SY29 - Moving Toward a Connected Enterprise by Modernizing Your Control and Information Systems: Hands-on Lab
For Classroom Use Only!
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SY29 - Moving Toward a Connected Enterprise by Modernizing Your Control and Information Systems: Hands-on Lab
Contents About This Hands-On Lab .......................................................................................................................... 4 What You Will Accomplish In This Lab ............................................................................................................................................. 4 Who Should Complete This Lab ....................................................................................................................................................... 4 Lab Materials .................................................................................................................................................................................... 4 Hardware .......................................................................................................................................................................................... 4 Software ............................................................................................................................................................................................ 5 Lab Files ........................................................................................................................................................................................... 5 Lab 1 – SLC to Compact Logix Migration ................................................................................................. 6 A. Use IAB to create a Bill-of-Materials ........................................................................................................................................... 6 B. Converting SLC Code to Logix ................................................................................................................................................... 20 C. Converting the Exported SLC500 Program Code ...................................................................................................................... 27 Lab 2 - MicroLogix to Micro800 conversion Tool .................................................................................. 47 Lab 3 – PLC5 to ControlLogix Migration ................................................................................................ 58 A. - Using IAB (this lab takes approximately 20 minutes to complete) ........................................................................................... 59 B. Migration Wizard and Add a PLC-5 Chassis............................................................................................................................. 62 C. Add 1771 I/O Modules................................................................................................................................................................ 69 D. Generate Hardware and Finish the Configuration ..................................................................................................................... 78 E. Converting a PLC-5 Program to a ControlLogix Program (approximately 20 minutes to complete) ......................................... 82 F. Using the RSLogix Project Migrator to create a .L5K file for Import into Studio 5000 ................................................................ 90 G. Correct any Issues with the New ControlLogix Program........................................................................................................... 94 H. Other Things to Consider When Migrating.............................................................................................................................. 103 Lab 4 – Migrating PanelView Standard to PanelView Plus 7 .............................................................. 106
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About This Hands-On Lab This Hand-On-Lab will introduce you to two new Migration Tools, the MicroLogix to Micro800 Conversion Tool and the upgraded PLC5 / SLC500 3.0 conversion utility now called the RSLogix Project Migrator. In this lab you’ll gain an understanding of what files are required for conversion, the process for importing, identification of what didn’t convert and conversion options. If you have performed a migration with a previous version of the tool you’ll be glad to see some of the upgrades that have been incorporated into the Migrator. Those include:
Added MicroLogix support
Comments are now exported in CSV format so they are no longer truncated
Existing 1746 I/O will be brought over and placed in I/O tree under a 1747-AENTR
There are options to migrate the I/O to Point and 69
The Input and Output sections are brought over as a way to migrate the comments associated with them.
Any I/O modules that are unsupported (BAS, SN, etc.) in RSLogix 5000 will be brought over as tags with the name Placeholder_xxx_yyy not sure what the format is.
The following sections explain what you’ll be doing in this lab session, and what you will need to do to complete the hands-on exercises.
What You Will Accomplish In This Lab As you complete the exercises in this hands-on session, you will:
Use Integrated Architecture Builder to assist in laying out hardware options Export SLC, MicroLogix and PLC5 programs to formats that are used in the Conversion/Migration process Run the Conversion Tools Resolve conversion issues associated with the code conversion process
Who Should Complete This Lab This hands-on lab is intended for individuals who:
Are interested in the considerations involved in converting existing SLC500, PLC-5 or MicroLogix systems to the Logix or Micro800 platforms.
Lab Materials For this Hands-On lab, we have provided you with the following materials that will allow you to complete the labs in this workbook.
Hardware This hands-on lab uses no hardware:
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Software This hands-on lab uses the following software:
RSLogix 500 v9.0 RSLogix 5 V8.0 Studio 5000 Logix Designer v28 RSLogix Project Migrator V3.0 MicroLogix to Micro800 Conversion Tool V1.00 Integrated Architecture Builder v9.7 or later
Lab Files This hands-on lab uses the following files:
SLC Lab SLC_MIG.RSS DII_Trigger_Rungs.L5X Micro Lab Paper Drilling Machine.RSS PLC5 Lab PLC5_MIG.RSP
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Lab 1 – SLC to Compact Logix Migration A. Use IAB to create a Bill-of-Materials 1. On the desktop, double-click the IAB shortcut
and select No to the Internet question.
2. The IAB opening dialog appears. Click New Project.
3. In the Create New Workspace dialog, click on the SLC 500 Migration Wizard entry in the left navigation pane and type the name ‘SLC Migration Wizard’ in the Workspace Name text box. Click OK.
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4. In the SLC Migration Chassis Selection dialog, click the Chassis dialog.
button. IAB opens the Add
5. Click OK in the Add Chassis dialog to accept the default name for the new chassis (SLC001). IAB opens the SLC Migration Module Selection dialog, in which you will make the conversion selections for this chassis. Notice the different areas of this window.
Conversion options
Original SLC Chassis
Replacement CompactLogix chassis and remote SLC I/O chassis
List of SLC modules
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In our example, the original SLC500 system consists of the modules shown below: 1747-L553
OB16
IB16
OB16
NIO4V
SN
NT4
ASB
OB16
empty
NIO4V
Add SLC Modules (Retain SLC I/O) In this first exercise, we’ll demonstrate how to configure the Bill of Material required to convert the SLC500 system to a CompactLogix system while maintaining the existing SLC500 I/O modules and wiring. 6. Using the up arrow change the Chassis Size from 4 to 7 and choose the 1746-P3 Power Supply. We will choose to Retain With 1769 CompactLogix for the SLC I/O in this example.
7. From the Processor module list, expand the Processor heading and drag a 1747-L553 processor module to slot 0 of the SLC chassis as shown.
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Because IAB has found more than one possible CompactLogix controller migration option, the SLC Migration Processor Options window appears. This dialog appears when you must make a decision about the conversion. The information in the dialog is specific to the action you are performing. In this case, we must select the CompactLogix processor that we wish to use. 8. Select the 1769-L36ERM processor in the list and click OK.
IAB adds processors to both the SLC chassis and the replacement CompactLogix chassis. Additionally, IAB also adds a 1747-AENTR Ethernet adapter module to the retained I/O SLC chassis at the bottom of the display.
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9. Using the same procedure, expand the I/O Module heading, then the Digital heading and select the 1746IB16 module. Drag it over to slot [1] in the SLC chassis.
Once again, IAB retains the 1746-IB16 module in the lower SLC I/O chassis.
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10. In the same manner, complete the local SLC 553 controller chassis I/O module layout using the list below as a guide. (If you incorrectly place a module, simply right-click on the module and click to try again)
Module Name
Slot #
1746-OB16(Digital)
(2)
1746-NIO4V (Analog)
(3)
1746-OB16(Digital)
(4)
1746-NT4(Analog)
(5)
You should have the following:
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11. The final slot contains a 1747-SN Remote I/O scanner module. To add this module, simply expand the Scanner heading and drag the 1747-SN over to the last slot in the SLC chassis.
The following warning occurs.
12. The 1747-SN is not supported as part of a retained I/O solution when connected to a Logix controller. Therefore, no module will be placed into the lower chassis. Click OK. 13. The local SLC chassis is now complete. Click OK in the lower left corner.
14. Our original system, however, does contain a 2nd chassis. Let’s capture this next. On the SLC Migration Chassis Selection dialog click the button. This chassis will replace the remote SLC I/O chassis in our system: a 1746-A4 with a 1746-P3 power supply, a 1747-ASB RIO adapter, a 1746-OB16 and a 1746-NIO4V. 15. Name this chassis ‘SLC002_Remote’ and click OK.
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16. Select a chassis size of 4 and the 1746-P3 power supply. As we did before, we will choose to retain the SLC I/O for this chassis.
17. In our original system this chassis has a Remote IO adapter in the first slot. Drag a 1747-ASB module to slot 0 of the SLC chassis.
Note that IAB replaces the 1747-ASB adapter with a 1747-AENTR Ethernet adapter in the replacement SLC remote I/O chassis. Hover over the module in the replacement chassis to see the description. 18. The next slot is unused in our system. Generally, it’s a good practice to fill unused slots with blank “filler” modules. From the module list, expand the Specialty Module heading and drag the 1746-N2 module into the next slot. 19. To complete the remote chassis configuration, drag a 1746-OB16 module into slot 2 and a 1746-NIO4V into the final slot.
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20. Click OK in the lower left corner to close the Module Selection Window. 21. In the SLC Migration Chassis Selection dialog, click the defined CompactLogix configuration in IAB.
button to create the wizard-
22. Click on the Hardware tab in the lower left hand corner of the IAB window and click on the SLC_Migration.1_SLC001 chassis to see the hardware.
