a number of text conventions used throughout this book.
CodeInText:Indicates code words in text, database table names, folder names, filenames, file extensions, pathnames, dummy URLs, user input, and Twitter handles.Here is an example:"Mount the downloadedWebStorm-10*.dmgdisk image file as another disk in your system."
A block of code is set as follows:
(* IF THEN ELSEIF ELSE Example *)if (TankLevel >= 50) then Pump1Permissive [:=] 1;elseif (TankLevel >= 100) then Pump1Permissive [:=] 1;Pump2Permissive [:=] 1;else Pump1Permissive [:=] 0;Pump2Permissive [:=] 0;end_if
When we wish to draw your attention to a particular part of a code block, the relevant lines or items are set in bold:
(* CASE Example *)case sequence_number of
1: StartPump [:=] 1;
OpenValve [:=] 1;
2: StartBlower [:=] 1; 3,4: StartMixer [:=] 1; 4..10: StartAuger [:=] 1;else StartPump [:=] 0;end_case;
Bold: Indicates a new term, an important word, or words that you see onscreen. For example, words in menus or dialog boxes appear in the text like this. Here is an example: "Click on the Finish button, or in RSLogix 5000, click on OK."
Get in touch
Feedback from our readers is always welcome.
General feedback: If you have questions about any aspect of this book, mention the book title in the subject of your message and email us at [email protected].
Errata: Although we have taken every care to ensure the accuracy of our content, mistakes do happen. If you have found a mistake in this book, we would be grateful if you would report this to us. Please visit www.packtpub.com/support/errata, selecting your book, clicking on the Errata Submission Form link, and entering the details.
Piracy: If you come across any illegal copies of our works in any form on the Internet, we would be grateful if you would provide us with the location address or website name. Please contact us at [email protected] with a link to the material.
If you are interested in becoming an author: If there is a topic that you have expertise in and you are interested in either writing or contributing to a book, please visit authors.packtpub.com.
Reviews
Please leave a review. Once you have read and used this book, why not leave a review on the site that you purchased it from? Potential readers can then see and use your unbiased opinion to make purchase decisions, we at Packt can understand what you think about our products, and our authors can see your feedback on their book. Thank you!
For more information about Packt, please visit packt.com.
Section 1: Introduction to RSLogix
This section starts by describing the history of the evolution of industrial control systems and of Rockwell Automation. You will then be introduced to the ControlLogix and CompactLogix families of controllers, which utilize RSLogix/Studio 5000 for programming purposes. Finally, we will introduce two virtual controllers that also leverage RSLogix/Studio 5000 for development.
This section comprises the following chapters:
Chapter 1
,
The History of the Rockwell Automation Technologies
Chapter 2
,
Understanding ControlLogix
Chapter 3
,
Understanding CompactLogix
Chapter 4
,
Understanding Softlogix
Chapter 5
,
Understanding Logix Emulate 5000
The History of Rockwell Automation Technologies
This book begins with some background history of industrial control systems and the Rockwell Automation ecosystem. It is essential to understand the legacy systems provided by Rockwell Automation because some of them can still be found operating in the field today. Also, it is important to understand the overall Rockwell Automation offering, the terminology, and how the platforms we focus on in this book fit into that world.
In this chapter, we will introduce Rockwell Automation and provide a history of the evolution of their technologies, right up to the Logix platform. Due to the 15- to 20-year industrial controller lifespan, it is not uncommon to encounter older versions of hardware and firmware and so it is critical to understand their evolution.
The following topics will be covered in this chapter:
Controlling equipment with water, air, and power
A brief history of Rockwell Automation
Understanding Integrated Architecture
In the first section of this chapter, we will look at the earliest examples of control systems in history.
Controlling equipment with water, air, and power
The earliest control systems can be traced back to the float regulator mechanisms that were used in Greece around 270 BC. The need for accurate time tracking inspired the Greek water clock (clepsydra), which leveraged the simple float regulator to maintain a constant flow of water. The float regulator would maintain the water level in a primary tank at a constant depth; water kept at a constant depth maintained a constant water pressure.
Constant pressure resulted in a constant flow of water through a tube that would fill a secondary tank at a constant rate. The level of the second tank was used to measure time, which was displayed on a dial using a second float. A similar float regulator mechanism is still used in our toilets today. A construct that uses input from another device (float) to maintain a value (water level) is called a feedback controller.
The following diagram details the components of a simple Greek water clock (clepsydra):
In the next section, we will discuss the advent of pneumatics and its place within industrial control systems.
