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Logix 5000 Configuration StandardProgramming Standards

Scope

CIS_409_ControlLogix_Configuration_Standard_WHQ.doc, Revision 2, December 2007 1

Logix 5000 Configuration StandardThis document provide design and installation standards for Logix 5000 control systems used in General Mills (GMI) manufacturing facilities. It provides system design philosophies and information about plant-wide communications requirements. Wherever cost effective, standardization is the main goal.

Table of Contents 1. Scope

2. Design Requirements

3. Hardware Configurations

4. Communications

5. Motion Control 6. Version Control—Firmware Upgrades

7. References and Related Documents

8. Acronyms and Abbreviations

9. Revision Summaries

1. Scope The standards described in this document are mandatory unless otherwise identified as optional or preferred. Any variance from GMI requirements or preferences requires prior GMI Engineering approval. Obtain approval from the engineer that issued this document or has been designated as responsible for project deliverables. GMI will provide and document specific project requirements and approvals. NOTE: If any standards in this document conflicts with standards required by the plant, please inform the plant immediately.

These requirements apply to all Logix 5000 control systems used in GMI manufacturing facilities. In addition, it applies to equipment from original equipment manufacturers (OEMs), including custom machines and process equipment. OEMs shall ensure that their equipment interfaces correctly with the whole system.

This document is NOT intended for use as an installation specification. However, the designer may extract relevant information to include in drawings and specifications.

In addition, the following terminology is used in this document

• Shall: designates unconditional requirements.

• Should: implies a preferred requirement.


Design Requirements


• Engineer: the supplier of the electrical or control design services covered in this document.

• Manufacturer: the original equipment manufacturer of the hardware components.

2. Design Requirements The engineer shall provide designs that meet the project’s scope of work, adhering to the application and component requirements described in the following sections. The engineer shall verify that the selected components will function properly in the final design.

2.1 Standard Voltages Use 120 VAC, single-phase, 60 Hz for all components, including Logix 5000 power supplies, unless otherwise specified. Refer to “Module Types” on page 7 for standard voltages for discrete input and output modules.

Equipment supplied with integrated controls shall have a single voltage source of 120 VAC.

UPS systems shall not be used for maintaining power to ControlLogix hardware.

3. Hardware Configurations Consult with plant support personnel on current plant conditions, including employee’s knowledge and skill levels, existing support equipment, and current software and hardware versions before designing Logix 5000 control system architecture.

Allen-Bradley Logix 5000 series PLC equipment should perform all process control. The engineer’s final design should include appropriate I/O cards and memory for items that might otherwise be handled outside the Logix control system (such as single loop PID controllers).


Hardware Configurations


The system’s overall requirements determine the appropriate size and selection of Logix hardware. Consider future expansion when making hardware selections: normally, 25–50% spare is preferred. Be sure to include the following items in your calculations.

• Maximum number of nodes

• Maximum number of connections

• Memory size

• Scan time

• Network bandwidths (scheduled and unscheduled)

• Rack sizing

• Specialized I/O module requirements

If you are designing architecture for an entire system, always consider legacy systems. Allen-Bradley SLC-5/04s, 5/05s and/or PLC-5 series systems must interface with all new Logix-5000-based control systems.

Each Logix-5000 control system shall be supplied with a minimum of one Ethernet communications interface card to network with all Logix controllers within a system. Generally, this network serves as the primary data and programming support network. Certain designs (such as gateways) might require additional network cards. See “Communications” on page 11.

All systems shall be sized to assure maximum control flexibility. All devices shall have independent I/O points—a single field device shall input directly to a single PLC input, and PLC outputs shall go directly to a single field device.

For large systems, GMI prefers a decentralized approach to I/O. Systems with several racks of I/O shall distribute the racks to locations closest to the field devices. For example, a process system with equipment on three floors that requires three 17-slot racks of I/O should be designed with each rack in a separate enclosure—one for each level. The enclosures should be located near the largest amount of equipment and field devices.




3.1 Controllers Allen-Bradley’s 1756-L6x ControlLogix or 1769-L3xE CompactLogix controllers shall be used. The specific model selected should be based on the memory and processing requirements of the project.

