Control Logix 5000 System

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SETTING UP THE CONTROL LOGIX 5000 SYSTEM

Setting up the Control LOGIX 5000 System

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CONTENTS Communicating with the Logix5555 Processor...........................................3 Establishing a Serial Connection (RS232):-................................................3 Establishing the 1756-ENET Module Configuration:- .................................5 Establishing an Ethernet Connection :- ......................................................7 Generating a Logix 5000 Project (*.ACD file) from a *.L5K File..................9 Loading a Project (*.ACD) onto the Logix 5000 Processor .......................10 Saving a Project (*.ACD) from the Logix 5000 Processor ........................14 Saving a Project (*.ACD) to the Logix 5000 Processor Nonvolatile Memory .................................................................................................................17 9. Setting up DDE Topics in RSLinx .............................................................21 10. Forcing IO Points From Logix 5000 ..........................................................24 11. Determining the revision of Firmware in a Logix5000 Processor..............29 12. Downloading New Firmware to the ControlLogix Processor.....................31 13. Adding a New ControlNet IO Module........................................................35 14. Unscheduling Programs in RSLogix 5000 ................................................40 1. 2. 3. 4. 5. 6. 7. 8.

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KEY TO SYMBOLS DO NOT PROCEDE UNTIL SAFE TO DO SO. POSSIBLE DAMAGE TO PLANT OR RISK OF PERSONNEL INJURY. INFORMATION/TIPS. CAUTION. EXERCISE CAUTION BEFORE PROCEDING.

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Setting up the Control LOGIX 5000 System

Revision 1

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Date Comment 03/02/2002 First issue

Author S.E.M

Note:- This is not a controlled document. The information contained in this guide is provided to promote understanding and assist site personnel. Changes to Rockwell Software versions and ECU core/user programs will affect the detailed steps in this procedure. Persons must seek advice from the Technical Support department if the procedure is in question.

Communicating with the Logix5555 Processor

Initial communication with the Control Logix 5000 system will be from a laptop PC via the 9 way RS232 connection on the front of the system processor as shown in the picture above. Once the Ethernet module (1756-ENET) has been configured normal communication will be via the local network. In order to communicate with the system you will need the following:• •

RSLinx software installed on your PC. Serial cable, RS232 Programmers Cable (64/52004053/071) or Ethernet cable (CT94732/01) via network hub.

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Establishing a Serial Connection (RS232):The serial cable pin assignments are shown in the inside of the processor door.

If you make your own serial cable limit the cable too no more than 15 meters in length. Make the connections as shown below:-

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Configuring a software driver is the first step in establishing a DDE hot link. This driver is the software interface that allows RSLinx to communicate with the controller. •

Connect the serial cable to the Logix5555 processor and the required com port on the PC.



Run the software Program “RSLinx” from the Start Programs button on the PC.

• Select “Communications” then “Configure Drivers” from the top menu. Alternatively you can use the Configure Drivers symbol on the shortcut bar . •

Select the required driver from the “Available Driver Types” list, and click “Add New”. The required driver is “RS-232DF1 devices”, as shown below.



The default name can be used as can the default settings in the driver configuration dialog box. Finally click the “Close” button on the Configure Drivers dialogue box.

This

should

have

created a similar connection . This path can be expanded to view the network and devices.

5

to

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Establishing the 1756-ENET Module Configuration:To enable an Ethernet connection to the system we need to know the configuration of the ENET module. The module has the following connections:

To view the configuration of the ENET module we need to run RSWho. RSWho is RSLinx's main window that displays networks and devices in a style similar to Windows Explorer. •

Run “RSLinx” from the Start Programs button on the PC.



Select “Communications” then “RSWho” from the top menu.

Alternatively you can use the RSWho symbol on the shortcut bar

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To view the ENET module expand the network as shown below:-



Right click on 1756-ENET/A, 1756-ENET/A and select Module Configuration to pop up the 1756-ENET Configuration dialogue box. Select the Port Configuration tab as shown below.

l From here you will be able to enter/check the IP Address for the ENET module. This address may require changing to suit the contract. Make a note of the address as it will be required when setting the IP address of the laptop. • When finished click the “OK” button. 7

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Establishing an Ethernet Connection :The Ethernet pins outs are as per a straight through cable. •

Connect the Ethernet cable to the PC and the local network via the TCM mounted Ethernet hub. To enable the laptop to communicate on the Ethernet it must have its own unique IP address that is compatible with the network. In the example above the IP Address of the ENET module is set to 163.70.117.203 and the Subnet Mask is set to 255.255.0.0 It follows then that the PC Address must follow the same format but with its own unique identifier. For example the following Address could be used 163.70.117.205. This must not conflict with any other device on the network. The Subnet Mask must match the ENET module. The procedure for setting the IP Address of the PC will differ depending on the operating system used. Windows2000 has the following dialogue box under the Internet Protocol (TCP/IP) component within the Network and Dial-up Connections option under My Network Places. Ensure that “Use the following IP address” is checked.