This chassis contains all the SLC I/O from the local rack that we replaced. A 1747-AENTR module has been added to connect this I/O remotely over Ethernet to the CompactLogix controller that is replacing our SLC processor.
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23. Let’s save our project so far. From the Menu Bar, click on the
icon.
24. At this point, we may want to get a rough idea of how much this conversion is going to cost. From the Menu Bar, click on the Project Bill of Material (BOM) icon.
From this screen, we can get a clear view of the material necessary to make the conversion based on the chassis layouts.
The list price of each item is shown along with the recommended software. In addition, the radio buttons along the bottom of the dialog allow users to manipulate the information either as a consolidated spreadsheet or by slot location. All of these arrangements incorporate pricing either with List or Custom pricing models.
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Replace the Local SLC System with CompactLogix Although retaining the SLC I/O when converting to a Logix system can save on re-wiring costs, adding a controller and a power supply to an existing control panel might prove to be impossible due to physical space limitations. In such cases, the best SLC conversion solution may actually involve converting the I/O to the 1769 or Point I/O platforms in addition to converting to a Logix controller. Let’s consider the hardware layout and bill of material associated with replacing the SLC I/O in the local SLC processor chassis with Compact I/O instead.
25. Close BOM and the Hardware View window to reveal the Wizard View.
26. Double click on the number icon for the SLC_Migration.1 subsystem to reopen the SLC Migration wizard.
27. Select SLC001 and click the
button.
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28. In the SLC Migration Module Selection dialog, use the drop down list next to SLC I/O to select Replace with 1769 CompactLogix.
29. In the Processor Options dialog, choose the 1769-L36ERM processor again and click OK.
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30. As before we get this message because the 1747 is not supported in the Compact I/O system. Since our intent is to replace any remote chassis with additional I/O on Ethernet anyway, click OK to acknowledge the warning. Now all the replacement I/O should be in the CompactLogix chassis and not the SLC chassis.
Let’s examine the conversion for the 2nd chassis. We have a few options with this remote chassis. First, if we were primarily interested in just converting the local SLC I/O, we could choose to simply leave the remote SLC chassis in place, add in the Ethernet wiring and rebuild our BOM. Or perhaps, we may wish to add the I/O modules from the 2nd SLC chassis into the new local CompactLogix system. As a third option, we may want to swap out the remote SLC I/O chassis with a more cost effective Flex or Point I/O system. In either case, this is best done outside the wizard, so we’ll first need to remove the remote SLC chassis from the system. 31. Click OK to close the SLC Migration Module Selection dialog. 32. Highlight the SLC002_Remote chassis and click the
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button.
33. Next, click the
button to generate a new set of local chassis hardware.
34. Choose Yes to the question about regenerating your subsystem and deleting the previous subsystem. 35. Click the Hardware tab to view the new CompactLogix system SLC_Migration.1_SLC001.CpLX.
From here you would then create your Ethernet/IP network and make the necessary connection between the Compact Logix process and whichever type of I/O you would select for the 2nd chassis. 36. As we did earlier Click the BOM button to generate the listing.
Now it contains just the 1769 product since we are replacing the SLC. Now we are ready to convert our old SLCbased code to the CompactLogix code. Close IAB. Let’s see how the Migration Tool works.
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B. Converting SLC Code to Logix We will be converting a relatively basic, but typical SLC500 program into a CompactLogix 5370 platform. Before we perform the conversion, let’s become a little more familiar with this existing system. Examining the Existing SLC500 Project 1. On the desktop, Double-click the RSLogix500 icon to start the programming software.
2. From the Menu bar, select FileOpen.
3. Browse to the “C:\Lab Files\SLC Migration” folder, select the SLC_MIG.RSS file and click
Before we execute the conversion of this project, let’s take a close look at how it’s set up and what it contains. 4. We’ll start with the I/O Configuration. From the Project Tree at the left, double click on the IO Configuration heading.
In the I/O Configuration dialog, compare the modules in the local SLC500 chassis to the graphic below. This is the same configuration we just finished using in IAB.
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These modules represent some of the most common digital and analog I/O modules used in SLC500 systems today. In addition, this project also uses a 2nd chassis on Remote I/O (RIO). This remote chassis also contains an ASB, OB16 and NIO4V. 5. The configuration of the digital modules is fairly straight forward, so let’s focus on the specialty modules and the RIO scanner. In the module configuration list, double click on the 1746-NT4 to open its Advanced I/O Configuration details. This module is currently set up to provide 8 words of input data. 4 Words are used for the actual thermocouple values and the remaining 4 words contain status information. The 8 Output words are reserved for module configuration. Let’s see how this module is set up.
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6. Click the button. We’ve only configured Channel 1 for this example. This channel is providing a temperature in °F for a Type J thermocouple connection.
This dialog writes information to a file in the controller. This configuration must then be written directly to the Output file for the NT4 module. This is done through code in the controller. The rung below simply takes the stored configuration and moves it to the NT4 output image when the controller first enters Run mode. This rung can be found in the MAIN routine of the program. We will be modifying this rung after our conversion is complete.
7. Click OK as necessary to close any open Configuration Detail dialogs and return to the I/O Configuration list. We have completed our examination of the I/O Configuration. Close the dialog.
This project also has a couple of special configurations using STI and DII. Let’s see how these are configured as they will require some special attention after the conversion. 8. From the Project Tree at the left, double click on the Processor Status heading.
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In the SLC500, the Selectable Timed Interrupt (STI) feature is used to specify details for a routine which must be executed at consistent intervals. Reliable time-based execution of code is essential in the regulation of variables typically used in process applications. 9. On the STI tab, we see that the Setpoint is at 200 meaning the code will run every 2 seconds and the File Number is set to 12 where the ladder will reside.
Here is a sample of the code contained in the
“STI” routine.
Next, let’s configure a routine which could be used to execute specific ladder logic based on a high speed input. In the SLC500, the Discrete Input Interrupt (DII) is used to perform this function. 10. On the DII tab, view the values as highlighted below.
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With the settings above, the DII is configured to execute the logic contained in Program File 13 (“DII”) when the 2nd input in slot 1 has been triggered five times. The rung below, from the DII routine, will simply move the value from N13:0 into N7:15 when the DII condition above is satisfied.
11. Close the Processor Status dialog when finished.
Finally, the screenshot below provides some background information on each of the remaining Program files in the SLC_MIG project. Feel free to browse each of these routines if you wish. MAIN – Contains initialization code and controls execution of subroutines IC500DMO/LOCAL IO – Contain code primarily to control digital I/O in the local SLC500 chassis SEQUENCER 1, 2, 3 – Contain additional code to uniquely control digital I/O in both the local and remote chassis THERMO – Contains code related to manipulation of data associated with the SLC500 thermocouple module ANALOG RIO – Manipulates data to/from the analog module in the remote SLC500 chassis STI/DII – Contain code designed to execute under special conditions (i.e. Time-based or high-speed interrupt)
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Exporting the Existing SLC Project Now that we have a better understanding of the current SLC500 project, let’s begin the conversion process. The first step in a procedure of this type is to export the current SLC (or PLC5) project into an ASCII text format. 12. From the Menu Bar, select FileSave As…
13. Browse to the “C:\Lab Files\SLC Migration” folder and set the file type to “.SLC”. The translation tool we will be using to convert the program into a Logix project accepts projects that have been exported to one of two formats. For PLC-5 Projects, this exported format would be a .PC5 file type. For SLC500 projects, the format is a .SLC. Leave the rest of the entries as they are. You should have the following settings so far.
14. Click the Save in this window and OK in the Export SLC Format pop-up.
The export occurs quickly and brings you back to RSLogix 500. Now we Export the documentation database.
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15. In the toolbar, click on Tools -> Database -> ASCII Export.
16. The ASCII export window allows us to create a .CSV file containing all of the Symbols, Descriptions and Comments from our current project. These files will then be used in the conversion tool to add documentation to the converted logic. Click the CSV tab, check the Addr/Symbol, Instruction Comments and Symbol Groups boxes then click OK.
17. In the Destination Directory window, select the SLC Migration folder the OK.
18. The Export Results window appears telling us that all 3 files were created. Click OK. 19. Close the RSLogix500 software and say yes to Save changes and OK in the Revision window. We have now completed the steps required to export the current SLC500 project. In the next section, we will begin the translation portion of the SLC500 conversion to Logix.
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C. Converting the Exported SLC500 Program Code The process of translating the exported SLC500 project begins with the RSLogix Project Migrator tool.