The 1756-L60M03SE controller may be used with permission, primarily for motion applications that have little potential for growth and change (such as OEM packaging equipment). This is a two-slot processor combining a 1756-L6x controller and SERCOS motion module. It can control up to three axes.

FlexLogix, SoftLogix, and ProcessLogix controllers shall not be used except by special permission from GMI, and only for OEM equipment already using these controllers.

Each system shall be supplied with Ethernet to connect to GMI’s PLC LAN.

3.2 I/O Configurations A “local” rack is one that contains a processor. Typically, there is one local rack per control system.

A “remote” rack does not contain a processor. Systems with remote racks of I/O shall use ControlNet as the network between all racks.

In a remote rack, slot 0 shall be used for the Remote I/O adapter module (normally, the 1756-CNB ControlNet communications card should be used).

Local racks within a control system shall have a unique identifier. Rack identifiers shall be assigned during the design phase of a project and shall be included on an architecture drawing. Identification serves two purposes: it names physical hardware within each system, and it is used as part of the module description when configuring I/O modules. (See the Logix-5000 Programming Standard.)

The engineer shall coordinate with OEMs and equipment vendors to ensure that unique, logical identifiers are assigned early in the design phase.

Identifiers shall be based on the format: aabbcddMGe.




Figure 1: Rack Identification Example

Code Part

Description

aa unique ID for local racks (AA-ZZ)

bb Slot number (00-16) of the parent communication card located in local rack

c Node or Rack (N or R)

dd Node number or rack address of the communications card in remote racks

MG* Module group

e* Starting module group number (0, 2,4, 6)

* Omit unless required for 1771 racks configured as ¼, ½ or ¾ racks




3.2.1 I/O Hardware Sizing The default I/O hardware size is a 17-slot rack 1756-A17 series B or later with the 1756-PA75, 13A power supply.

GMI prefers placement of intelligent cards (such as high speed counter cards, weigh scale modules, and DeviceNet communications cards) in the local rack for data transfer efficiency. See “Module Locations” on page 9.

When a limited amount of remotely located I/O for given geographical area is required, consider using Flex I/O. Communicate your decision and reasoning to the controls lead.

GMI prefers ControlNet for specialized equipment (for example, VFDs and checkweighers). DeviceNet may be used with permission.

In general, provide a minimum of 25–50% spare I/O space. Always provide at least one spare slot for each different kind of card used.

If additional racks are required to comply with the above spare space requirements, the engineer should consider the following options:

• Provide space in the control panel for an additional rack and power supply with mounting holes pre-drilled.

• Provide an additional I/O rack and power supply without any communication or I/O cards.

• Provide an additional I/O rack located in the same enclosure as the original rack and relocate a portion of the original I/O into the second rack.

• Distribute additional racks and a portion of the original I/O closer to the equipment or field devices. This approach might lower installation costs and minimize conduit runs, which allows a more sanitary and cost effective installation.




3.3 Module Types Digital I/O should be 120 vac for process applications and 24 vdc for packaging applications. Performance requirements may dictate 24 vdc I/O in processing applications. The engineer must supply performance analysis to justify using DC I/O. When DC I/O is used, the preference is for sinking input cards and sourcing output cards.

Analog inputs/outputs shall be 4–20 ma isolated or differential. Use of 0–10 vdc or other analog signal levels is strongly discouraged and requires special permission.

Temperature sensors wired directly to RTD input cards in the PLC I/O racks are preferred over resistance-to-current (R/I) transmitters.

Weighing applications should use Hardy Instrument’s HI1756-WS module. Standard software routines based on this module are being developed within GMI to simplify the operation and calibration of weighing systems.

Liquid metering applications shall use the 1756-CFM (Configurable Flowmeter Module). Standard software routines based on this module are being developed within GMI to simplify the operation and calibration of liquid delivery systems.

Applications requiring high speed counting (such as encoders) shall use the 1756-HSC.




Applications requiring interface with devices via serial communications should use one of the following modules manufactured by ProSoft.

• MVI56ADM is marketed by Allen-Bradley as the 1756-MVI, and requires development of custom programs using Visual C/C++. Several device drivers for commonly used devices, (such as bar code readers) are being developed. Contact CIS engineering for the latest drivers. New drivers should be coordinated with GMI-CIS engineering.

