&RQWURO/RJL[

DQG&RPSDFW/RJL[
2YHUYLHZDQG)LUPZDUH
In this chapter, we will introduce the ControlLogix and CompactLogix platforms by
exploring the evolution of the Allen-Bradley controllers. We will provide details of
the Rockwell Automation Integrated ArchitectureDQGWKHQÀQDOO\ZHZLOOGLVFXVV
WKHLPSRUWDQWUROHWKDWÀUPZDUHSOD\VLQWKHLogix5000 platform. Due to 15 to 20
years of industrial controller life span, it is common to encounter older versions of
KDUGZDUHDQGÀUPZDUHDQGFULWLFDOWREHIDPLOLDUZLWKOHJDF\V\VWHPV

A brief history of Rockwell Automation

This book begins with some background history on the Rockwell Automation
ecosystem. It is important to understand the legacy systems provided by Rockwell
$XWRPDWLRQEHFDXVHVRPHRIWKHPFDQVWLOOEHIRXQGRSHUDWLQJLQWKHÀHOGWRGD\
Also, it is important to understand the overall Rockwell Automation offering and
WHUPLQRORJ\DQGKRZWKHSODWIRUPVZHIRFXVRQLQWKHERRNÀWLQWRWKHUHDOZRUOG

[1]
ControlLogix and CompactLogix Overview and Firmware

Allen-Bradley was founded in 1904 by brothers, Harry (19 years old) and
Lynde Bradley (26 years old), with seed money from Dr. Stanton Allen. As a
teenager, Lynde Bradley developed the prototype for what would later become
$OOHQ%UDGOH\
VÀUVWFRPPHUFLDOSURGXFW7KHSULPDU\IRFXVRI$OOHQ%UDGOH\ZDV
motor controllers for several decades until they received an unusual challenge
from General Motors (GM) in 1968. Each time GM wanted to introduce a new car,
they needed to spend two or three months rewiring all their relays to support the
production process changes. The request was to build a system to replace their
KDUGZLUHGUHOD\ORJLFZLWKVRPHWKLQJPRUHG\QDPLF³Standard Machine
Controller. Modicon ultimately won the GM contract with their highly robust
Modicon 084 Controller. As a result, Allen-Bradley acquired a company called
Information Instruments Inc and SURGXFHGWKHLUÀUVWIXQFWLRQDOFRQWUROOHU³
Programmable Matrix Controller (PMC) in 1971. Shortly after the release of PMC,
Allen-Bradley released a more feature-rich product known as Programmable
Logic Controller 1 (PLC-16LQFHWKHLQWURGXFWLRQRIWKHÀUVW$OOHQ%UDGOH\ODWHU
Rockwell Automation) PLC-1, we have seen several platforms released, including
PLC-2 (1978), PLC-3 (1981), PLC-5 (1986), SLC 500 (1991), MicroLogix (1994),
&RQWURO/RJL[DQGÀQDOO\&RPSDFW/RJL[,Q$OOHQ%UDGOH\ZDV
acquired by Rockwell International and was later spun off as a part of Rockwell
$XWRPDWLRQ,QWKHÀHOGWRGD\WKH$OOHQ%UDGOH\QDPHDQGORJRFDQVWLOOEHVHHQRQ
many of the Rockwell Automation's products. The focus of this book will be on the
modern ControlLogix and CompactLogix controllers and Studio 5000 Automation
Engineering and Design Environment, which I will refer to as the Logix family.

Integrated Architecture
Like many other vendors, Rockwell Automation has recently rebranded and
reorganized their offering. The ControlLogix family is a part of Rockwell
Automation's larger solution offering called Integrated Architecture. It is a relatively
new term in the world of Rockwell Automation, but the concept has been in place for
quite some time. It represents a convergence of the control and information systems
within an industrial operations environment. This convergence is in line with the
industry trend we have witnessed over the past decade and has increased the ties
between Operational Technology (OT) and traditional Information Technology
(IT). We have seen a continuous increase in demand for operational information
WREHSURYLGHGWRWKHFRUSRUDWHLQIRUPDWLRQV\VWHPLQUHDOWLPHLQRUGHUWRIXOÀOO
the maintenance needs, environmental reporting, accounting, and other corporate
requirements. At the same time, we have seen OT move from proprietary protocols
and data access technology to traditional IT technologies such as TCP/IP and
Ethernet. The promise of Integrated Architecture is the ability to easily implement
SODQWZLGHRSWLPL]DWLRQUHGXFHWHFKQLFDOSURMHFWULVNLQFUHDVHPDFKLQHSHUIRUPDQFH
and improve long-term reliability.