20. Double-click the Migrator tool icon on the desktop. The tools first window gives us the choice of doing a PLC-5 or SLC-500 conversion. Click the For SLC-500 radio button.. click the Browse button
21. Next, and locate the “SLC_MIG.SLC” file in the “C:\Lab Files\SLC Migration” folder and click
22. Click
.
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23. Step 2 in the Migrator wizard provides the user with an option for the creation of Symbol aliases. The resulting controller alias tags may be useful to users who would otherwise have to modify tag names in the program code. Click the Migrate button.
The status log in Step 3 shows a syntax error
Delete the characters C,D from the first line.
After you have cleared those click the Save&Retry button. The Status Log will now show Application successfully parsed.
Click the Next button
.
24. In Step 4 we get to choose the target Logix controller for our project. Using the drop down lists, select the 1769L36ERM controller and select V24 for the version to be used. The default output file of SLC_MIG.l5k is OK.
25. Click.
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26. Step 5 allows us to choose what I/O platform we want to Migrate to. The first option continues to use the 1746/47 I/O that was in our original project.
With the 2nd option we can choose between legacy I/O(1746/47), Point I/O(1734) or Compact I/O(1769). We could also just create placeholder tags if we want to choose a different platform or just defer the decision.
We will stay with the legacy I/O for this lab but feel free to explore the other options. Select the top radio button and click Next. 27. Step 6 does the Translation. The Status Log window shows the progress of migrating the I/O modules and translating the code to Version 24.
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When the translation is complete click the “Launch RSLogix 5000” button.
This will actually start Studio 5000 in our case. While it is starting click the Finish button in Step 7 of the tool. 28. The “Save Imported Project As” window will open. The default SLC_MIG name for the new .ACD file is fine. Browse to the “C:\Lab_Files\SLC Migration” folder and click Import.
V28 of Logix Designer will open and our new program is ready. But now we must make some edits and adjustments.
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Resolving Differences in the New Logix Program 29. Let’s begin by having a look at our new Tag Database to see how the conversion affected the addresses and Descriptions. Double-click on Controller Tags to open the Tag Database window. Click on the Edit Tags at the bottom of the window. Here we see that our tags have been converted and that aliases have been created. The first Tag listed ALARM_DRY_MATL is Aliased to an I/O card with the address EnetBridge_1746:2.O.Data.6. That breaks down as follows: EnetBridge_1746 = the 1747-AENTR 2.O = the Slot #2 and the Output file of the 1746-OB16 Data.6 = the 6th bit of the output module. The Description associated with this tag comes from the EnetBridge which is why it is grayed out. It tells us that the module was generated by the tool. Let’s look at the actual module tag entries.
30. Scroll down the Tag Database until you see the EnetBridge entries
We see that there are entries for all five of the I/O modules in the 1st rack. And the Catalog numbers are shown in Column 4. Here the created Descriptions originate and we can now delete them so they don’t show up everywhere you use the associated tags. Click on the first description and hit the Delete key to remove it then click away. Do this for each of entries. So now when one of those tags is referenced in the ladder logic the Alias AND Base Tag show up.
In your applications, you may want to further update the descriptions after conversion. Let’s look at the program code itself and resolve any issues that the Tool couldn’t deal with directly. We’ll begin with the organization of code in the new project. In the Controller Organizer, note that the new project now consists of a Continuous Task called “MainTask”, a Periodic Task called “_12_STI”, and an Event Task called “_2_MAIN”.
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All of the standard SLC500 routines have been placed into the “_2_MAIN” event task.
The code for the DII routine in the SLC500 has been placed into the “MainTask”.
The STI code has been placed into the “12_STI” periodic task.
31. Expand the Main Task and then the Main Program.
32. Double-click on the Main Routine to open it The only rung in this routine simply calls the MainRoutine within the Event Task, “_2_MAIN”.
You may recall from the review of the SLC500 program we conducted earlier that we had configured a Discrete Input Interrupt (DII) to execute after five transitions of the 2nd Input in the IB16 in slot 1. This configuration mechanism did not convert completely since in the SLC there was no ladder created to jump to the DII subroutine only the information on the DII tab as we saw earlier. To address this we’ll need to add some program code. In the interest of time, the new code has been created for you complete with documentation. All we have to do is import it. 33. Right-click on the last rung in the routine and select “Import rungs…”
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34. Browse to the “C:\Lab Files\SLC Migration” folder, select the “DII_Trigger_Rungs.L5X” file and click Open.
Importing rungs using this method, allows the user to also import the tag and documentation details along with the code itself. The code we plan to import in this example contains a reference to a counter (C5) which builds onto an existing counter array. By default, the import wizard will simply recognize the conflicting tag and refuse to create the new array element on the end of the existing tag. If this behavior is satisfactory, then simply continuing with the import would result in additional effort by the user to alter the properties of the existing tag or change the tag name altogether. 35. Since this is such a simple task, let’s let the wizard make the tag correction for us. In the Import content tree at the left, select the Tags heading. Use the Operation dropdown list to select “Overwrite” for the C5 tag name. The I1 input tag is fine. You should have the following:
36. Click OK to complete the import. You should now have the additional rungs shown below in your MainRoutine. To take full advantage of our new addressing, let’s change the tag attached to the first contact.
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Double-click on I1[0].1.
In the Drop Down box, Scroll to DIAGN_INDIC and double-click on it.
We now see the hardware address and its Alias. So in the code, each time the DIAGN_INDIC goes true, the counter, C5[13], increments by 1. When the Accumulator reaches “5”, the DN bit is enabled and the “_13_DII” routine is called and the counter is reset.
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37. To view the code within the “_13_DII” routine, from the Controller Organizer, double click on the “_13_DII” routine to open it.
This routine also contains a new rung inserted by the Translation Tool.
We’ll see a few more of these rungs as we scan through the translated code. The Tool inserts special Program Conversion Error (or PCE) instructions anywhere there may be a conversion issue. The code within the instruction indicates what type of issue should be addressed. This is a warning to the user that the instruction should be examined to determine if a modification is required. In many cases, the instruction, or in this case, the entire rung may be deleted with no code adjustment at all. Error 153 is about this being a DII routine and not used by RSLogix5000 38. For now, let’s delete this rung. Highlight the rung number “0” at the left and press Delete or right-click on the rung number and choose “Delete Rung”.
39. The remaining rung is fine as is. Let’s save our changes so far. From the Menu Bar, click the Save icon. Next, let’s look at our Selectable Timed Interrupt routine. Remember, this routine is part of the STI task, a periodic task in the controller. 40. Right-click on the “_12_STI” periodic task and choose Properties…
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41. On the Configuration tab, note the Period is set to 2000ms. (2 seconds).
42. No changes required here, so just click OK to close the dialog. 43. As for the STI code, double click on the “_12_STI” routine as shown below to open it.
Just a single rung in this routine which will move the value in N13[0] to N7[14].
44. Continuing on, let’s see what changes need to be made in the basic control code, that is, the code in the “_2_MAIN” task. From the Controller Organizer, drill down through the _2_MAIN task and _2_MAIN Program and open the “_2_MAIN” Routine.
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This routine contains a few common conversion errors that we need to address. The first rung in this routine contains a reference to data that is being copied directly to an I/O module. Since we have not yet looked at the I/O let’s come back to this later. Scroll down to the 2nd rung which looks like the screenshot below.
This rung references a timer. The timer instruction and its associated elements are compatible between the SLC500 (and PLC-5) and the Logix platform. However, the SLC500 only supports either a .01 or 1 second time base for timers. Logix supports a 1ms time base. The code conversion resulted in an increase of the timer Preset value by an order of magnitude. That is, the original Preset in the SLC500 for this timer was “32767” and now it has been changed to “327670”. All related references to this timer have been adjusted automatically, except those which may reference a specific bit within the Accum or Preset. We do have one instance of this which we’ll address in a moment. 45. For now, this rung is acceptable since both the Preset in the TON and the Source in the MOV have been adjusted by the tool. Highlight the PCE instruction and Delete it.
While we are here let’s fix up the rung comment. 46. Double-click on the rung comment for Rung 1. An editing window opens.
47. Select just the text that includes and is between the 3 *** leaving just the correct comment. Hit the Delete key, then the green checkmark in the editing window.
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This should be done for all the rung comments once you’re done with each rung. 48. Continue to scroll down to the end of the routine to locate the next PCE instruction
The last rung contains an STE instruction which is used to enable the Selectable Timed Interrupt. If we truly wished to enable or disable the STI, we would simply add permissives to program control instructions such as a JSR to perform this function. In this instance, we did not plan to disable the function anyway, so this instruction, and hence, the entire rung is not needed. 49. Highlight the rung number at the left and Delete it. 50. From the Menu Bar, click the Save icon. 51. Let’s continue on. From the Controller Organizer, open the “_3_IC500DMO” routine.