• MVI56CSC is a generic ASCII interface module. Configuration requires downloading Logix-5000 code from ProSoft’s web site (the communications between the processor and the module) and setting parameters in the module based on the protocol of the device. There are two ports for connecting devices and a third port for debugging the ASCII communications.

• MVI56BAS is a BASIC module similar to the 1771-DB and 1746-BAS. The MVI56BAS requires development of custom BASIC programs and should be considered for legacy applications which interface with devices using either of Allen-Bradley’s BASIC modules.




3.4 Module Locations Local racks should contain a majority of the intelligent cards for a system. Placement of intelligent cards in the Local rack minimizes data being sent and received across ControlNet. For example, placing a 1756-DNB DeviceNet card in a remote rack limits the transferred data to 50 words or less. That same module in a local rack transfers 123 words each time data is transferred.

When laying out I/O racks, the following sequence shall (from left to right) be followed:

1. Remote I/O adapter module—normally 1756-CNB (Remote racks only)

2. Processor(s)

3. Ethernet modules

4. ControlNet modules

5. Other communication modules (such as Data Highway/Remote I/O and DeviceNet)

6. Specialty & smart cards including motion modules

7. Analog input cards

8. Analog output cards

9. Discrete input cards

10. Discrete output cards




In Local racks, load the analog and discrete input and output cards starting from the right end of the rack. In Remote racks, load these cards starting from the left. In either case, include spare slots between each group of analog or discrete inputs and outputs.

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Figure 2: Typical Local Rack Layout

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Figure 3: Typical Remote Rack Layout


Communications


4. Communications Direct System Control shall use Allen-Bradley ControlNet or Local I/O.

Use Ethernet for peer-to-peer communications between systems. However, some applications might require the determinism of ControlNet. These applications shall include ControlNet peer-to-peer communications in addition to Ethernet.

Generally, network redundancy is not required for GMI control systems. Systems and applications that seem to need this capability require analysis, justification, and approval prior to final design.

Fiber-optics should be considered for installations in areas with large amounts of electrical interference (noise), applications requiring distances in excess of recommended limitations, and systems requiring communications between separate buildings.

Figure 4: Fiber Media between Remote Systems

Electronic documentation of the final physical architecture shall be provided to GMI in AutoCad 2000 or Visio 2000 format(s).


Communications


4.1 Gateways Each GMI facility shall have at least one Logix-5000 Gateway. Each gateway should contain the required communication modules to tie together non-Ethernet control networks (such as Allen-Bradley’s Data Highway Plus and ControlNet).

When designing systems, the engineer should consider existing gateways (if any), loading, and size. If a new or additional gateway is required, the engineer shall provide one as part of the project’s scope.

Large GMI manufacturing facilities should consider one gateway per major manufacturing line. Multiple gateways reduce network loading and overall dependence on a single device.

For the purposes of data concentration, gateways should contain a Logix processor. These processors shall not be used for direct control. However; they may contain programs used for production analysis (such as equipment downtime detection).

Connect legacy DH+ systems to a gateway using the 1756-DHRIO interface card. Both channels (A & B) on the interface card should be configured as Data Highway+. Baud rate settings for each channel should be set to 57.6 Kbaud. Although DH+ networks support a maximum of 64 nodes, networks requiring more than 32 nodes shall be broken into multiple segments. Each segment should be divided into logical groupings (such as Line #X or Line #Y).

4.2 Ethernet Ethernet networks, at a minimum, shall be 10/100 Base-T and shall be designed to provide optimal throughput and minimize any loss of production due to excessive dependence on any given segment (such as multiple production lines on the same segment).

Communication loading on any Ethernet segment shall not exceed 30% of the theoretical maximum throughput.

Belden MediaTwist (copper cabling) or fiber-optics shall be the only media used for Ethernet on the plant floor.

When configuring Ethernet communications for Logix hardware, “Bootp” must be disabled as the default.


Communications


Every PLC shall be connected to the plant PLC network for information and program support. The plant shall supply fixed IP addresses for each 1756-ENBT (or the 1761-NET-ENI module when using Logix-53XX and Logix-54XX) on the network prior to installation.