The rise of pneumatics
The Greeks also invented a more sophisticated feedback control mechanism that utilized steam or compressed air, rather than water, called pneumatics. The Greek mathematician Hero of Alexandria created inventions that were powered by steam or the wind. German physicist Otto von Guericke (1602 – 1686) was the first to invent a vacuum pump that can draw out air or gas from the attached vessel. After the industrial revolution, the air pressure from pneumatics was used as a method of activation and signal transmission within control systems. In the 1950s and 1960s, pneumatics signal transmission started to be replaced by electric signal transmission, which gave rise to the modern control systems we see today. However, it is not uncommon to see pneumatics still used today in a wide range of applications. Today, pneumatics are still a ubiquitous part of many Heating Ventilation and Air Conditioning (HVAC) systems.
The following diagram illustrates a typical pneumatic HVAC heating system (image courtesy of Spirax Sarco Limited):
The preceding diagram shows how a pneumatic controller is used to regulate the temperature of a steam heating system using a pneumatic temperature control valve based on the feedback loop from the temperature sensor.
In the next section, we will introduce the electromechanical relay and discuss how it changed industrial automation forever.
Understanding electric relay logic
The electromechanical relay was first created in 1835 by Joseph Henry (1797 – 1878). Although Joseph Henry built and demonstrated the first mechanical relay, he had no intention of applying it to a practical application. The relay was used to demonstrate the phenomenon of self-inductance and mutual inductance to his students. In 1836, when Samuel F. B. Morse learned of the electromechanical relay, he began to consider its potential application for communications and controlling machinery.
Samuel Morse soon used Henry's relay device to carry morse code signals over long distances of wire. As electromechanical relays began to be widely adopted to control electrical equipment, a standard method of documenting the relay wiring was required. This led to the advent of ladder diagrams, which were used to document the convoluted logic of these systems so that they could be maintained and upgraded.
Control systems evolved into a complex mixture of industrial relays, rotary drum sequencers, pneumatic plunger timers, counters, motors, push buttons, selector switches, limit switches, and valves, all connected together and controlled using hundreds or thousands of failure-prone electromechanical relays. As complex control systems evolved and were maintained, they inevitably transformed into a rat's nest of wires, leading to outages and extended turnarounds. General Motors (GM) had grown tired of the shortcomings of hardwired relay logic within their automotive factories and were aware of advances in solid-state computers. So, as the story goes, on New Year's Day 1968, they detailed a specification for what would later be known as the Programmable Logic Controller (PLC). GM’s requirements were as follows:
Competitively priced with a traditional relay logic system
Leveraging a solid-state system that is flexible, such as a computer
Programmed in a manner that aligns with accepted relay ladder engineering diagrams
Robust enough to work in industrial environments where they would be exposed to dirt, moisture, electromagnetism, and vibration
Modular and expandable to support a wide range of process sizes and types
We have now covered the past 2,000 years of industrial automation evolution. In the next section, we will introduce Rockwell Automation and detail their contributions to the automation industry.
A brief history of Rockwell Automation
In 1901, while working for Milwaukee Electric, Lynde Bradley (a teenager at the time) devised a better way to build the controllers that regulate motor speed. He soon quit his job, secured a small $1,000 investment from his lifelong friend, Dr. Stanton Allen, and co-founded the Allen-Bradley company with his brother, Harry Bradley, in 1903. The primary focus of Allen-Bradley was,for several decades, motor controllers, until they received an unusual request from GM in 1968 to build a system to replace their hardwired relay logic with something more dynamic—a standard machine controller.
Program Data Quantizer II and the Programmable Matrix Controller
Allen-Bradley responded to GM's request with two solutions—first, a large, difficult-to-program, expensive minicomputer-based Program Data Quantizer (PDQ) II in 1970 and later, the smaller and easier-to-program Programmable Matrix Controller (PMC) in 1971. The PMC was an early precursor to the modern PLC, and Allen-Bradley later adopted the term PLC for future releases of their automation products.
Although Allen-Bradley did not win the GM bid, the PMC continued to evolve until the release of the PLC-2. GM awarded the contract to Dick Morley and his company, Bedford and Associates. Dick Morely spun off a new company, named Modicon, and started to sell a PLC product called the Modicon 084 (named because it was prototype #84) based on this initial design.
PLC-2 controllers
Allen-Bradley introduced their very first PLC (PLC-1) in 1970, and it continued to evolve until the release of the PLC-2 in 1978. The PLC-2 played a vital role in the Space Shuttle program as Rockwell International was a primary contractor. The PLC-2/20 and many other AB controls were used in the manufacturing and testing of the 153-foot one-time-use tank, which fueled and provided structure to the shuttle.
The PLC-2 family of processors featured three versions:
PLC-2/10
PLC-2/20
PLC-2/30
The more-powerful PLC-2 processors ran on a 1772-LP3D4 processor running at 47 to 63 Hz and supporting up to 16 K (16 data bits) of memory capacity.