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To establish an Ethernet connection with the Logix5000 system you need to configure a driver for Ethernet devices in RSLinx. •

Run the software Program “RSLinx” from the Start Programs button on the PC.

• Select “Communications” then “Configure Drivers” from the top menu. Alternatively you can use the Configure Drivers symbol on the shortcut bar . •

Select the required driver from the “Available Driver Types” list, and click “Add New”. The required driver is “Ethernet devices”.



The default name can be used. Clicking “OK” on the “Add New RSLinx Driver” window will pop up the “Configure driver” window as shown below. To this window add the IP address of the 1756-ENET module as station 0.



When finished click “OK”. This should have created a new driver “AB_ETH-1 A-B Ethernet”. The status section should report that the driver is running. Finally click the “Close” button on the Configure Drivers dialogue box. The path from the ENET module can be expanded to show the network and device structure.

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Generating a Logix 5000 Project (*.ACD file) from a *.L5K File A file with the .L5K extension is the file format used by Logix5000 to import /export text information. These files contain an ASCII representation of the data for an entire project. Once imported this data will create a new project file with the .ACD extension. *.L5K files are generally smaller than *.ACD files and is the format used to issue new builds of software to site. • •

Run the software Program “RSLogix 5000” from the Start Programs button on the PC. Select “Open file” from the top level menu or use the open symbol on the shortcut bar

• •

Select the required file and click on “Open”. When prompted Save the imported project to a named file and click Import. The .L5K file should then be imported.

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Loading a Project (*.ACD) onto the Logix 5000 Processor To down load a project to the processor the key switch on the processor must be in the REMOTE or PROGRAM position.

• •

Run the software Program “RSLogix 5000” from the Start Programs button on the PC. Having previously generated a project or having been sent one, open the

required project using the button from the menu bar. This will take a few minutes depending on the size of the project. • Once open the project needs to be downloaded. Select download from the “Processor Status” button, . If a communcation path does not exist the following pop up window will appear.

The communication path will need to be configured using RSWho.

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Select “Communications” then “Who Active” from the top menu of Logix5000. Point down the communications path to the processor and highlight it. Check the “Apply Current Path to Project” option. Click “Apply” then the “Go Online” button.

If the processor does not contain a project or the off line project does not match an existing on line project the “Connected To Go Online” window will appear with a condition statement,

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The “Connected To Go Online” window should contain information about the off line project and its location. Ensure this is correct for the project you selected. • Clicking the “Download” option will start the process of writing the project to the controller. See below.

This will take some time typically 5 to 10 minutes depending on the size of the project. When finished the project should be visible in Logix 5000 and no errors should have been detected. The Controller status tab should show the current condition of the controller.

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Saving a Project (*.ACD) from the Logix 5000 Processor This procedure should only be carried out with the turbine and associated plant in a safe state. During the saving process the processor functions will be suspended. Please make sure all processes affected by this controller are in a safe state and that all safety critical functions are not affected. Prior to carrying out this procedure it will be necessary to make a communication connection to the Logix5555 processor via the Ethernet module and have an “Online” connection using RSLogix 5000 software. See the relevant sections of this procedure. The processor must be in either “REMOTE PROGRAM” or have the keyswitch in the “PROG” position prior to saving the project to the nonvolatile memory. •

Run the software Program “RSLogix 5000” from the Start Programs button on the PC.



Once it has started the project needs to be uploaded. Select Upload from the “Processor Status” button, .

If a communication path does not exist the following pop up window will appear. The communication path will need to be configured using RSWho.

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Select “Communications” then “Who Active” from the top menu of Logix5000. Point down the communications path to the processor and highlight it. Check the “Apply Current Path to Project” option. Click “Apply” then the “Upload” button.

The “Connected To Upload” window will appear with a condition statement. If no matching project exists on the hard disk then this dialog box will appear. •

Click on "Select file" and when prompted, either use the default filename or choose a suitable one.

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If a matching project already exists on the hard disk then this dialog box will be displayed:-

If you are happy that the project on the hard disk is current and valid, you can click "Cancel" and abort the upload. If you click on "Upload" the matching project on the hard disk will be overwritten. If you click on "Select File" you can choose a new file to save the project into. If you do upload, a status bar will appear to show the progress of the upload.