HMI systems are outside the scope of this document, however HMIs must communicate effectively with Logix-5000 control systems. Wonderware HMI systems reside on a separate segment from the PLCs. The HMI and PLC segments shall be tied together via dual NIC (Network Interface Cards) located in WonderWare Tagserver(s). The total number of Wonderware Tagservers depends on the network’s final design.

At the time of publication, there is a problem with the auto-negotiate feature of the 1756-ENBT modules. They sometimes set themselves to half duplex even though the switch port to which they were connected was full duplex. A work-around that forces the ENBT module’s baud rate and duplex appears in the Rockwell Knowledgebase (Rockwell Tech Note A4193091 – Forcing the Baud and Duplex of a 1756 or 1788-ENBT).

4.3 ControlNet ControlNet communications shall be designed for appropriate, time-determinant I/O and critical message delivery as dictated by the project requirements.

ControlNet communications and I/O are connection based. Connection requirements vary and must be planned for during the design phase. The total number of connections for a single Logix processor shall not exceed 225. Systems exceeding this limit shall be divided into multiple processors with each processor having a logical division of the connections and the respective programs.

The total number of connections shall be optimized by configuring all discrete I/O modules located in remote racks as Rack Optimized.


Communications


Determine the total number of connections based on the following Connection Documentation Example table. A document similar in format shall be maintained as part of the system(s) overall documentation.

Connection Type Quantity Multiplier Total

Local I/O modules 1

Direct connect modules in Remote racks 1

Remote racks W/rack optimized I/O 1

Local 1756 CNB Module 0

Remote 1756 CNB module connected to local CNB 1

1756 ENBT module 0

1756 DNB module 2

1756 DHRIO module 1

1771-ASB Remote I/O adapter 1

1756-MO2AE or 1756-MO8SE 3

Produced Tags: Produced tag and one consumer Each additional consumer

1 1

Messages 1 (while executing)

Block transfer messages 1 (while executing)

Programming terminal 1

OPC server (RS-Linx or TOPS) to W/W Tag Server ~5-20

System Total

Although the 1756-CNB module supports 64 connections, the total number of connections per segment (remote racks, intelligent cards, and similar) shall not exceed 40.


Communications


Use Belden Quad Shielded Coax #3092A cabling between ControNet nodes. Use of equivalent cable types is not allowed. Connectors shall be installed using Allen-Bradley’s ControlNet cabling kit and tools

For applications requiring excessive movement, (such as portable machinery) use High Flex Belden #3092F with a repeater between cable types to compensate for the difference in impedance. Use of equivalent cable types is not allowed.

The total allowable length of a segment using Belden Quad Shielded Coax #3092A cable depends upon the number of taps in your segment. There is no minimum trunk-cable section length requirement. The maximum allowable total length of a segment is 1,000 meters (3,280 feet) with two taps connected. Each additional tap decreases the maximum length of the segment by 16.3 meters (53 feet). The maximum number of taps allowed on a segment is 48 with a maximum length of 250 meters. Use the following equation.

Metric: Maximum segment length = 1000m - 16.3m X [number of taps - 2]

Imperial: Maximum segment length = 3280ft - 53.4ft X [number of taps - 2]

For example, if the segment requires 10 taps, the maximum segment length is 1000m (3280ft) - 16.3m (53.5ft) x [10 - 2]

Refer to Rockwell’s Publication CNET-IN002A-EN-P for complete ControlNet design and installation requirements.

Although ControlNet supports 99 nodes per segment, the total nodes on any one segment shall not exceed 40 for very lightly loaded networks and 20 for heavily loaded networks. Networks exceeding these limits shall be broken into multiple segments. Each segment should be divided into logical groupings and should have a reasonably balanced number of nodes per segment

Obtain permission to use repeaters to extend networks beyond the allowable length.

Node numbers shall be assigned during the design phase of a project and shall be included on an architecture drawing. Node numbering for each ControlNet segment shall be sequential starting with the local rack as node 01.


Communications


Systems requiring separate ControlNet peer-to-peer communications shall also number nodes sequentially starting with 01 in the order of overall process flow.