The following diagram depicts the original PLC-2/30 controller:
It is possible that a few PLC-2/30s or PLC-2/20s could still be found in the field today. The PLC-2 can be programmed using 32-bit operating systems, such as Windows 8. The PLC-2 can be programmed using the 6200 programming terminal or Application Interface (AI) programming version 6.24 and a serial interface. The Rockwell AI software is an MS-DOS-based programming interface that provides a text-based graphical interface for viewing and editing ladder logic.
In the next section, we will discuss the third PLC created by Allen-Bradley—the PLC-3.
PLC-3 controllers
The PLC-3 was introduced in 1981 (the same year that the first Space Shuttle launched) and provided significant scalability increase for control systems. The PLC-3 was usually packaged with a programming terminal, much like the PLC-2. The PLC-3 supported up to 128 K (16 data bits) of memory capacity.
The following diagram depicts the Allen-Bradley PLC-3 controller unit, which featured a numeric keypad for programming and adjustments:
In the following section, we will introduce the robust PLC-5 platform, which replaced the PLC-3 and can still be found operating in some plants today.
PLC-5 controllers
The 1785 catalog number PLC-5 was launched in 1986 based on the Motorola 68000 32-bit CISC microprocessor and was designed to scale and support both centralized and distributed control architectures.Allen-Bradley defined a centralized architecture design as one that featured a single processor managing a plant where a distributed architecture contained multiple processors and user interfaces to manage a plant.
At the time of its release, a PLC-5 network would likely be managed by a VAX/VMS host or a panel-view operator terminal and programmed using dedicated programming terminal computers engineered by Allen-Bradley. As the PLC-5 platform evolved, it later adopted Ethernet connectivity (PLC-5/20E, PLC-5/40E, and PLC-5/80E) using a 15-pin Ethernet port, the first Allen-Bradley PLCs to do so.
Around the same time as the PLC-5 release in 1985, Allen-Bradley was acquired by Rockwell International (now known as Rockwell Automation), but the Allen-Bradley name and logo can still be found on many of Rockwell Automation's products.
The PLC-5 was an extremely robust platform and although it has been discontinued and replaced with the ControlLogix platform by Rockwell, it continues to operate in many plants. I have personally owned a PLC-5/40E and worked with plants that still operate these devices today.
Over the years of development of the PLC-5, Allen-Bradley released 15 versions of the platform, which were later categorized by Rockwell as Classic PLC-5 processors and Enhanced PLC-5 processors.
The PLC-5 Classic family of processors leveraged DataHighway Plus (DH+) and remote I/O for its communications. The PLC-5 Enhanced family of processors also had serial communications and Ethernet communications. Although the early programming software for the PLC-5 was DOS-based, Allen-Bradley eventually created a Windows-based programming environment for the PLC-5, called RSLogix5. The PLC-5 rack was entirely made of metal, making it very heavy and giving it an industrial feel. The following diagram depicts the PLC-5 rack with a processor and some I/O cards:
In the next section, we will discuss Allen-Bradley's first foray into the midsize control system market with the SLC-500 controller.
SLC-500 controllers
The SLC-500 was launched in 1991 and was designed to be used in smaller plants; in fact, SLC stands for Small Logic Controller. The SLC-500 is an integrated platform that contains the CPU, power supply, and I/O in a single unit. The SLC-500 platform eventually received communications support for DH485 (Data Highway) and Ethernet. The Allen-Bradley RSLogix 500 software was used to program the SLC-500s. The SLC-500 has been replaced with the newer CompactLogix 5370 or 5380 control platforms. The following is a diagram of the SLC-500 controller:
Next, we will introduce the low-cost control system solution from Allen-Bradley, the MicroLogix controller.
MicroLogix
MicroLogix and Flex I/O were launched in 1994. MicroLogix used the RSLogix 500 software for programming their PLCs (the same software used for the SLC controller family). The first MicroLogix unit to be introduced was the MicroLogix 100 PLC, which was released with several different combinations of I/O. Its creation was a response to the need for a low-cost automation solution with a limited feature set. The MicroLogix controller did not originally use a rack and modular cards, but rather a fixed set of input and output channels.
The following is a diagram of a Rockwell MicroLogix controller:
Over the years, Rockwell also introduced other new MicroLogix controllers, such as the Bulletin 1763 MicroLogix 1100, the Bulletin 1762 MicroLogix 1200, and the Bulletin1766 MicroLogix 1400 series. The 1100, 1200, and 1400 series controllers have reached their end of life and have been replaced with the Micro800 series or CompactLogix series of controllers.