52. This routine is somewhat longer, so perhaps we can use the software to help us locate the issues. From the Menu Bar, select the Verify Routine icon.
The Results window at the bottom of the screen now contains an updated list of Errors and Warnings. Expand the Errors window and scroll up to see more of the list. TIP: Many of the Warnings reference bits that are used as outputs in more than one rung, Duplicate Destructive Bits. While using this type of coding is generally not recommended, with careful programming, using the same outputs on several different rungs can be done.
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53. Double click on the first error located on Rung 3 to highlight it in the ladder window. This rung contains one of those Accumulator bit references discussed earlier. Using the rung just above this one, you’ll notice the original T4:9 timer had a Preset = 100. With the new 1ms time base in Logix, the new Preset has been converted to “1000”. RSLogix 500
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RSLogix 5000
Subsequently, any instructions using intermediate values within this timer MUST also be adjusted. To make the change, double click on the High Limit value in the LIM instruction and change the value to “400”.
Again here you would want to delete the Rung Comment in your application. 55.
With the change complete, Delete the PCE instruction just to the left of the LIM. The same procedure could be done to modify the High Limit values on the LIM instructions in rungs 24-27, 84, and 88 in the same manner. For this lab let’s leave the rest and move on.
56. From the Menu Bar, click the Save icon.
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Resolving Issues with Physical I/O The remaining issues are all related to instructions that ultimately refer to physical I/O addresses. Let’s make sure we have all of the necessary corresponding tags in order to complete the I/O mapping. Most of the I/O conversion errors are related to mismatched data types and improper aliasing of the tags to their I/O module data. 57. The tool brought over our original I/O (since we choose to keep it) from the 1st rack. But we need to add the second rack. Right-Click the Ethernet entry in the I/O Configuration in the Controller Organizer and select New Module.
58. In the Select Module Type window, click Communication and select the 1747-AENTR.
59. In the New Module window, name the Adapter Remote_Rack and give it an IP address of 192.168.1.12 then click OK.
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60. Close the Select Module Type window. 61. Now in the I/O tree right-click on the 1747-AENTR Remote_Rack and select New Module.
62. Scroll down to the 1746-OB16 and select Create.
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63. Give it the name Remote_Output and leave the rest as is. Click OK.
64. Now scroll to the 1746-NI04V, click Create, name it Remote_Analog and click OK.
Our I/O tree now looks like this:
Close the Select Module Type window. 65.
With our new I/O in the tree, open the Controller Tags database, click the Edit Tags tab and scroll to the set of tags listed as Remote_Rack
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Here we see the new structures that were created for the modules we just added in Slot 1 and 2 of the 2nd chassis. We will use these later in the lab. 66.
Let’s complete the rest of the raw code conversion process. From the Controller Organizer, open the “_2_MAIN” routine. This first rung is used to initialize the configuration for the 1746-NT4 in slot 5 of the local SLC500 chassis. This module was taken care of in the conversion and so has the EnetBridge address.
The 120 error code is for a type mismatch. But there really isn’t so just Delete the PCE. 67.
Now let’s examine the analog Remote I/O code. From the Controller Organizer, open the “_10_Analog_RIO” routine. In order for many specialty modules to transfer data over RIO, sophisticated instructions called Block Transfers were used. In the conversion they were replaced with the MSG instructions shown below.
The need for messaging to/from these modules is no longer needed since we will be communicating with them directly over EtherNet/IP through the new 1747-AENTR module.
Data to be written to the remote NIO4V module in our example, was entered into N11:0 (2 words).
Data to be read from the NIO4V into the controller was placed into N13:0 (2 words).
This is the only information we need to create the instructions necessary to replicate the original program functionality.
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68.
Delete the two rungs containing the PCE instructions and replace them with the two new rungs shown below.
TIP #1: Do not try to type in the variable information manually. Double click on each “?” when creating the COP instruction and use the tag browser to locate the Source and Dest tags. TIP #2: The 1st rung references analog OUTPUT “O” data and the 2nd rung references INPUT “I” data.
The data comes across from the 2nd chassis through EtherNet/IP and so the Block Transfers are not needed. The CPS instruction is used because it is recommended over a regular COP when communicating with real I/O. 69.
We have a few more I/O references that need to be addressed. From the Controller Organizer, open the “_4_Local_IO” routine. The first rung in this routine uses a timer accumulator to simulate an analog output value for the NIO4V module.
70. This is the timer issue we’ve seen before so just delete the PCE instruction but leave the MOV.
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71. Let’s look at another I/O issue. From the Controller Organizer, open the “_5_Sequencer1” routine. The only rung in this routine is used to pulse various output patterns to the 1746-OB16 module in the 2nd I/O chassis. The trigger mechanism is the 4th bit of the T4[30] timer, which flagged the PCE instruction on the rung. As the T4:30 timer executed in the SLC500, bit 4 was enabled approximately four times per second. Because the time base has changed from .01 seconds to .001 seconds, this 4th bit now pulses at a much faster rate. In order to compensate for this, we’ll need to adjust the timer address. 72. Modify the input instruction shown below to use the 7th bit in the T4[30].ACC word.
73. With the timer adjusted, we can remove the PCE instruction. Highlight the PCE instruction and press Delete. We have one more item to address on this rung. The Dest element of the Sequencer Output (SQO) instruction needs to be linked to the physical outputs on the 1746-OB16 in the 2nd adapter. While this might seem trivial, the Array, Dest and actual I/O address data types are not the same so they cannot be linked within the SQO instruction. The Array and Dest tags are double integer (DINT) data types and the output address, which was just a placeholder for the data in the 2nd chassis, is an integer (INT). And we can’t just put our new Remote_Rack tags in there because they are INTs as well. 74. To eliminate the data mismatch, we need to create a DINT tag to hold the data then a COP instruction to get it to the hardware. The COP takes care of moving the data from a DINT to an INT.
75. Double-click on the DEST entry, type DEST_Seq and Enter.
76. Right-click on DEST_Seq and select New “DEST_Seq”. This is a shortcut way to create a new tag.
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77. In the New Parameter or Tag window the defaults are what we need so just click the Create button.
The error indicators on the rung go away so our data is good. 78. Now let’s get the data to the module. Create a new rung with the CPS instruction as shown below.
This will take the data from our holding tag and send 16 bits (Length =1) to the OB16 in the 1st slot of the Remote Rack. 79. From the Menu Bar, click the Save icon. 80. The same procedure would be used in Routines _6_SEQUENCE2 and _7_SEQUENCE3. 81. Now let’s see where else some errors exist. Click on the Verify Controller icon in the toolbar. . In the Errors window you will see around 11 errors and 5 warnings. Scrolling thru the errors you will see the same types as the ones we already fixed. In the real world you would go back and fix the rest but at this point that would be redundant to what we’ve learned already. So you have completed the conversion of this project into Logix. Of course the time needed for the conversion and the number of fixes you will need to make will vary depending on the complexity of the original project. Now let’s take a new tool out for a spin. This is the MicroLogix to Micro800 Conversion Tool.
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Lab 2 - MicroLogix to Micro800 conversion Tool While we have had the SLC to Logix Conversion Tool around for a while, this tool is just being released. It will take a MicroLogix1000 program and convert it to a Micro800 program. The methodology is very similar to what we just went through. So let’s take a look at the Tool. 82. Open the Lab Files folder on the Desktop then the Micro Migration folder. Double-click on Paper Drilling Machine.RSS.
83. RSLogix 500 opens the Paper Drilling Machine program. Let’s take a look at the program before we convert it. Click on the Controller Properties.
We can see that it is a MicroLogix 1000 with 17 Program Files and 8 Data Files 84. Close the Properties window and double-click on the LAD2 – MAIN_PROG.
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85. Scroll thru the ladder noticing the High Speed Counters and I/O control. The last two rungs are JSRs for files 6 and 7. Both of those routines are fairly simple but go ahead and take a look.
86. Open up file LAD 4. This contains the Sequencer for the hole cutting machinery
87. Now that we are familiar with the way this program works let’s use the conversion tool. Click on File in the toolbar then select Save As…
The Save Program As… window opens
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88. Change the Save as type to Library Files(*.SLC), click the Export database checkbox and make sure that Logix is selected as the Export file type. Finally click Save.
89. Select OK for the next 2 Export windows to complete the export. These windows give us some documentation options and report that the export has completed. 90. Close RSLogix 500 and pick No to Save changes. 91. Now we will start up the Connected Components Workbench(CCW) where the Migration Tool resides. Double-
click on the CCW icon on the desktop. 92. From the toolbar, select Tools then MicroLogix Library Conversion
93. In the Conversion window, click on the ellipse button next to the Source project window.
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94. Navigate to the Paper Drilling Machine.SLC file and Double-click.