Figure 5: Typical ControlNet Network with Assigned Node Numbers

For systems that require unscheduled nodes, leave a gap in node numbering between scheduled and unscheduled devices. The number of spare nodes shall not exceed 5. Systems comprised of only scheduled nodes should avoid intentional gaps as these affect the network’s overall performance.

The NUT (network update time) shall be set to optimize the network and ControlNet bridge traffic. The default NUT of 5 ms should work for most applications. However, additional tuning might be required depending on project requirements.

The RPI (requested packet interval) for network nodes should be set for a binary multiple of the NUT (for example, if the NUT=5 ms, then the RPI must be set for 5, 10, 20, 40, 80, 160, and so on).

The target average for 1756-CNB utilization is 60% of the network’s bandwidth. Networks whose utilization peaks above 60% should decrease their NUT or adjust their RPI(s) to bring utilization under 60%.


Communications


4.4 DeviceNet DeviceNet has been used within GMI on a limited basis mainly interfacing with VFDs and Motor Control Centers (Allen-Bradley’s “IntelliCenters”). Applying DeviceNet beyond these applications requires permission.

The DeviceNet scanner module, 1756-DNB, should reside in the Local rack of the owning Logix controller and shall be assigned the node address of 0.

Node address 63 shall not be used. This node is reserved for new nodes that are yet to be configured.

Refer to DeviceNet reference sources for node limitations, cabling requirements, and other information.

4.5 Legacy Remote-I/O Systems Legacy Remote-I/O systems connect to Logix-55XX control systems using the 1756-DHRIO interface card. Channel A should be configured for DH+ communications to eliminate accidental disruption of Remote-I/O communications by plugging a programming terminal into the DIN connector which is electrically tied to channel A.

When installing and configuring a Remote-I/O network in a Logix-5000 control system, the baud rate should be set to 57.6, 115 or 230 Kbaud (depending on the device or series of the 1771-ASB).


Motion Control


4.6 Typical Physical Architecture Figure 6 depicts the relationships between base level control systems and the facilities administration network services. Specifically there are three separate LAN’s: the Plant LAN, the HMI LAN, and the PLC LAN. Six control systems are connected to the PLC LAN, each one depicting different I/O configurations covered in this document. It also shows an optional Logix-5000 gateway used to communicate to legacy networks and to serve as a data concentrator for the overall system.

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Figure 6: Typical Physical Architecture

5. Motion Control Use a SERCOS digital interface for all motion applications. An analog interface may be used in cases where the equipment being interfaced does not support SERCOS.

For digital interfacing, use Allen-Bradley’s 1756 MxxSE series SERCOS interface modules and Kinetics 6000 amplifiers.

For analog interfacing, use Allen-Bradley’s 1756-M02AE 2-axis servo module.


Version Control—Firmware Upgrades


Allen-Bradley’s SynchLink shall be used for all motion applications that are distributed across multiple Logix control systems and require sharing of axis information.

6. Version Control—Firmware Upgrades Firmware revisions for each family of Logix controllers within a facility, including Gateway processors, should be the same and should be kept current. The facility’s RSLogix software shall also be maintained at the same level as all processors.

Prior to upgrading firmware on a processor, ensure that a current back-up of the application exists and that adequate processor memory exists in order to successfully perform the upgrade.

NOTE: If the flash process fails, there is no recovery method. The processor must be sent to Allen-Bradley for repair. GMI recommends having a spare Logix processor of the same type and memory size available in case a failure occurs.

In some cases, upgraded processor firmware might also require upgrades for the software or firmware of other system components. Check with Rockwell prior to upgrading to determine what hardware and software might be affected. Refer to the following web site for upgrade requirements: http://support.rockwellautomation.com/controlflash/

http://support.rockwellautomation.com/controlflash/


References and Related Documents


7. References and Related Documents References and related documents include:

• CIS_401_ControlLogix_Programming_Standard

• CIS_305_Plant_Floor_Networking_Standard

• http://support.rockwellautomation.com/controlflash/

8. Acronyms and Abbreviations Acronym Definition

ASCII American Standard Code for Information Interchange

BCD Binary Coded Decimal, a type of number coding

BOOL Boolean, a data type

BOOTP Bootstrap Protocol, a method to assign an Ethernet device its network configuration from a host.