[2]
 Chapter 1

7KHÀYHFRUHtechnologies of Integrated Architecture Programmable Automation

Controller (PAC) product line include the following platforms:

‡ ControlLogix
‡ CompactLogix
‡ GuardLogix
‡ DriveLogix
‡ SoftLogix

Logix
Designer
Studio 5000
View Designer

Logix ControlLogix

Kinetix CompactLogix

Integrated Logix
Stratix SoftLogix
Architecture Controllers

View DriveLogix

PowerFlex GaurdLogix

Rockwell Automation Integrated Architecture overview

The preceding diagram outlines the Integrated Architecture structure and shows
ZKHUH&RQWURO/RJL[ÀWVLQWRWKHmix. The FlexLogix (bulletin 1794) controllers were
also part of the Logix PAC family and was used to communicate with PLC-5 and
SLC 500 Flex I/O blocks. However, FlexLogix has now been retired from the lineup,
so it will not be covered in this book.

The product, formally known as RSLogix 5000 (used for programming the
ControlLogix and CompactLogix controllers), is now included within the automation
engineering and design software suite called Studio 5000 and is now referred to as
Logix Designer)RUWKHUHPDLQGHURIWKLVERRNZHZLOOEHXVLQJWKHWHUPV³/RJL[
'HVLJQHU56/RJL[DQG/RJL[³LQWHUFKDQJHDEO\WRUHIHUWRWKH/RJL[FRQWUROOHU
family programming environment.

[3]
ControlLogix and CompactLogix Overview and Firmware

ControlLogix controllers
ControlLogix FRQWUROOHUZDVÀUVWODXQFKHGLQDVDUHSODFHPHQWIRU
Allen-Bradley's previous large-scale control platform, PLC-5. The ControlLogix
platform includes a bulletin 1756 ControlLogix 5550 controller, bulletin 1756
ControlLogix I/O modules, and the RSLogix 5000 programming software platform
(now referred to as Studio 5000 Logix Designer). ControlLogix represented a
VLJQLÀFDQWWHFKQRORJLFDOVWHSIRUZDUGWKDWLQFOXGHGDELW$505,6&FRUH
microprocessor and an ABrisc Boolean processor combined with a bus interface on
the same silicon chip. At launch, the series 5 ControlLogix (also referred to as L5 and
ControlLogix 5550) controllers were able to execute the code three times faster than
PLC-5. The following diagram is an illustration of the original Logix L5 controller:

[4]
 Chapter 1

The L5 controller is considered to be a PAC rather than a traditional PLC due to its
modern design, power, and capabilities beyond a traditional PLC (such as motion
control, advanced networking, batching, and sequential control). The ControlLogix
platform is built on the ControlBus backplane, which performs like a mini-network
and allows devices to be Removed or Inserted Under Power (RIUP).

Warning: Removing modules while under power can

create an arc and have disastrous consequences in
explosive environments.

L5 has since been retired from the lineup, so we will focus on the newer L6 and
L7 controllers in this book. Throughout this book, we will be referring to the
ControlLogix controllers as PACs, which are the modern day equivalent of PLCs.

Logix operating cycle

The entire Logix family of controllers (ControlLogix and CompactLogix) has
diverged from traditional synchronous PLC scan architecture in favor of a
PRUHHIÀFLHQWDV\QFKURQRXVRSHUDWLRQ/LNHPRVWPRGHUQFRPSXWHUV\VWHPV
asynchronous operation allows the Logix controller to handle multiple tasks at
the same time by slicing the processing time between each tasks. The continuous
updating of information in an asynchronous processor creates some programming
challenges, which we will address throughout the book. The following diagram
illustrates the difference between the synchronous and asynchronous operation:

Communications,
Read Inputs Logic
Status, Watchdog Outputs
Execution
Tasks 20 ms RPI

Traditional Logix
Synchronous Asynchronous
PLC Scan Operation
Inputs
Write Outputs Execute Logic Communications
200 ms RPI

[5]
ControlLogix and CompactLogix Overview and Firmware

ControlLogix series 6 controllers

In 2002, the bulletin 1756 ControlLogix L6 (Logix556x) processor was released with
a more powerful processor and more memory, and the CompactFlash nonvolatile
memory card was added to the entire lineup.

Even though the ControlLogix platform is approaching its 20th birthday,

it is still in the early stages of its product life cycle. For example,
Allen-Bradley's 1747 series SLC500 family, which was introduced in
1989, is still available for sale today. Although no longer actively being
developed, SLC500 represents a product life in excess of 25 years.

ControlLogix represents a common control engine with a common development

environment and tight integration between the programming software, controller,
and I/O modules. This close integration greatly reduces automation engineering
development time and cost.