95. Leave the rest of the options as is and click OK. The conversion process begins
When it completes the new Micro830 is shown. We can see that the correct Controller was selected
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96. The conversion tool did a lot of work and it documented it for us. Click in the toolbar on View then select Output.
97. The Output window gives us a listing of all the work the tool performed. Here are some samples. It tells us what was converted, where the full conversion report is stored, some Warnings that need to be addressed, what comments were truncated and what needs to be done to complete the conversion of the Interrupts.
The Warnings are summarized in the Error List window at the bottom of the frame. Fortunately we have no errors so the conversion completed. But the Warnings need to be addressed.
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98. Expand the Error List window so you can see all 18 Warnings.
In the Migrator Tool from the previous lab we got this listing by doing a Project Verify which showed the PCEs. Here the information is presented to us. Of the 18 warnings: Four (3, 5, 8, 10) are telling us that S:1/15 were converted to the Micro800 version of the First Scan bit so nothing needs to be done there. Three (4, 6, 7) have to do with the fact that HSLs in the Mcro800 are rising edge triggered where in the MicroLogix they were level triggered. Let’s focus on items 15 and 16 regarding the HSC Interrupt and the HSC Function Block that was created for us.
The warnings tell us to add in a UID/UIE combo to stabilize the Interrupt if needed. Let’s move on to how the actual code got converted and where it lives. 99. In the original MicroLogix program LAD 4 had the routine that was associated with High Speed Counter and the first rung contained the INT instruction.
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100. Looking at the Project Organizer we see the programs and User-Defined Function Blocks that were created for us during the conversion process. Interrupt4_HSC_INT contains the equivalent of the INT instruction from LAD 4 while the rest of the code from LAD 4 has been incorporated in a User-Defined Function Block(UDFB) labeled HSC_INT containing more UDFBs for the Sequencer instruction.
LAD 2 – Main_Prog
The Interrupt instruction from LAD4 rung 0
The rest of the LAD 4 code including the sequencers.
So when the Interrupt occurs Interrupt4_HSC_INT calls the HSC_INT UDFB.
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101. The HSC Interrupt was configured for us back on the Controllers page. Double-click on the Micro830 icon.
102. Click on Interrupts in the Controller tree then double-click on the 5 entry in the table.
103. The Configure HSC window appears. This is where the link is made between Counter 5, the Interrupt and the code in HSC_INT. Click OK.
On your own check out the rest of the Function Blocks that were created to accommodate the other instructions that didn’t have direct replacements in the Micro800. 104. Three other warnings involve Status bits from the MicroLogix being converted to a standard variable. The first is S:4/7 used to provide a 2.5 second pulse in FB7 to flash a warning light. This would be simple to replace with a Timer.
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105. The next warnings we will address are associated. Let’s look at these three
They all reference the rung 3 in LAD 7 in our original MicroLogix program:
Error 17
Error 11
Error 12
Error 11 and 12 just alert you to review the usage of the Status Bits and make sure they are be used correctly. Error 17 says that block RA_FRD is empty. The FRD instruction in MicroLogix converts a BCD number to Integer and that function does not exist in the Micro800. The current state of rung 4 in FB7 looks like this:
So you would have to create your own converter and take into consideration the Overflow bits shown above. The rest of the warnings would require similar effort. Like the SLC/Compact conversion tool this tool gets you most of the way there with some relatively minor adjustments and additional programming.
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Appendix A: PCE Instruction Error Codes Program Conversion Error (or PCE) instructions are special instructions inserted into Logix routines when converting application code from legacy control systems such as SLC500 or PLC-5. The instructions themselves flag the engineer that there may be an issue with a legacy instruction, referenced I/O or perhaps scaling. In many cases, the code flagged by a PCE instruction may be fine without making any changes at all. The table below provides detailed descriptions of the various Message IDs contained in PCE instructions.
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Lab 3 – PLC5 to ControlLogix Migration Before you begin This lab will cover two major topics. First you will use Integrated Architecture Builder (IAB) to assist in converting the physical PLC-5 hardware into its equivalent ControlLogix hardware. Second you will use the RSLogix Project Migrator to assist in converting an existing PLC-5 program into a ControlLogix program. IAB includes a wizard that helps you migrate an existing PLC-5 configuration to a ControlLogix controller-based configuration. You specify the PLC-5 configuration graphically by placing PLC-5 modules in a PLC-5 chassis. IAB automatically selects equivalent ControlLogix controllers and I/O modules to duplicate the original configuration. You will have options for chassis size and whether or not to use the Migration Conversion hardware available from RA. This lab shows how to use the IAB Migration functionality. This Hand-On-Lab will introduce you to the RSLogix Project Migrator conversion tool which can assist the user in converting a PLC5/SLC 500/MicroLogix program to a ControlLogix program. In this lab you’ll gain an understanding of what files are required for conversion, the process for importing, identification of what didn’t convert and conversion options. The latest RSLogix Project Migrator contains some enhancements which include: Added MicroLogix support Comments are now exported in CSV format so they are no longer truncated Any existing 1746 I/O will be brought over and placed in I/O tree under a 1747-AENTR There are options to migrate the I/O to Point and 69 The Input and Output sections are brought over as a way to migrate the comments associated with them. In an SLC 500 system, any I/O modules that are unsupported (BAS, SN, etc.) in RSLogix 5000 will be brought over as tags with the name Placeholder_xxx_yyy not sure what the format is. Tools & prerequisites IAB v 9.2 or higher RSLogix 5 V8 Files required: PLC5_MIG.RSP and PLC5_MIG.ACD
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A. - Using IAB (this lab takes approximately 20 minutes to complete) About This Lab Integrated Architecture Builder (IAB) provides users with the ability to weigh each of the options to make an informed decision. In this lab, we will use Integrated Architecture Builder (IAB) to assist with the conversion of the existing PLC-5 hardware to a ControlLogix system. In this lab we will replace the local PLC-5 controller and all of its I/O. 1. Use the shortcut on the desktop to Launch IAB. If prompted about establishing an internet connection Select No.
The IAB opening dialog appears. Click New project.
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2. In the Create a New Workspace dialog, click on Migration Workspaces PLC-5 Migration Wizard. Then type PLC_5 Migration in the Workspace Name: text box, then click OK.
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3 IAB opens the new workspace and launches the 1771 Migration Wizard.
For purposes of this lab exercise, suppose you have the following PLC-5 configuration and want to migrate it to ControlLogix. 1) 1785-L40L processor in a 1771-A2B chassis that contains the following: 1) 1771-P4S, 1) 1771-IFE analog input, 1)1771-OFE1 analog output, 2) 1771-IA AC input and 3) 1771-ID16 AC/DC input.
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You want to migrate this PLC-5 system to a ControlLogix system
The following steps will take you through the IAB migration process, showing some of the features of the migration wizard along the way.
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B.
Migration Wizard and Add a PLC-5 Chassis
1. Click the Add Chassis button. IAB opens the Add Chassis dialog. Click the View Video button and watch the 1½ minute video that shows how Rockwell Automation conversion modules are used. When the video is finished, close the video player and select OK in the Add Chassis dialog to accept the default name for the new chassis (PLC001) and add the chassis.
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2. IAB opens the 1771 Migration Module Selection dialog, in which you will make the conversion selections for this chassis. Notice the different areas of this window.
Conversion Options
PLC-5 Chassis will go here
List of PLC-5 and 1771 I/O Modules
ControlLogix Chassis will go here
3. Select a 1771-A2B chassis in the 1771 Chassis Size dropdown list.
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IAB displays a 1771 Migration Conflict Resolution dialog. Conflict resolution dialogs appear when you must make a decision about the conversion. The information in the dialog is specific to the action you are performing. In this case, you must select the ControlLogix chassis that you wish to use. Notice that for each choice, there is a description and a comment. The comments provide application information that can help you make a decision about which option to choose.
Click in the checkbox for the 1756-A10 chassis, then click the View Application Considerations button.
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IAB displays a message: Select OK.
Even though you have an item checked, you have not selected an item for the Application Considerations button. To select the item for Application Considerations, click in the item text. Click in the text of the 1756-A10 line to highlight the item, then click the View Application Considerations button.
Be sure to highlight the 10 slot chassis first
Now IAB opens product documentation about selection of chassis for conversion.
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The Bulletin 1492 I/O Wiring Conversion Sytems publication 1492-SG121 will appear. Skim through the Bulletin 1492 I/O Wiring Conversion Systems selection guide to get a base understanding of some of the 1492 conversion products available.