This will take some time typically 5 to 10 minutes depending on the size of the project. When finished the project should be visible in Logix 5000 and no errors should have been detected. The Controller status tab should show the current condition of the controller.

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Saving a Project (*.ACD) to the Logix 5000 Processor Nonvolatile Memory This procedure should only be carried out with the turbine and associated plant in a safe state. During the update process the processor functions will be suspended. Please make sure all processes affected by this controller are in a safe state and that all safety critical functions are not affected. Prior to carrying out this procedure it will be necessary to make a communication connection to the Logix5555 processor via the Ethernet module and have an “Online” connection using RSLogix 5000 software. See the relevant sections of this procedure. The processor must be in either remote programe or have the keyswitch in the “Prog” position prior to saving the project to the nonvolatile memory. The latest Logix 5000 processors have been fitted with a memory expansion card (M24) that contains a nonvolatile memory. This nonvolatile memory is used the store a copy of the downloaded project for recall at a later date should the need arise. • •

With the project open right click the controller folder and select the properties option from the pop up window. On the Controller Properties dialog box select the “Nonvolatile Memory” tab.

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If the nonvolatile memory is empty then no details will be shown on this tab.



Click the “Load / Store…” option to display the following dialogue box:-



Ensure that the options on the right hand side of the dialogue box are set as shown e.g. “Load Image:” is set to “On Corrupt Memory” and “Load Mode:” is set to “Run (Remote Only)”. A comment should be entered in the “Image Note:” section.

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When ready click the “< -- Store” option. The following pop up window will appear.

Read the warnings and consider any possible implications this could have on the turbine and any interfacing systems.



When ready click the “Yes” option and “OK” the following prompt.

During this process the “OK” LED on the processor will be flashing green and all other LED’s will be off. At the end of the store process the “OK” LED will briefly display a steady red indication before changing to a steady green if all is OK. On completion your RSLogix 5000 connection will be “Offline”.

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The “Nonvolatile Memory” tab in the controller properties, post save should now indicate the details of the stored image.

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Setting up DDE Topics in RSLinx RSLinx is a complete 32-bit product that links Allen-Bradley networks and devices to Microsoft Windows applications. These range from device programming and configuration applications such as RSLogix and RSNetWorx, to HMI applications such as RSView32, or Wonderware InTouch. RSLinx also incorporates advanced data optimisation techniques and contains a set of diagnostics. RSLinx is an OPC Data Access Compliant Server and a DDE server. To enable correct communication between the Logix system and the display system DDE topics need to be configured in RSLinx to match topics configured in InTouch. In RSLinx, a topic represents a specific path to a processor. If one of the topics is missing the IDS will not display the correct information and data could be missing. The Three topics needed for a standard interface are:CLOGIX CMESSAGES CSETPOINTS DDE topics should already be defined in InTouch WindowMaker in “Access Names” under the “Special” tab of the top menu bar. As shown below,



To configure the DDE topics in RSLinx run RSLinx on the IDS PC. Click the “DDE/OPC” button and select the “Topic Configuration…” option from the drop down menu.

The left-hand side of the “DDE/OPC Topic Configuration” window lists the defined topics. If any of the Three topics already stated are missing they will need to be added. •

Click the “New” button and type in the missing name as previously stated. Next you will need to state where the data source is located.

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Expand the network path as shown on the “Data Source” tab of the configuration window to highlight the system processor.



Then click the “Apply” button. If prompted click “Yes” to update the topic.

Repeat the above steps until the Three topics have been defined. The information on the other Two tabs can be left as default and should look like the following examples:-

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RSLinx is configured to run when the IDS application is started. When a communication link has been established the Three topics just defined should appear on the topic list in RSLinx preceded with a locked symbol. This indicates that the topic is active and cannot be modified.

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Forcing IO Points From Logix 5000 Forcing allows you to override an I/O module's values in the controller. Forcing an input value overrides the actual input value being received by the controller, but will not affect the value received by other controllers monitoring that physical input module. Forcing the input value overrides the value no matter what the state of the physical input is. Forcing an output value overrides the logic for the physical output module. Other controllers monitoring that output module in a listen-only capacity will also monitor the forced value. Forcing IO is straight forward once a connection has been made with the controller using RSLogix 5000 software and an appropriate project file. This procedure will not cover the opening of a project or the connection to a controller. Examples used are for illustration purposes only. Once the connection has been made the list of controller tags can be viewed in RSLogix 5000 by double clicking the Controller tags option from the project structure as shown down the left-hand side of the current window. Not all tags can be forced. Tags that can not be forced will have the “Force Mask” box greyed out.

