SETTING UP THE CONTROL LOGIX 5000 SYSTEM

Setting up the Control LOGIX 5000 System Page 1 of 42

CONTENTS

1. Communicating with the Logix5555 Processor...........................................3

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

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KEY TO SYMBOLS

DO NOT PROCEDE UNTIL SAFE TO DO SO. POSSIBLE DAMAGE

TO PLANT OR RISK OF PERSONNEL INJURY.

INFORMATION/TIPS.

CAUTION.

EXERCISE CAUTION BEFORE PROCEDING.

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Revision Date Comment Author

1 03/02/2002 First issue S.E.M

Note:- This is not a controlled document. The information contained in this

guide is provided to promote understanding and assist site personnel.
Changes to Rockwell Software versions and ECU core/user programs will
affect the detailed steps in this procedure. Persons must seek advice from the
Technical Support department if the procedure is in question.

Communicating with the Logix5555 Processor

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

In order to communicate with the system you will need the following:-

• RSLinx software installed on your PC.

• Serial cable, RS232 Programmers Cable (64/52004053/071) or Ethernet
cable (CT94732/01) via network hub.

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Establishing a Serial Connection (RS232):-

The serial cable pin assignments are shown in the inside of the processor
door.

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

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

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

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

• Select “Communications” then “Configure Drivers” from the top menu.

Alternatively you can use the Configure Drivers symbol on the shortcut bar
.

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

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

This should have created a similar connection to this

.
This path can be expanded to view the network and devices.

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Establishing the 1756-ENET Module Configuration:-

To enable an Ethernet connection to the system we need to know the

configuration of the ENET module.

The module has the following connections:

To view the configuration of the ENET module we need to run RSWho.

RSWho is RSLinx's main window that displays networks and devices in a
style similar to Windows Explorer.

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

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

Alternatively you can use the RSWho symbol on the shortcut bar .

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

• Right click on 1756-ENET/A, 1756-ENET/A and select Module

Configuration to pop up the 1756-ENET Configuration dialogue box. Select
the Port Configuration tab as shown below.

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

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Establishing an Ethernet Connection :-

The Ethernet pins outs are as per a straight through cable.

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

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

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

• Select “Communications” then “Configure Drivers” from the top menu.

Alternatively you can use the Configure Drivers symbol on the shortcut bar
.

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

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

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

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Generating a Logix 5000 Project (*.ACD file) from a *.L5K File

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

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

• Select the required file and click on “Open”.

• When prompted Save the imported project to a named file and click
Import.
The .L5K file should then be imported.

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Loading a Project (*.ACD) onto the Logix 5000 Processor

To down load a project to the processor the key switch on the processor
must be in the REMOTE or PROGRAM position.

• Run the software Program “RSLogix 5000” from the Start Programs button
on the PC.
• Having previously generated a project or having been sent one, open the
required project using the button from the menu bar. This will take a
few minutes depending on the size of the project.
• Once open the project needs to be downloaded. Select download from the
“Processor Status” button, .
If a communcation path does not exist the following pop up window will
appear.

The communication path will need to be configured using RSWho.

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

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

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The “Connected To Go Online” window should contain information about the

off line project and its location. Ensure this is correct for the project you
selected.
• Clicking the “Download” option will start the process of writing the project
to the controller. See below.

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

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Saving a Project (*.ACD) from the Logix 5000 Processor

This procedure should only be carried out with the turbine and
associated plant in a safe state. During the saving process the processor
functions will be suspended. Please make sure all processes affected by this
controller are in a safe state and that all safety critical functions are not
affected.

Prior to carrying out this procedure it will be necessary to make a

communication connection to the Logix5555 processor via the Ethernet
module and have an “Online” connection using RSLogix 5000 software. See
the relevant sections of this procedure.

The processor must be in either “REMOTE PROGRAM” or have the

keyswitch in the “PROG” position prior to saving the project to the nonvolatile
memory.

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

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

If a communication path does not exist the following pop up window will
appear.

The communication path will need to be configured using RSWho.

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

The “Connected To Upload” window will appear with a condition statement. If

no matching project exists on the hard disk then this dialog box will appear.

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

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

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

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

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Saving a Project (*.ACD) to the Logix 5000 Processor

Nonvolatile Memory
This procedure should only be carried out with the turbine and
associated plant in a safe state. During the update process the processor
functions will be suspended. Please make sure all processes affected by this
controller are in a safe state and that all safety critical functions are not
affected.

Prior to carrying out this procedure it will be necessary to make a

communication connection to the Logix5555 processor via the Ethernet
module and have an “Online” connection using RSLogix 5000 software. See
the relevant sections of this procedure.

The processor must be in either remote programe or have the keyswitch

in the “Prog” position prior to saving the project to the nonvolatile memory.