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4. When finished close the document and click OK in the Conflict Resolution dialog box.
IAB will display the existing 1771 chassis and the newly selected 1756 10 slot chassis.
Existing 1771 Chassis
1756 Chassis we are converting to
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5. In the 1771 Power Supply dropdown box, select a 1771-P4S power supply.
A Conflict Resolution dialog appears. Click the checkbox for the 1756-PA72 power supply and click OK.
Even though you have selected a power supply that occupies a slot in the 1771 chassis, IAB does not show the power supply in the chassis. 6. Leave the Conversion Kit and Wiring Type selections at Yes and Screw, respectively.
Now you are ready to add modules to the PLC-5 chassis and make conversion selections.
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C. Add 1771 I/O Modules 1. From the Processor list, drag a 1785-L40L processor module to the PLC chassis.
IAB displays a Conflict Resolution dialog for the processor. Notice the items in the Classification column. For each named Classification, you can make one choice. So in the window below, you can scroll through the choices and select one choice among ten ControlLogix processors and one choice each in the Channel 1A, Channel 1B, Channel 2A, and Channel 2B classifications. In this migration, we will only choose a processor. You don’t have to make a choice where the option is not used, so we will leave the Channel 1A, 1B, 2A, and 2B choices blank.
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7. For the Processor, Check the box next to the 1756-L71 and then click on the 1756-L71 text to select it and click the View Application Considerations button. Be sure that the processor is highlighted in blue.
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3 2 IAB displays the following message:
You need to choose the ControlLogix processor that will best handle the system requirements. For this application, we will choose the 1756-L71. Click the checkbox for the 1756-L71. Leave the other selections blank. Click OK on the 1771 Migration Conflict Resolution dialog.
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IAB adds the 1785-L40L to the PLC-5 chassis and adds the 1756-L71 to the ControlLogix chassis.
1785-L40L
1756-L71
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8. Expand the I/O Modules and Analog sections, then drag a 1771-IFE module from the module list to the PLC chassis.
IAB displays a Conflict Resolution dialog. Although all the choices result in a 1756-IF16 module being selected, the wiring configuration is different for each choice, so the conversion module selected will be different with each choice. Click the checkbox for Single-Ended Current Mode and click OK.
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IAB adds the 1771-IFE and 1756-IF16 modules to the configuration. Notice the icon that indicates that a wiring conversion module has been applied.
9. In a manner similar to the 1771-IFE, Drag a 1771-OFE1 module to the PLC chassis. IAB adds a 1756-OF6VI module to the ControlLogix chassis. In this case there is no Conflict Resolution dialog because no application choices need to be made.
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10. From the I/O Module Digital section drag a 1771-IA module to the PLC chassis. IAB adds a 1756-IA16 to the ControlLogix chassis. Drag a second 1771-IA module to the PLC chassis. IAB does not add an additional 1756IA16, because the one 1756-IA16 module can accommodate all the inputs from both 1771-IA modules.
Notice that you dragged 2) 1771-IA (8 point modules) but only 1) 1756-IA16 (16 point module) was added
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11. Drag 3 1771-ID16 modules to the PLC chassis.
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12. Take note of the text highlighted in the Red box below and displayed on your screen. The text is indicating the dimensions of the 1771 chassis system and the 1756 chassis system. If you analyze the numbers you will see that all dimensions are different. In our scenario the most important dimension is the Width. The 1771 chassis is 14.01 inches wide and the 1756 chassis is 19.02 wide.
So our example indicates that the 1756 chassis is about 5 inches wider than the existing system which could indicate a potential cabinet space issue when you do the conversion. A user could expect scenarios where the 1756 dimensions may be greater than or less than the existing 1771 chassis depending on the exact system being converted.
13. Click OK at the bottom left in the 1771 Migration Module Selection dialog.
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IAB returns to the Chassis Selection dialog.
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D. Generate Hardware and Finish the Configuration 1. In the 1771 Migration Chassis Selection dialog, click the Generate Hardware button to create the wizard-defined ControlLogix configuration in IAB.
14. Click on the Hardware tab and Click on various components in the chassis to see the hardware details.
2 As you select various components in the chassis the details will show up at the bottom right of the screen.
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15. Right click on the power supply and select Configure Chassis. In the Configure 1756 Chassis dialog, check to see that the power supply can handle the current requirements, and then close the dialog by clicking OK.
If necessary, you could select a different/larger power supply, if the one selected was not sufficient. In our case we are well within the limits of the power supply so no changes are necessary.
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16. Click on the Project BOM button to generate a bill of materials for the project. Answer Yes to the save changes dialog. This may take a moment.
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2 If prompted Save the project.
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The BOM includes all the conversion modules, ControlLogix hardware and associated costs, needed for the configuration.
Notice the different options for viewing and saving the BOM. Close the Project Bill Of Material dialog. Close IAB selecting Yes to any Save Changes dialogs that appear Congratulations this concludes the IAB Migration Wizard lab exercise. Continue on to Section E.
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E. Converting a PLC-5 Program to a ControlLogix Program (approximately 20 minutes to complete) About This Lab This lab will walk a user through some of the major steps involved in converting a PLC-5 program to a ControlLogix program. In this lab, you will:
Export an existing PLC-5 program, preparing it for use by the RSLogix Project Migrator tool Use the RSLogix Project Migrator tool to convert an existing PLC-5 Program to a Studio 5000 program Complete the conversion process by addressing any conversion issues in Studio 5000.
Preparing a PLC-5 Program for the RSLogix Project Migrator Tool by Exporting the PLC-5 Program 1. Using the shortcut on the desktop Launch RSLogix 5.
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2. Open the file PLC5_MIG.RSP it is located in C:\Lab Folder\PLC Migration directory.
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3. PLC5_MIG.RSP is a very simple sample program that we will use to illustrate various components of the RSLogix Project Migrator.
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4. PLC5_MIG.RSP was created purely for illustrative purposes and for use with this lab. The important things to note are: It is a 1785-L40L with the same I/O structure as the previous IAB lab.
It contains an STI in Ladder File 4 that executes every 100mS.
It contains Subroutines, Rung Comments and Instruction Comments.
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It contains Block Transfer, PID and Message instructions.
It contains Timer instructions.
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5. To begin the migration process we must first export the PLC-5 program to the format desired by the RSLogix Project Migrator. Select File Save As… and then be sure you are in the C:\Lab Folder\PLC Migration directory. Select Save as type: of Library Files [*.PC5].
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Take the default settings on the Export PC5 Format dialog and Select OK.
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6. We must now export the database containing the program comments/descriptions. Select Tools, Database, ASCII Export.
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On the Documentation Database ASCII Export dialog Select the CSV tab, Check Instruction Comments and Symbol Groups. Then Select OK.
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Save the export to the C:\Lab Folder\PLC Migration directory and then Select OK.
Select OK on the Export Results dialog
7. Exit RSLogix 5. Select NO to any prompts about Saving before exiting.
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F. Using the RSLogix Project Migrator to create a .L5K file for Import into Studio 5000 1. Using the shortcut on the desktop Launch the RSLogix Project Migrator.
2. Step 1 of the RSLogix Project Migrator will appear. Browse to the C:\Lab Folder\PLC Migration\PLC5_MIG.PC5 file that we previously exported in RSLogix5 and Open it. Leave all other settings as shown. Then Select Next.
Note that the tool will indicate the desired formats needed.
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3. On Step 2, Select Migrate.
4. On Step 3, Select Next.
This area will contain any relevant information. In our case “Application successfully parsed”.
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5. On Step 4, leave all settings as shown and Select Next. Be sure that the Output File location is C:\Lab Folder\PLC Migration.
Notice that the output format is an .L5K extension, which is the standard import/export file type for Studio 5000.
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6. On Step 6 we have completed the use of the RSLogix Project Migrator tool. Step 7 will launch Studio 5000 and complete the import of the .L5K. After the import into Studio 5000 we would need to add the I/O modules to the I/O tree to complete the conversion. If you remember from the IAB portion of the lab, IAB converted all of the 1771 I/O modules to a combination of 1756-IF16, 1756-OF6VI, 1756-IA16, 1756-IA16I and 1756-IH16I modules. We do not want to use our valuable lab time adding modules to the I/O tree so a completed .ACD file has been created for you and we will use that to complete the lab. Select Exit.
We will stop here because the final step of the RSLogix Project Migrator is a standard Studio 5000 import. After the import you would also need to add I/O modules to the I/O tree. It will be a better use of your lab time if the import and I/O tree additions were done for you.
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G. Correct any Issues with the New ControlLogix Program 1. Using the shortcut on the desktop Launch Studio 5000.