To search for a tag you can scroll down the tag list using the scroll bar or use the text entry box along the top of the RSLogix 5000 window. Into which can be typed the tag name of the item you wish to find. Pressing the return key on the keyboard will initiate the search of the controller tags.

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Example of forcing an output:Forcing a Boolean type tag (Switch output). Searching for “Sol110”.

It is possible to force this tag by entering a Boolean value i.e. zero or one into the “Force Mask” box and clicking the “Force Status” button on the top left of the window and selecting the “Enable All Forces” option. CAUTION this will now move the valve to the forced position i.e. force value of one equals open. The value for the tag will now be highlighted in red to indicate that it is subject to a force. This may not match the force value. The value in the force box can now be toggled as required. To remove the force select the “Disable All Forces” option from the “Force Status” button. If this tag is one of many tags subject to a force and you wish to leave the other forces in place then individual forces can be removed by a right mouse button click over the selected tag and select the “Remove Force” option from the drop down menu.

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Forcing an Integer type tag (Analogue out):This could be the Hydrostart demand MCV101. Searching the controller tag list for “MCV101” will highlight a tag that is not forcible. To force the value of the Analogue out it is the “Raw” unscaled tag that must be forced. This is the value as sent to the module on the ControlNet. The range of this “Raw” tag is set in the MCV101_SCALE box as found in the instrument scaler program. This can be located by right mouse clicking the raw tag name box from the controller tags list and selecting the “Go To Cross Reference” option from the drop down menu. This will list all references to the selected tag.

Double clicking the entry that has a “Y” in the Destructive column will take you to that entry. Destructive means this reference will set the value of the tag.

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This is the function block where the input is scaled and fed out to the ControlNet module. It shows the input on the left and the output on the right of the function block. Clicking the “View Block Properties” box, will display the following properties,

From this information it can be seen that the Input is scaled from 0 to 100. This is outputted as a 0.0 to 31200 value. This is the value that has to be entered in the Force column of the MCV101_RAW tag.

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Example of forcing an input:Forcing an Integer type tag (Analogue input). This example could be a thermocouple e.g. TC1. Searching the controller tag list for “TC1” will highlight a tag that is not forcible.

This is true for all the thermocouples if the actual tag name is used in the search box. To force the value of the thermocouple it is the “Raw” unscaled tag that must be forced. This is the value as read in from the module on the ControlNet. The range off this tag is generally 10 times greater than the engineering unit range for the device i.e. device range –100 to 1000oC will have a raw range of –1000 to 10000. Therefore if a value of 5000 is placed in the force box the forced value for the device will be 500 oC. To check the actual scaling factor used follow the procedure as described in forcing an analogue out for locating the scaling function block.

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Determining the revision of Firmware in a Logix5000 Processor This has to be performed through RSLinx. If RSLinx is already open the window can be viewed by either clicking on the icon in the system tool tray or selecting it from the Windows "Start" bar. • If RSLinx is not open then from the "Start" button select: Start Æ Programs Æ Rockwell Software Æ RSLinx Æ RSLinx The following window will be displayed. • Select "RS Who" from the "Communications" dropdown menu.

The RSWho window will be displayed. • Select the required path to the controller.

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Right click on the controller and a dropdown menu will appear:-



Click on "Device Properties". The following box will be displayed

The Revision field gives the revision of the firmware. In this case it is 7.9 and would need to be updated to the current version (8.x).

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Downloading New Firmware to the ControlLogix Processor It may be necessary to update the firmware of the Logix5555 processor to allow connection/downloading using RSLogix 5000 at the current version. ControlFLASH is the firmware update tool used for electronically updating firmware. ControlFLASH has an easy-to-use interface that will walk you through the entire firmware update. To facilitate this, ControlFLASH uses pages in the form of dialog boxes that will prompt you for the information it needs. This procedure should only be carried out with the turbine and associated plant in a safe state. During the update process the processor functions will be suspended. Please make sure all processes affected by this controller are in a safe state and that all safety critical functions are not affected. This section assumes that the user is running version 3.17 of the ControlFLASH software. This can be obtained from Software Admin in Lincoln. Prior to carrying out this procedure it will be necessary to make a communication connection to the Logix5555 processor via the Ethernet module. See the relevant section of this procedure. •

Run ControlFLASH from the programs menu under “Rockwell Software – Flash Programming Tools”.

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Clicking the “Next” option brings up a dialog box prompting you to select the processor type. The processor type is normaly “1756-L55”.



