Modernizing Data Streams

Modernizing SLC 500 to CompactLogix 5380 Control Systems 01 • 23 • 2020

Keith Parker • Consultant, Remote Support

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Agenda

1 5

Lifecycle and Longevity information

Troubleshooting Common Migration Errors

2 6

Integrated Architecture Builder (IAB) SLC Migration Wizard

3

1492 Wiring System Conversion 1746 I/O to 5069 I/O

4

RSLogix 500 to Studio 5000 Code Conversion

Modernization Resources

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Lifecycle and Longevity Information

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SLC Longevity  30+ years of achievement for SLC 500 platform  More than 100 products satisfying the requirements of very diverse applications  Continues to be in demanded  May want to consider migration to Logix 

Some 1747 processors are discontinued.



Some 1746 I/O modules are discontinued and several are end-of-life



1747 processors that are active mature:

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Product lifecycle status - CompactLogix™ & SLC

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Benefits of CompactLogix™ 5380 controller High performance • Dual one Gb Ethernet port enables high-performance I/O and Integrated Motion on EtherNet/IP™ up to 32 axes • Controller firmware is optimized for maximum performance

Enhanced productivity with Logix • Two Ethernet ports for Dual-IP or support for Linear and Device Level Ring topologies for up to 180 nodes • Supports up to 31 local I/O modules and memory from 0.6 … 10 MB • Onboard display allows for enhanced diagnostics and troubleshooting • USB port supports local programming, troubleshooting and firmware updates

Security capabilities • Digitally signed and encrypted controller firmware • Controller-based change detection and logging • Role-based access control to routines and Add-On Instructions • Ability to enable and disable all embedded ports PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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SLC controller modernization

 Recommended CompactLogix 5380 controllers were selected based on memory size  Users are welcome to choose other variations of the CompactLogix 5380 controllers  1746 I/O to 5069 I/O cross reference list found in Chapter 3 of SLC 500 Migration Quick Reference PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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CompactLogix 5380 Standard Controllers

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SLC modernization plan – Retaining 1746 I/O

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SLC modernization plan – Replacing 1746 I/O

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Modernization tools – Hardware 1747-AENTR module 

Enable SLC I/O rack to be controlled by CompactLogix™ 5380



Support various network topologies (DLR, Star, Linear)



Must be located in slot 0 of SLC rack o

Replaces the existing SLC processor

o

Replaces ControlNet adapter (1747-ACN15, 1747-ACNR15) in remote racks

o

Firmware v2.001 supports up to 30 I/O modules and 3 chassis in Studio 5000 v21+

o 

Replaces the existing Remote I/O adapter (1747-ASB) in remote racks

Requires RSLogix 5000 v20 or greater and SLC I/O electronic data sheet files

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Modernization tools – Hardware 5069-SERIAL module  

2 channel 9 pin D-sub connector supporting RS232C, RS422 and RS-485 media o

Generic ASCII, Modbus RTU Master/Slave, and Modbus ASCII Master/Slave

o

DF1 Master, DF1 Slave, DF1 Point to Point, DF1 Radio Modem, DH485

Firmware v2.011 is backward compatible to DF1 & DH-485 functionality in SLC™ controllers and 1769-L23E, -L31, -L32E, -L35E, 1768-L43, -L45 controllers



Use with Studio 5000 v31 or greater

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Can reside in local chassis for 5069 controllers or in a distributed I/O rack with the 5069-AENTR

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Firmware v.2.011 can be upgraded using ControlFLASH v15.03 or ControlFLASH Plus v3.01 o o

Controller must be in PROG or REM PROG mode. Module connection must be inhibited.

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Integrated Architecture Builder (IAB) SLC Migration Wizard

Modernization tools – Integrated Architecture Builder(IAB) 

IAB includes a Migration Wizard specifically created for SLC to 5380



Helps you accurately convert an existing 1747 chassis to the equivalent 5069 counterpart  selection of a mounting base  conversion modules for each I/O module  appropriate cabling



Creates Bill of Material including:  fully configured 5069 chassis and modules  1492 Wiring Conversion System accessories

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Modernization tools – Integrated Architecture Builder(IAB)  Play SLC_Mig_Wiz_IAB1 video

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1492 Wiring System Conversion - 1746 I/O to 5069 I/O

Modernization tools – 1492 Wiring conversion system Aim



Provide great ease of migration for customers with existing SLC system to a complete 5069 CompactLogix system



Allow customers to upgrade their control system without rewiring their existing field devices while maintaining their existing control cabinet