2. On the Studio 5000 Splash Screen Select Open Existing Project then Project File.
3. On the Open Project dialog navigate to C:\Lab Folder\PLC Migration and Select the PLC5_MIG.ACD project file and Select Open.
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4. After Studio 5000 opens you will see a Left Pane similar to what is shown below. Keep in mind that the only thing displayed below that was not created by the RSLogix Project Migrator tool is the I/O tree entries. Let us take a moment to compare to two files. Note use the screen captures below to do the comparison do not try to do it using RSLogix 5 and Studio 5000.
PLC-5
ControlLogix
The PLC-5 had ladder file 2 as a main routine, with ladder files 3 and 5 as subroutines. The RSLogix Project Migrator converted those to their ControlLogix equivalent.
The PLC-5 had a Selectable Timed Interrupt (STI) configured in ladder file 4 with a Setpoint of 100mS. RSLogix Project Migrator converted that to a Periodic task with a 100mS period in ControlLogix.
The PLC-5 had the listed 1771 I/O modules in its chassis. We manually added equivalent 1756 modules recommended by IAB to the ControlLogix chassis.
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5. Let us continue our comparison. Double Click on _2_LADDER.
PLC-5
The RSLogix Project Migrator converted the PLC-5 rungs to their equivalent ControlLogix rungs. Notice that all rung and instruction comments were brought forward in the migration.
Note that in the PLC-5 the preset is 100 but in ControlLogix it is 1000. More on the in the next step.
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ControlLogix
6. Compare rungs 3 and 4 between the PLC5 and the ControlLogix programs using the screenshots below.
PLC-5
ControlLogix IMPORTANT THINGS TO NOTE 1 The PLC-5 timer preset is 100 but the same timer in ControlLogix is 1000, both timers will time for 1 second. The RSLogix Project Migrator changed the preset because a PLC-5 had a choice of timer resolutions of .01 S or 1 S, while ControlLogix only has a resolution of .001 S. So to keep the timers true intent the same between controllers the preset was changed from 100 to 1000. 2 Notice the new Program Conversion Error instruction (PCE). RSLogix Project Migrator inserts a PCE instruction any time it detects some type of conversion issue that may/may not need addressed by the user. The PCE will also insert a new rung comment with specific details about the PCE. In this specific case the PCE is telling us that the MUL needs modified because of the differences in timer resolution between a PLC-5 and ControlLogix.
What the PCE is really telling us is that in the PLC-5 we multiplied the timer accumulated by 10 and placed that value in the Dest but in ControlLogix you may need to make adjustments to the MUL to keep the original intent. In a typical conversion it would be likely that a user would experience many such PCEs that may need correction. In a real situation a user may need to change the value of Source B, delete the PCE instruction and delete the added Rung Comment. For the sake of time we will just ignore the PCE.
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7. Double Click on _3_ANALOG_COM. Note that the BTW was replaced with a MSG. The ControlLogix MSG can be the equivalent of a BTW or BTR. Also note the PCE and added rung comment. In this case the PCE means that additional work will need done to the new MSG instruction. In our case since we converted the I/O from 1771 to 1756, the MSG is actually not needed but we would need to add additional rungs to make our system work. More on that in the next step. Had we chosen to keep the 1771 I/O there would have been two options to communicate with the 17711 I/O, a 1756-RIO or a 1756-DHRIO and depending on which module picked the conversion changes needed to make them work would have been different. The important take away here is the RSLogix Project Migrator does a good job of converting the PLC-5 program to ControlLogix but there will always be additional work that needs done. Sometimes the work can be trivial and sometimes the work can be extensive.
PLC-5
ControlLogix
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8. In our case since we converted to 1756 I/O, any BTW/BTR instruction will not be needed and for the most part can be deleted. However we needed to “map” the old BTW/BTR data to the new 1756 module location from the old 1771 module location. We must also configure the new 1756 I/O module. One typical example is shown below but it would be very likely that many similar rungs and configuration would need added to your ControlLogix program. The example below is a single example of the types of changes needed to migrate the 1771-IFE to the 1756-IF16. First you would configure the Module Filter and RTS to match the existing system.
ControlLogix 1756-IF16 Configuration Second you must configure the 1756-IF16 to behave in the same manner as the 1771-IFE by changing from the default settings of +/-10V
PLC-5 1771-IFE Configuration
Third you must “scale” the 1756-IF16 data to match the same range as the 1771-IFE. The 1756-IF16 does not have built in scaling values so a user must add some additional rungs to get the data scaled properly. In this case the 1771-IFE was scaled from -4095 to +4095 and we would need to add rungs to our program to scale the 1756-IF16 values to that range. The 1756-IF16 in Integer mode will return values of +/- 32,767. Fourth we would need to move the newly scaled IF16 value to the appropriate old IFE data location. We will not do that as part of this lab but it would look something like this.
This page briefly covers some very complex conversion topics and was not intended to be an in-depth guide. The important take away here is the RSLogix Project Migrator does a good job of converting the PLC-5 program to ControlLogix but there will always be additional work that needs done. Sometimes the work can be trivial and sometimes the work can be extensive.
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9. Double Click on _5_EXAMPLES.
Look at the PID instruction on rung 1. Notice a PCE instruction has been added. This PCE instruction is indicating that PID instructions are very complex in nature, take a lot of supporting ladder logic, and that a user must verify that the PID works as intended after the conversion to ControlLogix. Click on the Ellipsis of the PID instruction. PID instruction tend to have a lot of supporting ladder logic for such actions as Auto/Manual, Cascaded loops, manipulation of PV, CV and even though the various Gains were carried over there is no guarantee that the loop does not need re-tuned or that the original logic still acts as intended.
That will bring up the PID Setup dialog. Notice that the RSLogix Project Migrator did bring forward many of the PID parameters that directly correlate between the PLC-5 and ControlLogix.
PLC-5
ControlLogix
The important take away here is the RSLogix Project Migrator does a good job of converting the PLC-5 program to ControlLogix but there will always be additional work that needs done. Sometimes the work can be trivial and sometimes the work can be extensive. 100 of 113
10. Look at the MSG instruction on rung 2. Notice a PCE instruction has been added. This PCE instruction is indicating that MSG instructions are very complex in nature and that a user must verify that the MSG works as intended after the conversion to ControlLogix. Click on the Ellipsis of the MSG instruction
Notice that the Configuration tab of the MSG has been populated with correct data but the Communication tab has been left blank. This is because in the PLC5 you had various built in networks (DH+, ControlNet, Serial and Ethernet) but in ControlLogix those networks are not built in so it is not possible for the RSLogix Project Migrator to fill in the proper path.
PLC-5
ControlLogix
The important take away here is the RSLogix Project Migrator does a good job of converting the PLC-5 program to ControlLogix but there will always be additional work that needs done. Sometimes the work can be trivial and sometimes the work can be extensive.
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11. Close Studio 5000. Select Yes if any prompts occur about Saving Changes. 12. So far this Lab has shown how to convert a PLC-5 program to a ControlLogix program. It has also just skimmed the surface of some complicated topics like I/O data manipulation, Timers, BTW/BTR, PID and MSG instructions. The remainder of the lab is going to highlight other complex topics without going into much detail. These topics should be thoroughly investigated before undertaking any PLC-5 to ControlLogix migration.
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H. Other Things to Consider When Migrating HMI A discussion on existing PLC-5 HMI and PanelView communication is beyond the scope of this document. There were multiple HMI packages from both Rockwell and various third parties which could communicate to the PLC-5 controller over multiple networks (DH, DH+, Remote I/O, Ethernet, ControlNet, serial etc.). A discussion on this subject would be quite lengthy and have multiple options. Let us just say that in any conversion using some form of HMI, it is likely that a significant amount of effort will be needed to migrate the HMI application to a ControlLogix system. The user needs to plan for this effort accordingly. PLC5 Networks Data Highway DH If your existing application uses Data Highway and you intend on keeping it, your conversion options to Logix are limited. The only solution for placing a Logix controller on Data Highway is a serial DF1 to Data Highway interface like a 1770-KF2 (obsolete) connected to the serial port of a Logix controller (see KB ID 24506 for more details). Be aware that controllers with a USB port like the L7x series of controllers do not support DF1, therefore a 1770-KF2 type solution would not work with an L7x series processor. Data Highway Plus DH+ If you intend on keeping an existing DH+ network you can connect your Logix controller to DH+ via a 1756-DHRIO module or a serial DF1 to DH+ interface like a 1770-KF2 (obsolete) connected to the serial port of a Logix controller. Be aware that controllers with a USB port like the L7x series of controllers do not support DF1 so a 1770-KF2 type solution would not work with an L7x series processor. In general a Logix controller’s access to DH+ is capable of meeting the needs of the application. This is done via the 1756-DHRIO's built in routing capability and the controller’s ability to map PLC/SLC type message from older PLCs including PLC2s. The DH+ portion of the 1756-DHRIO module can operate at 57.6, 115.2 or 230.4KBaud, however if a channel is configured for DH+, it is recommended to make the other channel unused. Ethernet Some PLC-5s came with a built in Ethernet port. Ethernet could only be used as a peer communication link. ControlLogix can support these conversions generally by using a 1756-EN2xx module. However it will require a lot of user intervention to migrate Ethernet. Note that some PLC-5s could inherently talk to a ControlLogix controller over Ethernet but some could not. This distinction was based on the series and revision of the PLC-5. ControlNet Some PLC-5s came with a built in ControlNet port. ControlNet could have been used for both controlling I/O or as a peer communication network. ControlLogix can support these conversions generally by using a 1756-CN2(R) module. However it will require a lot of user intervention to migrate ControlNet. Serial Port Most PLC-5s had a built in serial port. The serial port generally was used in one of two ways, as a DF1 communications port or as a generic RS232C ASCII communications port. At the writing of this document Rockwell Automation still sells several ControlLogix controllers with a built in serial port but as time progresses it is unlikely that serial ports will still be available on ControlLogix controllers. If your migration requires the use of a serial port you may need to go to a third party module to meet your needs.
