Simatic S5 to RSLogix 5000 Application Conversion Guide.PDF

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LOGIX-A010A-EN-P, Simatic S5 to RSLogix 5000 Application Conversion Guide
Simatic S5 to RSLogix 5000
Application Conversion Guide
Application Solution
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Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the
Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales
office or online at http://literature.rockwellautomation.com ) describes some important differences between solid state equipment and hard-
wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all
persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or
application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements
associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the
examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in
this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING
Identifies information about practices or circumstances that can cause an explosion in a
hazardous environment, which may lead to personal injury or death, property damage, or
economic loss.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and
recognize the consequence
SHOCK HAZARD
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.
BURN HAZARD
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.
Rockwell Automation, Allen-Bradley, and TechConnect, are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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Table of Contents
Preface
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conversion versus Translation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PLC Logic Conversion Services Provided by Rockwell Automation . . 9
Service Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
One-stop PLC Program Conversion Services . . . . . . . . . . . . . . . . . 9
Service Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Services Offered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Conversion Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversion Plus Initial Clean-up Package . . . . . . . . . . . . . . . . . . . 10
Additional Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Additional Program Conversions Available . . . . . . . . . . . . . . . . . . 11
Chapter 1
Controllers and I/O Modules
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
S5 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Logix Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Logix Controller Memory Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
S5 Controller Memory Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Digital Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing 6ES5 420-4UA13/14 and 6ES5 430-4UA13/14 DI
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing 6ES5 431-4UA12 DI Modules. . . . . . . . . . . . . . . . . . . . 19
Replacing 6ES5 432-4UA12 DI Modules. . . . . . . . . . . . . . . . . . . . 19
Replacing 6ES5 434-4UA12 DI Modules. . . . . . . . . . . . . . . . . . . . 19
Replacing 6ES5 435-4UA12 DI Modules. . . . . . . . . . . . . . . . . . . . 20
Replacing 6ES5 436-4UA12 DI Modules. . . . . . . . . . . . . . . . . . . . 20
Replacing 6ES5 436-4UB12 DI Modules . . . . . . . . . . . . . . . . . . . . 20
Digital Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Analog Input/Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Logix Controller with S5 I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
S5 Controller with Logix I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 2
Software Conversions - Program
Structure
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Organization Blocks/Logix Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Continuous Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Periodic Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Event Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Task Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RSLogix 5000 Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Blocks/Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Function Blocks/Add-On Instructions . . . . . . . . . . . . . . . . . . . . . . . . 36
Watchdog Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Table of Contents
Logix Aliasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Internal Memory Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Flag Words/Bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Programming Languages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
RSLogix 5000 Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
RSLogix 5000 Structured Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
RSLogix 5000 Function Block Diagram . . . . . . . . . . . . . . . . . . . . . 47
RSLogix 5000 Sequential Function Chart. . . . . . . . . . . . . . . . . . . . 47
Conversion of STEP 5 Code to RSLogix 5000 . . . . . . . . . . . . . . . . . . 47
Chapter 3
Software Conversions
Instructions
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Jump Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Arithmetic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Block Call Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Shift Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Conversion Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Chapter 4
Additional RSLogix 5000 Features Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Task Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Asynchronous I/O Updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DINT Data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
String Data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coordinated System Time (CST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Coordinated System Time (CST) Object . . . . . . . . . . . . . . . . . . . . 97
WallClockTime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Timestamped Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Scheduled Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Chapter 5
Conversion of System Functions
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Logix System Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Read/Write System Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Save/Load Scratchpad Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Chapter 6
Communications and Networking S5 Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
S5 Serial Communication Processors
(CP 521, CP 523, CP 524 and CP 525) . . . . . . . . . . . . . . . . . . . . . 103
Serial Communication Memory Submodule. . . . . . . . . . . . . . . . . 103
Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Logix Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
S5 Distributed Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Table of Contents
S5 Network Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
CP 530 Network Communications Module . . . . . . . . . . . . . . . . . 106
CP 143 Network Communications Module . . . . . . . . . . . . . . . . . 107
NetLinx Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Produced / Consumed Tags in RSLogix . . . . . . . . . . . . . . . . . . . 109
Fiber Optic Communications
IM 307/IM 317 Fiber Optic Interface Modules . . . . . . . . . . . . . 110
S5 CP 580 & CP 581 Communication Processor Modules . . . . . 111
IP 265 High Speed Sub Control . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Chapter 7
Drive and Loop Control
Encoder/Positioning Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Logix Servo Drive Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Replacing S5 Positioning Module with Logix . . . . . . . . . . . . . . . . . . . 114
Controller with Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
S5 Analog Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
IP 243 Analog Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
IP 244 Temperature Controller Module . . . . . . . . . . . . . . . . . . . . 115
IP252 Closed Loop Control Module . . . . . . . . . . . . . . . . . . . . . . 115
IP 260 Loop Controller Module . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Logix Analog Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Chapter 8
Logix Replacements for S5
Components
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Controller Memory Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
CPU Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Digital Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Digital Output Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Digital Relay Output Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Analog Input Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Siemens S5 Analog Input Range Cards . . . . . . . . . . . . . . . . . . . . 123
Analog Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Installation Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
New Product Satisfaction Return . . . . . . . . . . . . . . . . . . . . . . . . . 128
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