Highlight the correct processor type for your application and click the “Next” option.

At this point you should have made a connection to the procesor using RSLinx. At this stage you are requested to point to the device you wish to upgrade. •

Using the network path on the lefthand side of the window navigate to the Logix5555 processor and highlight.

Click the “OK” button to continue. 32

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The following window will contain the details of the firmware version you wish to upgrade to:-

The default location folder will contain one version this being 8.21. Highlight this version and click the “Next” button. The following summary window details the dangers associated with proceding. Click the “Finish” button to continue.

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The process of upgrading the firmware will now be carried out.

On completion you should see the following status window verifying the new version of the firmware. • Click “OK” to finish.

This will take you back the beginning of the utility. • At this point click the “Cancel” button to exit the ControlFLASH utility.

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Adding a New ControlNet IO Module At some point it may be necessary to add a new ControlNet IO module to an existing Node. This procedure will explain how to configure RSLogix 5000 and how to register the new module in RSNetWorx for ControlNet. This example will add a 1794-IRT8/A 8 Channel 24V DC RTD/Thermocouple Analogue Input Module to Node 02 slot 06. It is assumed that a connection has been made to the RSLogix 5000 processor and a current project is open. The following modifications will be made Offline. Under the I/O Configuration folder as shown below select the Node to which the new module will be added.



Right mouse clicking this node will bring up a dialogue box, from this select “New Module”. You will be prompted to select the type of module from an extensive list. If available the exact module type can be found on the module or its packaging.

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• Highlight the module type and click “OK”. This will be followed by a series of dialogue boxes into which you need to enter the module properties e.g. name and description, RPI, channel details etc. Move from frame to frame using the “Next>” option.

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Channel details:-

After the final frame select “Finish>>”. The new module should now have been added and will be listed in the project. This modified copy of the project will need to be saved and then downloaded to the processor (see relevant sections). Once downloaded to the processor and with an online connection the new module should show as being “Unscheduled” as denoted by a yellow warning triangle over the module icon.

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To allow the new module to be scheduled it must have as a minimum the relevant power supply connected (dependant on module type). For connection details refer to the documentation for the module concerned. The next step is to run the RSNetWorx for ControlNet software. This will find the new module and update the keeper file with the details. RSNetWorx for ControlNet will open with the last accessed file. This example will use this file as it is from this system. To open a new file, see the relevant section. •

Once open select “Go Online” from the top menu bar

.

The new module will be highlighted with a green box containing a cross. Floating the mouse pointer over this module will show the text box as shown in the above window. • Check the “Edits Enabled” box and save the configuration from the top menu bar. This will produce the following prompt,



Ensure that the “Save Type” is set to “Optimize and re-write schedule for all connections”. Click “OK”.

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This will save the configuration to the keeper file location on the Allen Bradley ControlNet Bridge. The processor will need to be in program mode to allow the save to be made. You may be prompted to allow the processor to put in program mode before the save is carried out. Once finished the new module should be visible from RSNetWorx.

Once satisfied the new module has been added shutdown RSNetWorx. With the controller back in run mode the new module’s status can be confirmed by double clicking the module in RSLogix 5000.

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Unscheduling Programs in RSLogix 5000 Unscheduling of programs in RSLogix 5000 should only be carried out by experienced personnel with the express permission of Technical support, Helpdesk or the department responsible for the software module. Sometimes during commissioning for example it may become necessary to disable blocks of software to allow other tasks to be carried out. This would normally involve temporarily disabling contract specific tasks to allow the turbine commissioning to proceed.

CAUTION. To unschedule programs in RSLogix 5000 the controller MUST NOT be in run mode. It is advisable to unschedule programs in remote PROGRAM MODE. •

With the project open and online in program mode select the task folder under which the program/routine resides.



Right clicking this folder and selecting the properties option will produce the following pop up window,

this window details the scheduled and unscheduled tasks under the “Program Schedule” tab.

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Prior to unscheduling the required task note its position in the scheduled task list for later use. •

To unschedule a task highlight it from the list and click the “<-- Remove” option. This routine should now be visable in the Unscheduled list. To finish this procedure click the “Apply” button.

This task has now been unscheduled and can be found in the “Unscheduled Programs” folder as listed in the RSLogix 5000 project.

Once the controller is back in Run mode this program will no longer run as part of the main program untill it is added to the scheduled programs list. • To add the unscheduled program to the scheduled list follow the above procedure and click the “Add -->” button. Use the “Move” arrow buttons to place the program back in its oringinal location within the list.

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