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DeviceNet DeviceNet was generally supported in a PLC-5 by the use of a 1771-SDN module. If you were keeping the 1771 chassis the migration would entail communicating with the 1771-SDN with either a 1756-DHRIO or a 1756-RIO. If you were not keeping the 1771 I/O then you would migrate DeviceNet by using a 1756-DNB or a 1788-EN2DN. However in any case it will require a lot of user intervention to migrate DeviceNet. PLC-5 in Adapter Mode Adapter mode was commonly used in a PLC5 as a way for to PLC5s to communicate and share data via Remote I/O. This type of adapter mode did not directly control any I/O. One PLC5 was configured as a scanner, scanning various racks of discrete I/O and analog cards. Another PLC5 was configured as an adapter which allowed it to emulate a 1771-ASB which might contain various analog cards. This type of adapter mode was quite common as a method of bi-directional communication between PLCs on Remote I/O. The 1756-DHRIO module does not support adapter mode. If the PLC-5 you are replacing is supporting adapter mode and you plan on continuing its use then only a 1756-RIO module can support this mode referred to in the 1756-RIO manual as Active mode. The 1756-RIO module can actually support multiple racks as an adapter and multiple Block Transfers within that rack, which means that it may be able to replace multiple PLCs that were in adapter mode. The user needs to plan for this effort accordingly. Note: Adapter mode does not mean that the scanning controller can directly control 1756 I/O contained in the 1756-RIO module’s chassis. It is not possible to directly control 1756 I/O via any method over Remote I/O. Sequential Function Chart, SFC While both the PLC-5 and ControlLogix processors have SFC capability, RSLogix Project Migrator will not convert any SFCs and you must delete any SFCs from the PLC-5 program before running the RSLogix Project Migrator tool. You would then need to add the SFCs into your ControlLogix program manually. Structured Text While both the PLC-5 and ControlLogix processors have Structured Text capability, RSLogix Project Migrator will not convert any Structured Text and you must delete any Structured Text files from the PLC-5 program before running the RSLogix Project Migrator tool. You would then need to add the Structured Text into your ControlLogix program manually. Processor Input Interrupts (PII) vs Event Task A PLC-5 can have a special file dedicated to run based on interrupts from a particular I/O modules state. A ControlLogix controller has a similar functionality called an Event Task. However the RSLogix Project Migrator cannot convert between a PII to an Event task so it is up to the user to manually migrate this process. If a PII exists in the PLC-5 you will get the PCE instruction shown below after the conversion.
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Performance Various series and revision PLC-5s had different scan times for the same program. Various ControlLogix controllers had different scan times for the same program. This variability makes it difficult to predict how much faster a ControlLogix program will run when compared to a comparable PLC-5 program. Just note that a comparable ControlLogix program will run significantly faster (4-20 times magnitude), than the same PLC-5 program. While it may sound great on the surface to get such an improvement in performance, this faster scanning can affect to operation of the program as a system. Synchronous vs Asynchronous I/O The PLC-5 processor maps I/O data into I and O data table files. The I/O data is updated synchronously to the program scan so you know you have current values each time the processor begins a program scan and that the I/O data does not change during the program scan. A Logix controller references I/O which is updated asynchronously to the logic scan. If you need to maintain I/O data integrity throughout the program scan and/or you need to maintain synchronous I/O data transfers in the Logic controller you must use a CPS copy instruction. Reference KB ID 50235 for more information on how to use the CPS instruction. Controller Memory Comparison When choosing a ControlLogix controller to migrate to, you must consider the memory size of your existing PLC-5 program and what type of ControlLogix controller will the program fit into after conversion. PLC-5 maximum memory sizes vary from about 7 KWords to 100 KWords. ControlLogix controllers vary in maximum memory size from about 380 Kbytes to about 10 Mbytes. While no two PLC-5 programs memory usage before and after conversion will be the same, a good rule of thumb would be that the ControlLogix program will use 10 times the amount of memory that the PLC-5 used. Controller Boot up Time As Rockwell Automation moves forward with technology and adds more functionality into the controllers, boot-up time can be affected. PLC-5 processors boot-up times were relatively small, taking only several seconds. Be aware that some Logix controllers can take 40 seconds or longer to boot-up. Congratulations!! You gave completed the “PLC-5 Modernization from Legacy to Contemporary Systems Lab”
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Lab 4 – Migrating PanelView Standard to PanelView Plus 7 Before you begin This lab will cover the conversion of a saved PanelView Standard file (.pba) to PanelView Plus 7 compatible file. This conversion occurs within the FactoryTalk View Studio program and requires no additional software. Tools & prerequisites PanelBuilder 32 V 3.83 FactoryTalk View Studio V 9.0 Files required: CONVERT_PV.pba 1. Let’s first take a look at the PanelBuilder application. Open the Lab Files folder on your desktop and Doubleclick on the CONVERT_PV.PBA file.
2. From the navigation pane Double-click on the 1-Paint Control entry in the Screens folder.
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We will be using this later to show the before and after. For now Close the application. 3. Double-click on the FactoryTalk View Studio icon.
4. Click the New tab. Enter an Application name and click Import.
5. Read the FactoryTalk View dialog box and click OK. RSLinx® Enterprise software for FactoryTalk View does not need to be installed before you import your PanelBuilder32 application.
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6. Select PanelBuilder Application (*.pba) and click Next.
7. Click the ... button.
8. Browse to the Lab Files folder, select the CONVERT_PV.PBA file and Click Open.
9. Click Next.
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10. Configure the import options that are based on your replacement terminal.
Click the Convert to new window size button Select the size (in pixels) of your PanelView Plus 7 terminal display as shown in the chart. Check Scale graphic displays. When checked, this setting rescales all displays. If your original PanelView Standard terminal had a touch screen, or both a touch screen and keypad, check the box under Touch property conversion. Click the Help button to read the differences between the caption alignment options, then select an option for your new application. Click Finish. You will see a number of windows reporting the progress of the conversion This process may take a while, depending on the size of your application. When done, you will see the Project Status dialog box in the next step. 11. Review the Project Status dialog box .
This shows you screen by screen items that were converted and items that are not supported or converted. The same report is available in the file shown at the bottom.
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12. Open Displays under the Graphics folder and Double-click on the 1-Paint Control Display
13. Reopen the original file from the Lab Files folder as we did earlier and open the Paint Control screen.
The PVP7 version Matches the PB32 one . 14. Looking back at the Project Status report we have an entry for Screen 1indicating that a Message display object in PB32 has been converted to a Multistate Indicator object
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Double-click on the text box with the line Paint Line Down object in each application.
This brings up the Properties box for each object
So while some of the options are different we see that the conversion picked the best fit in FT Studio. 15. Now let’s look at a screen that didn’t convert completely. The Status report indicated that screen 7-Login had 2 issues.
We see that the Select Operator Button and Verify Password button are both missing in the new screen.
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Fortunately, both of these have comparable buttons in Studio. Click on Objects in the Studio toolbar and hover over the User Management entry.
Using a combination of these object you can achieve the same functionality in the Studio version. With more complex applications you will have a lot more adjustments to make but they are detailed very well in the publication 2711P-AP006A-EN-P.
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Notes
Publication XXXX-XX###X-EN-P — Month Year
Copyright© 2016 Rockwell Automation, Inc. All rights reserved.
Supersedes Publication XXXX-XX###X-EN-P — Month Year
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