CAD Computer-Aided Design

CIS Control & Information Systems, a department of General Mills Engineering

COS Change of State

CSFD Control System Functional Description

DHCP Dynamic Host Control Protocol, a method to dynamically assign an Ethernet device its network configuration

DINT Double Integer, a data type representing a 32-bit integer

DNS Domain Name Server (or Service

ECB Equipment Control Block, A Foxboro block used to communicate with control equipment

FBC File Bit Comparison

FVNR Full-Voltage, Non-Reversing (applies to motors)

http://support.rockwellautomation.com/controlflash/


Acronyms and Abbreviations


Acronym Definition

HEX Hexadecimal

HMI Human-Machine Interface

I/O Input/Output

InSQL Industrial SQL, the brand name of the historian software GMI uses.

INT Integer, a data type representing a 16-bit integer

IP Internet Protocol

ISA Instrumentation, Systems, and Automation Society, (formerly the Instrument Society of America) an international standards organization.

LAN Local Area Network

MASS The brand name of the PLC backup and change management software GMI uses, sold by MDT.

MCR Master Control Relay

MDT The company that makes MASS, the PLC backup and change management software we use

MQIS Manufacturing & Quality Information System, a General Mills suite of software and systems to collect and report manufacturing data

NAD Network Application Development, a Wonderware tool to deploy InTouch applications over a network

NUT Network Update Time

OEM Original Equipment Manufacturer

P&ID Piping & Instrumentation Diagram

PID Proportional, Integral, Derivative (control)

PLC Programmable Logic Controller

R/I Resistance-to-Current

RPI Requested Packet Interval

RTD Resistance Temperature Detector, a type of temperature probe




Acronym Definition

RTS Real-Time Sampling

SCADA Supervisory Control And Data Acquisition

SERCOS Serial Real-time Communication System, method used to communicate with motion control equipment

SFC Sequential Function Chart, one of several PLC programming languages

SQL Structured Query Language, a method for querying a database

UDT User-Defined Type

UPS Uninterruptible Power Supply

URL Uniform Resource Locator, an address that specifies the location of a file on the Internet

VHSC Very High Speed Counter

VFD Variable Frequency Drive

WAN Wide Area Network

XML Extensible Markup Language, a format for structured document interchange on the Web

Abbreviation Definition

Hz Hertz

ma milliampere

ms millisecond

VAC AC (alternating current) voltage

VDC DC (direct current) voltage




8.1 PLC Instruction Mnemonics Mnemonics Definition

AFI Always False Instruction

BSL Bit Shift Left

BSR Bit Shift Right

BTD Bit Field Distribute

JMP Jump

JSR Jump, Shift, and Return

MSG Message

RTO Retentive Timer On

SQI Sequencer Input

SQL Sequencer Load

SQO Sequencer Output

TND Temporary End

TON Timer On

UID User Interrupt Disable

UIE User Interrupt Enable

MCR Master Control Relay


Revision Summaries


9. Revision Summaries Enter information in these tables to track revisions to the master document.

NOTE: In the Entry column, enter your information between the dashes. The entries automatically update matching document properties.

Document Property Entry

Master Owner -Mark Chatterton-

Master Revision Number -1-

Master Revision Date -10/18/05-

Increment revision numbers by one.

Revision Number

Revision Date

Revision Owner

Revision Summary (Brief description of major changes)

0 3/28/2005 Mark Chatterton Original Development

1 10/19/2005 Mark Chatterton Sec. 3.3: Added sinking/sourcing DC input/output card preference.

2 12/7/2007 Mark Chatterton Retitled document to indicate it is a standard not a guideline.


Revision Summaries


9.1 Plant Customization Tracking Enter information in these tables to track revisions to plant customized documents.

NOTE: In the Entry column, enter your information between the dashes. The entries automatically update document properties.

Document Property Entry

Plant Code -XXX-

Plant Owner -Enter Name-

Plant Revision Number -0.0-

Plant Revision Date -3/29/05-

Use the following format for the Plant Revision Number:

<Master Revision Number>.<Plant Revision Number>

Revision Number

Revision Date

Revision Owner

Revision Summary (Brief description of major changes)

0 3/28/2005 Karen Murri Template Development