Preface
In 1997, Rockwell Automation launched their current generation control platform, Logix. It represented decades of automation technical advancement for robust, large-scale solutions. When it launched, it included the ControlLogix 5550 controllers (Bulletin 1756), ControlLogix I/O modules, and RSLogix 5000 programming software platform. In 2001, CompactLogix Controller (Bulletin 1769) was added to the Logix family to support intermediate-sized automation solutions under the same development platform. The RSLogix 5000 programming software (in version 21 and higher, is now referred to as Logix Designer within the Studio 5000 software package) provided a unified IEC61131-3 control platform, featuring user-friendly interfaces and workflows. Ultimately, the Logix platform reduced programming complexity, eased troubleshooting, and increased plant reliability.
RSLogix 5000 provides intuitive access to real-time information, easy to follow run-time logic animations, and a comprehensive suite of online change capabilities. Rockwell is the automation market leader 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. Outside North America, it is widely considered to be the fourth largest automation manufacturer (after Siemens, ABB, and Schneider). Its total global installation 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 resources, which is the ultimate source of all the Logix platform knowledge. Rockwell has created a web of over 10,000 documents that is often difficult to navigate for beginners. Learning RSLogix 5000 Programming 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 this book, the reader will have a clear understanding of the capabilities of the Logix platform and how to quickly navigate through the Rockwell Automation Literature Library resources.
Learning RSLogix 5000 Programming provides a gentle introduction to RSLogix 5000 and the Logix platform. If you understand the basics of PLC programming or have experience with programming other PLC platforms, this book will provide you with the knowledge to become proficient at implementing Logix solutions from the ground up.
What this book covers
Chapter 1, ControlLogix and CompactLogix Overview and Firmware, introduces the ControlLogix and CompactLogix platforms by exploring the evolution of the Allen Bradley controllers. It provides details of the Rockwell Automation Integrated Architecture and then discusses the important role that firmware plays in the Logix5000 platform.
Chapter 2, Industrial Network Communications, details the various communication technologies available for the Logix platform. The focus of this book is on the current state of Rockwell Automation's ControlLogix and CompactLogix controllers, however, this chapter discusses some legacy communications protocols, which you may still find running in the field today.
Chapter 3, Configuring Logix Modules, looks at the available modules for the Logix platform, how to configure them, and their usage in a Logix project. It also includes methods for identifying module features by their Logix Module Catalog numbers and the address tree that a typical I/O module creates.
Chapter 4, SoftLogix, introduces the Rockwell Automation SoftLogix 5800 Controller and Virtual Chassis. It guides you through the setup of the SoftLogix chassis monitor and configuration of your SoftLogix controller within Logix. Finally, this chapter investigates the techniques for simulating I/O using the 1784 SIM module.
Chapter 5, Writing Ladder Logic, looks at the history of ladder logic and the development of the IEC standard programming languages. Then, it lets you jump into ladder logic programming by creating a simple pump control program. It demonstrates how to buffer inputs and outputs in our ladder logic code and discusses the importance of this process. Finally, it explores the buffering capabilities of the new Program Parameter features in Studio 5000 Logix Designer.
Chapter 6, Writing Function Block, explores the merits of function block programming by building a small sample application. It also provides instructions for modifying the function block properties and performing online edits.
Chapter 7, Writing Structured Text, explores the strengths and weaknesses of structured text programming by exploring the typical uses of this language and demonstrates several sample applications.
Chapter 8, Building Sequential Function Charts, implements a sequential function chart routine and breaks down the steps, actions, transitions and branches that are used to construct it. Finally, it lets you work with the online editing capabilities of sequential function chart routines.
Chapter 9, Using Tasks and Programs for Project Organization, looks at the ways to structure a Logix project using the basic organization units—tasks, programs, and routines. It also looks at the ways in which task scheduling and prioritization can be used to balance the processing time of a controller.
Chapter 10, Faults and Troubleshooting in Logix, teaches you how to identify and troubleshoot faults in a Logix controller. It details a list of fault codes that provide insights into the problems encountered by the platform. It introduces the process of fault recovery, which allows a program to resume its execution after encountering a specific fault type. Finally, it brings you the convenient troubleshooting applications available for your iPhone and iPad.
Appendix, Rockwell Automation Literature Library Resource, gives you topic-specific documentation links.
Safety warning – loss of control/view
The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. The examples of critical control functions are emergency and over-travel stop that may include the following capabilities:
Separate or redundant control paths must be provided for critical control functions.
System control paths may include communication links. Consideration must be given to the implications of unanticipated transmission delays or failures of the link.
Each implementation of a control system must be individually and thoroughly tested for proper operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
This book is not comprehensive for any systems using the given architecture. It does not absolve users of their duty to uphold the safety requirements for the equipment used in their systems or compliance with both national or international safety laws and regulations.
What you need for this book
In order to complete the exercises in this book, you will need RSLogix 5000 version 17+ or Studio 5000 Logix Designer version 20+. You will also need a Rockwell ControlLogix Programmable Automation controller or a software controller such as Emulate 5000 / SoftLogix 5800.
Who this book is for
The purpose of this book is to explore the hardware, software, and programming of the Logix platform so that electricians, instrumentation techs, automation professionals, and students who are familiar with automation, get up to speed with a minimal investment of time. I intentionally focus on the essential requirements for selecting, configuring, and programming a modern Logix application in order to get the reader working with the platform as quickly as possible. Once the reader has a solid foundation in Rockwell Automation Integrated Architecture, they will be able to further their knowledge on any topic using the online Literature Library.
Conventions
In this book, you will find a number of text styles that distinguish between different kinds of information. Here are some examples of these styles and an explanation of their meaning.
Code words in text, database table names, folder names, filenames, file extensions, pathnames, dummy URLs, user input, and Twitter handles are shown as follows: "This module can be configured to record or latch the time at which a state is changed from ON to OFF, OFF to ON, or both."
A block of code is set as follows:
(***** Alarm Totalizer *****)
if (OSRI_01.OutputBit AND NOT FC1001_FLT_ALM.Disabled) then
Total_Alarm_Count := Total_Alarm_Count + 1;
end_if;New terms and important words are shown in bold. Words that you see on the screen, for example, in menus or dialog boxes, appear in the text like this: "First, in the Controller Organizer pane, select and double-click on the Controller Tags option to open the Controller Tags panel."
Note
Warnings or important notes appear in a box like this.
Tip
Tips and tricks appear like this.
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