The latest Logix 5000 processors have been fitted with a memory expansion
card (M24) that contains a nonvolatile memory. This nonvolatile memory is
used the store a copy of the downloaded project for recall at a later date
should the need arise.

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

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

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

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

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

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

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

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

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

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Setting up DDE Topics in RSLinx

RSLinx is a complete 32-bit product that links Allen-Bradley networks and

devices to Microsoft Windows applications. These range from device
programming and configuration applications such as RSLogix and
RSNetWorx, to HMI applications such as RSView32, or Wonderware InTouch.
RSLinx also incorporates advanced data optimisation techniques and contains
a set of diagnostics. RSLinx is an OPC Data Access Compliant Server and a
DDE server.
To enable correct communication between the Logix system and the display
system DDE topics need to be configured in RSLinx to match topics
configured in InTouch. In RSLinx, a topic represents a specific path to a
processor.
If one of the topics is missing the IDS will not display the correct information
and data could be missing.
The Three topics needed for a standard interface are:-

CLOGIX
CMESSAGES
CSETPOINTS

DDE topics should already be defined in InTouch WindowMaker in “Access

Names” under the “Special” tab of the top menu bar. As shown below,

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

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

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

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

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

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

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RSLinx is configured to run when the IDS application is started. When a

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

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Forcing IO Points From Logix 5000

Forcing allows you to override an I/O module's values in the controller.

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

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

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Example of forcing an output:-

Forcing a Boolean type tag (Switch output).

Searching for “Sol110”.

It is possible to force this tag by entering a Boolean value i.e. zero or one into
the “Force Mask” box and clicking the “Force Status” button on the top left of
the window and selecting the “Enable All Forces” option.

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

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Forcing an Integer type tag (Analogue out):-

This could be the Hydrostart demand MCV101.

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

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

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

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

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Example of forcing an input:-

Forcing an Integer type tag (Analogue input).

This example could be a thermocouple e.g. TC1.

Searching the controller tag list for “TC1” will highlight a tag that is not forcible.

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

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Determining the revision of Firmware in a Logix5000

Processor

This has to be performed through RSLinx.

If RSLinx is already open the window can be viewed by either clicking on the

icon in the system tool tray or selecting it from the Windows "Start" bar.

• If RSLinx is not open then from the "Start" button select:

Start Æ Programs Æ Rockwell Software Æ RSLinx Æ RSLinx

The following window will be displayed.

• Select "RS Who" from the "Communications" dropdown menu.

The RSWho window will be displayed.

• Select the required path to the controller.

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

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

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

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Downloading New Firmware to the ControlLogix Processor

It may be necessary to update the firmware of the Logix5555 processor to
allow connection/downloading using RSLogix 5000 at the current version.

ControlFLASH is the firmware update tool used for electronically updating

firmware. ControlFLASH has an easy-to-use interface that will walk you
through the entire firmware update. To facilitate this, ControlFLASH uses
pages in the form of dialog boxes that will prompt you for the information it
needs.

This procedure should only be carried out with the turbine and
associated plant in a safe state. During the update process the processor
functions will be suspended. Please make sure all processes affected by this
controller are in a safe state and that all safety critical functions are not
affected.

This section assumes that the user is running version 3.17 of the
ControlFLASH software. This can be obtained from Software Admin in
Lincoln.

Prior to carrying out this procedure it will be necessary to make a

communication connection to the Logix5555 processor via the Ethernet
module. See the relevant section of this procedure.

• Run ControlFLASH from the programs menu under “Rockwell Software –

Flash Programming Tools”.

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

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

At this point you should have made a connection to the procesor using
RSLinx.

At this stage you are requested to point to the device you wish to upgrade.

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

Click the “OK” button to continue.

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

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

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

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

This will take you back the beginning of the utility.

• At this point click the “Cancel” button to exit the ControlFLASH utility.

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Adding a New ControlNet IO Module

At some point it may be necessary to add a new ControlNet IO module to an
existing Node. This procedure will explain how to configure RSLogix 5000 and
how to register the new module in RSNetWorx for ControlNet.
This example will add a 1794-IRT8/A 8 Channel 24V DC RTD/Thermocouple
Analogue Input Module to Node 02 slot 06.

It is assumed that a connection has been made to the RSLogix 5000

processor and a current project is open. The following modifications will be
made Offline.
Under the I/O Configuration folder as shown below select the Node to which
the new module will be added.

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

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• Highlight the module type and click “OK”.

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

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Channel details:-

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

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

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

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

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

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

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Unscheduling Programs in RSLogix 5000

Unscheduling of programs in RSLogix 5000 should only be carried

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

CAUTION. To unschedule programs in RSLogix 5000 the controller

MUST NOT be in run mode. It is advisable to unschedule programs in remote
PROGRAM MODE.

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

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

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

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

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

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

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

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