Save time with installation with utilizing existing mounting holes



Retains existing SLC chassis footprint

Value



Speed – Significantly reduce I/O rewiring time and effort

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Compatibility - Pre-engineered and pre-tested conversion modules converts old 1746 terminations to new equivalent 5069 I/O terminations

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Modernization tools – 1492 Wiring conversion system

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Modernization tools – 1492 Wiring conversion system Catalog No

Technical Description

1492-CH1746-4

SLC 500 to 5069 CompactLogix conversion system chassis, 4 Slot

1492-CH1746-7

SLC 500 to 5069 CompactLogix conversion system chassis, 7 Slot

1492-CH1746-10

SLC 500 to 5069 CompactLogix conversion system chassis, 10 Slot

1492-CH1746-13

SLC 500 to 5069 CompactLogix conversion system chassis, 13 Slot

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1492 Wiring Conversion Systems – Installation Procedure 

An overview of the general installation guidelines for 1492 chassis and modules

Upper Mounting Plate

Lower Mounting Plate

Mounting Hardware

End Anchors (Not included)

Conversion Modules PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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1492 Wiring Conversion Systems – Installation Procedure

STEP 1:

Remove I/O wiring terminal blocks from 1746 (SLC) modules by removing screws or pulling out the connector.

STEP 2:

Remove 1746 (SLC) chassis from the backplane by loosening the 2 screws at the top and removing the 2 screws at the bottom. Remove ground wire.

STEP 3:

Install the lower mounting plate where the previous chassis was removed. Start with 2 screws that were loosed at the top and reinstall 2 screws at the bottom.

STEP 4:

Attach the grounding wire to the bottom-right screw of the lower mounting plate. ***Ground wire cannot be attached to upper mounting plate or DIN rail.

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1492 Wiring Conversion Systems – Installation Procedure

STEP 5:

Obtain all 1492 conversion modules. Slide and snap the first conversion module into the lower mounting plate. The tab at bottom ensures alignment.

STEP 6:

Repeat step 5 for the remainder of the conversion modules; move from left to right along the lower mounting plate chassis.

STEP 7:

Retrieve the I/O wiring terminal blocks (Step 1) and secure them onto the 1492 conversion modules (torque both screws or push-in the connector).

STEP 8:

Align the upper mounting plate with the lower mounting plate. Open the mounting hardware bag and install the two screws to secure both mounting plates together. Do not tighten screws all the way. PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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1492 Wiring Conversion Systems – Installation Procedure

STEP 9:

Align the holes of the upper and lower mounting plates. Insert pins from the mounting hardware bag through each end of the assembly..

STEP 10:

Insert one hitch pin from mounting hardware the into the hole of each pin used in Step 9. Go back and tighten the two screws in Step 8.

STEP 11:

Attach the 5069 system onto the DIN rail of the upper mounting plate. Install the end anchors (not included) on each end of the 5069 system.

STEP 12:

Ensure the 5069 I/O cards are in the same order as the conversion system. Snap the conversion module terminal blocks into each 5069 I/O card.

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Modernization tools – 1492 Wiring conversion system  Play SLC to CompactLogix Explainer Video

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RSLogix 500 to Studio 5000 Code Conversion

RSLogix 500 to Studio 5000 – Code conversion

SLC™

CompactLogix™ 5380

 Convert 80-100% of code using automated code conversion  Take advantage of power constructs and features that can be leveraged for improvement of applications  RSLogix 500 v12 Pro, Standard, and Starter all support the Integrated Migration to Logix Designer  RSLogix 5000 Translation Tool, v1, v2, v3 and RSLogix Project Migrator are now the Integrated Migration to Logix Designer

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RSLogix 500 to Studio 5000 – Code conversion

STEP 1:

With the program open in RSLogix 500, Click on File, Save As.

STEP 2:

Change the Save as type from RSLogix files (*.RSS) to Logix Designer files (*.ACD). Then click Save.

STEP 3:

The Logix Designer Export screen will open, select the CompactLogix option.

STEP 4:

Select the Catalog Number and Revision that will be used for the project migration. Then select Next.

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RSLogix 500 to Studio 5000 – Code conversion

STEP 5a:

An option will appear to keep the existing I/O, or Update all I/O to the new platform. In this example, select Keep Existing I/O and Migrate.

STEP 6a:

Once the migration is complete, select Launch RSLogix 5000.

Comparison of the logic files between RSLogix 500 and Studio 5000.