ControlLogix series 7 controllers

In 2010, Rockwell Automation launched the series 7 (also referred to as L7 and
ControlLogix 5570) controllers, which featured the following enhancements over
the series 6 (L6) controllers:

‡ The performance capability doubled due to a more powerful dual core CPU.
‡ The adoption of modern SDRAM memory.
‡ The replacement of the 9-pin serial port with a USB 2.0 port (programs
transfer 200 times faster over USB 2.0 than serial).
‡ The replacement of the CompactFlash memory card with a Secure Digital
(SD) memory card.
‡ The replacement of the lithium battery with the capacitor-based Energy
Storage Module (ESM). The ESM provides power to the controller during a
power loss event to allow it to copy the contents of its memory from volatile
memory to the onboard nonvolatile memory. The ESM eliminates the issue
with L6 series controllers that would lose the program after a few weeks
without power once the battery was completely drained.
‡ The ability to store program comments and tag descriptions on the controller
(firmware v21 and higher).

[6]
 Chapter 1

‡ The addition of the onboard four character display.

ControlLogix L73 controller

[7]
ControlLogix and CompactLogix Overview and Firmware

Selecting a ControlLogix controller

When selecting a ControlLogix controller, it is important to consider the
following points:

‡ Supported Logix Designer software versions

‡ Processing the requirements of your current application and future expansion
‡ Memory requirements of your current application and future expansion

The ControlLogix series 6 and series 7 controllers and their software version
compatibilities are shown in the following table:

ControlLogix controllers Logix Designer software (RSLogix 5000)

Controller Memory Minimum version Maximum version
Series 6 (L6)
1756-L61 2 MB v12 v20
1756-L62 4 MB v12 v20
1756-L63 8 MB v10 v20
1756-L64 16 MB v16 v20
1756-L65 32 MB v17 v20
Series 7 (L7)
1756-L71 2 MB v18
1756-L72 4 MB v19
1756-L73 8 MB v18
1756-L74 16 MB v19
1756-L75 32 MB v20

It is important to note that the L6 controllers are not supported in Version 21 and
higher of Studio 5000 Logix Designer.

[8]
 Chapter 1

GuardLogix safety controllers

With the launch of the (bulletin 1756) GuardLogix controller in 2005, the
ControlLogix platform supported both standard and safety system control in
the same chassis. The GuardLogix controller system is designed for use in safety
applications, including SIL 3 (IEC 61508) and the ISO standard for Safety of
Machinery (ISO 13849-1 General Principles for Design and PLe/Cat.4). GuardLogix
safety controllers represent an essential piece of a fail-safe (de-energize to trip)
solution. Fail-safe refers to a solution that when a fault is detected, all of its outputs
are set to zero. And, in the event of a faulty input or input module, it automatically
sets any input values associated with them to zero. Both the L6 and L7 controllers
are available in the GuardLogix form factor. Physically, the GuardLogix controllers
feature a red faceplate and are usually installed in SDLUV³SULPDU\DQGVDIHW\SDUWQHU
controller. The GuardLogix controllers are only supported in Version 18 and higher
of RSLogix 5000 and Studio 5000 Logix Designer.

Extreme environment controllers

The Rockwell Automation's extreme environment controllers (bulletin
1756 ControlLogix-XT) share the same features and programming interfaces
as WKHVWDQGDUG&RQWURO/RJL[FRQWUROOHUVEXWDUHFHUWLÀHGWRRSHUDWHLQH[WUHPH
conditions. The ControlLogix-XT modules are darker gray in color than the
ControlLogix modules and are spaced in every other slot to provide an improved
ventilation/isolation. In addition, the ControlLogix-XT modules are treated with a
conformal coating that improves the product's resistance to corrosive environments.
The ControlLogix-XT controllers and modules are rated for temperatures
ranging from -20°C to 70°C (-4°F to 158°F) and have the following environmental
FHUWLÀFDWLRQV³F8/XV&ODVV'LY&7LFN&($7(;=RQH6,/,(&
ANSI-ISA-S71.04-1985, Class G1, G2, and G3. The L6 and L7 standard controllers and
GuardLogix controllers are all available in Extreme Environment (XT) form factors.

[9]

www.itbookshub.com
ControlLogix and CompactLogix Overview and Firmware

CompactLogix controllers
In 2006, Rockwell $XWRPDWLRQÀUVWVKLSSHGWKHEXOOHWLQ/&RPSDFW/RJL[
controllers targeted at cost effective, small- to medium-size automation solutions.
At the time of launch, CompactLogix controller was planned as the long-term
replacement for the SLC 500 controller family. The CompactLogix control platform
is designed with an emphasis on the controller software. As the CompactLogix
hardware evolves with an improved performance and additional features, the
ORJLFZLOOHDVLO\PLJUDWHWRQHZKDUGZDUHDQGÀUPZDUHYHUVLRQV8QOLNHWKH6/&
500 platform, the CompactLogix controllers can be programmed using the same
RSLogix 5000 (Logix Designer) software suite that is used with ControlLogix. In
2006, CompactLogix L43 with integrated motion support was added to the family. It
features a CompactFlash memory card, Ethernet port, Serial RS-232 port, 1769 / 1768
modules, and a power supply module. The following is an illustration of the L43
CompactLogix controller:

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Modules on L43 can only be placed to the right of the power supply.

[ 10 ]