Comparison of the I/O configuration between RSLogix 500 and Studio 5000.

For Update All I/O, go to step 5b. PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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RSLogix 500 to Studio 5000 – Code conversion

STEP 5b:

When Update All I/O is selected, a list becomes available for the I/O selection in the new platform. Verify the I/O modules are correct and select Migrate.

STEP 6b: Once the migration is complete, select Launch RSLogix 5000.

Comparison of the logic files between RSLogix 500 and Studio 5000.

Comparison of the I/O configuration between RSLogix 500 and Studio 5000.

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Troubleshooting Common Migration Errors

Troubleshooting common migration errors PCEs (Program Conversion Errors) and Translation Difficulties  PCEs are error instructions inserted in the ladder logic to force you to check certain types of instructions or status file operands that do not have direct, unambiguous equivalents in the CompactLogix controller. See Appendix A in the SLC/MicroLogix 1500 to CompactLogix Migration Guide, publication 1769-AP001C-EN-P, for more information on PCEs.

 BTR, BTW, MSG and PID instructions will always be flagged with PCEs so that you are required to configure and verify them. PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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Troubleshooting common migration errors  Status file operands from the SLC processors do not exist in the same format in CompactLogix controllers. You must use GSV and SSV instructions to get and set system variables. 

Studio 5000,  Help ”GSV / SSV Objects”



Chapter 4 in the Logix5000 Controllers General Instructions Reference Manual publication 1756-RM003T-EN-P

 Additional status flags in Logix controllers are discussed in Answer ID 21410 - ControlLogix Configuration & Status Flag Bits o S:1/15

 S:FS = First scan

o S:0/3

 S:N = Negative flag

o S:0/2

 S:Z = Zero flag

o S:0/1

 S:V = Overflow flag

o S:0/0

 S:C = Carry flag

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Troubleshooting common migration errors  The following instructions are not supported for migration to Logix Designer: 

DCD, DDV, DLG, ENG, HSC, HSD, HSE, HSL, LCD, IID, IIE, IIM, IOM, PTO, PWM, RAC, RCP, REF, RHC, RMP, RPI, RTA, SQC, STS, SUS, SVC, SWP, TDF, UID, UIE, and UIF are not supported to convert to Logix Designer. These instructions will migrate to a PCE (Program Conversion Error) instruction in Logix Designer and then must be manually migrated to a valid Logix instruction.

 The following data files and function files cannot be exported to Logix Designer: 

Data files RI, RIX, and MG, and function files HSC (LOP and UNF) and DAT (CN[4]'s [1] - [3]) cannot be converted to Logix Designer correctly. To resolve this, correct the values of these data files and function files in RSLogix 500 before exporting.

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Troubleshooting common migration errors  RSLogix Project Migrator: Syntax error at line 1.

 Issue is caused by the catalog number entry.  Correct the entry by removing the ,D in line 1, then select Save & Retry. PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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Modernization Resources

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Modernization resources - CompactLogix™ 5380 Resources

Access

SLC/MicroLogix 1500 to CompactLogix Migration Guide, pub 1769-AP001C-EN-P

Literature Library

SLC Quick migration guide, pub 1746-RM003D-EN-E

Literature Library

SLC 500 to CompactLogix 5380 and 5069 I/O Migration Solution, pub MIGRAT-PP004B-EN-E

Literature Library

1072211 - Converting SLC programs to 5380 or 5580 controllers

Knowledgebase

5514 - PLC5/SLC to Logix Translation Tool: General Information

Knowledgebase

CompactLogix 5380 Controllers, pub 5069-PP003E-EN-P

Literature Library

Integrated Architecture Builder (IAB)

Web Page

Product Lifecycle Status

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Modernization resources - CompactLogix™ 5380 Resources

Access

468487 - 1747-AENTR EtherNet/IP Communication module: SLC to Logix Conversion Basics

Knowledgebase

471083 - 1747-AENTR SLC Ethernet Adapter General Information and FAQs

Knowledgebase

SLC 500 EtherNet/IP Adapter User Manual, pub 1747-UM076D-EN-P

Literature Library

1081688 - 5069-SERIAL information and quick start

Knowledgebase

1066410 - 5069-SERIAL FAQ (Frequently Asked Questions)

Knowledgebase

Compact 5000 I/O Serial Module User Manual, pub 5069-UM003A-EN-P

Literature Library

21410 - ControlLogix Configuration & Status Flags Bits

Knowledgebase PUBLIC | Copyright ©2019 Rockwell Automation, Inc.

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