CONTROLEDGE TRANSITION

Transcription

1 CONTROLEDGE TRANSITION RELEASE Rockwell PLC to ControlEdge PLC Migration Guide CDDOC-X533-en-100A December 2017

2 Disclaimer This document contains Honeywell proprietary information. Information contained herein is to be used solely for the purpose submitted, and no part of this document or its contents shall be reproduced, published, or disclosed to a third party without the express permission of Honeywell International Sàrl. While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a purpose and makes no express warranties except as may be stated in its written agreement with and for its customer. In no event is Honeywell liable to anyone for any direct, special, or consequential damages. The information and specifications in this document are subject to change without notice. Copyright Honeywell International Sàrl - 2 -

3 Contents 3 Chapter 1 - About this guide Scope Revision history Intended audience 6 Chapter 2 - Preface Purpose Conversion versus Translation Terminology PLC Conversion Phases Consulting for Migration and Conversion Site Survey and Follow Up Hardware Conversion Software Conversion System/ Product Training 10 Chapter 3 - Hardware Conversion Introduction PLC-5, SLC 500 and and Memory PLC-5 Controllers to SLC 500 Controllers to PLC-5 to Maximum Memory SLC 500 to Maximum Memory PLC-5, SLC 500 and I/O Chassis Dimensions of PLC-5, SLC 500 Chassis mount and Chassis mount Dimension Comparison between PLC-5 I/O Chassis and ControlEdge PLC CPM Chassis Dimension Comparison between SLC 500 I/O Chassis and ControlEdge PLC CPM Chassis PLC-5, SLC 500 and I/O Modules PLC-5, SLC 500 I/O Channels for controller Comparison between PLC-5 and Maximum Total I/O Channels for controller Power Supply PLC-5 Power Supply SLC 500 Power Supply

4 3.6.3 Power Supply Network Communication EtherNet/IP Network Communication Network Topology 33 Chapter 4 - Features and Architecture Key Features of Architectural differences between PLC-5, SLC 500 and 36 Chapter 5 - Converting the Program Structure Function POUs Function Block POUs Program POUs Programing languages in Tasks Variables Scope of Variables Local variables Global variables Symbolic Variables Directly represented and located variables 39 Chapter 6 - Converting the Data PLC-5, SLC 500 and files identifying data table values I/O Addressing in PLC-5, SLC 500 and Converting Input (I) and Output (O) data Converting the Binary (B) file type Converting the Timer (T) file type Converting the Status (S) file type Converting the Integer (N) file type Converting the Floating Point (F) file type Converting the String (ST) file type Unsupported Data types for Converting the Control (R) file type

5 6.9.2 Converting the Counter (C) file type 50 Chapter 7 - Conversion of System Software and Standard Functions Introduction PLC5 Instruction to ControlEdge Instruction Mapping Relay-Type Instruction Timer Instructions: Using Counters: Compare Instructions: Compute Instructions: Conversion Instructions Bit Modify and Move Instruction Shift Register Instructions: Program Control Instructions ASCII Instructions Unsupported functions of PLC Unsupported functions of SLC Chapter 8 - Appendix A PLC-5/SLC500 I/O Modules and their Equivalents

6 CHAPTER 1 ABOUT THIS GUIDE 1.1 Scope This Application Conversion Guide contains essential information on conversion from PLC-5 and SLC 500 to. This guide compares all the details between PLC-5, SLC 500 and its equivalent of for convenience in converting the hardware. 1.2 Revision history Revision Supported Release A Date December 2017 Description Document released to support R100 release of ControlEdge Transition. 1.3 Intended audience This guide is intended for Honeywell Engineers and Channel Partners who use ControlEdge PLC CPM. This guide is also for those who intend to migrate from PLC-5, SLC 500 to ControlEdge PLC CPM

7 CHAPTER 2 PREFACE 2.1 Purpose This document provides guidance for users who have used legacy control systems based on Rockwell Automation PLC-5 and SLC500, and desire to migrate to. This manual helps to adopt best practice and to avoid common mistakes, while converting projects to. 2.2 Conversion versus Translation An understanding of difference between conversion and translation is necessary to avoid common mistakes. Translation is simply replacing a single instruction or sequence on one system by another instruction or sequence on the other system. This is done on a line by line base. Conversion on the other hand, focuses on the higher-level design of the application and the knowledge of both the technology and the target system. The conversion uses translation, but is not limited by a strict line by line rewriting of the existing code. For instance, user may benefit from choosing a different programming language, utilizing different programming techniques, and designing a different scheduling scheme to solve the same task. So, conversion is performed in a context of a higherlevel design and knowledge of the strengths of the ControlEdge system. Conversion provides the freedom to solve a certain task in another way to fully utilize the features of the new system

8 Chapter 2 - Preface 2.3 Terminology Table 2.1 Terms used in the documents with description Terms AI AO ControlEdge Builder ControlEdge PLC CPM ControlEdge Transition CPM DI DO DH EPM Expansion I/O rack FDM FDM Express HART-IP Description Analog Input Analog Output An integrated configuration tool to design, configure, program and maintain ControlEdge controllers. The engineering software that provides automatic translation of source PLC system s ladder logic and configurations to their Honeywell equivalents. An application migration tool for migration of PLC to ControlEdge PLC. Control Processor Module Digital Input Digital Output Data Highway Expansion Processor Module I/O rack with EPM installed Field Device Manager Field Device Manager Express HART-IP extends the HART protocol to Ethernet connected nodes. This facilitates host level systems and asset management applications to access and integrate measurement and device diagnostics information from HART-enabled field devices using the existing plant networking infrastructure. I/O Network Network between CPM and expansion I/O rack IPSec Local I/O Rack Modbus OPC UA PI POU QTR RTP RTU Redundant CPM Rack Redundant Controller Rack SCADA UIO Internet Protocol Security I/O rack with CPM installed (non-redundant) A communication protocol supports communication between Modbus slave devices and Modbus master devices via serial port or Ethernet port. An industrial machine-to-machine (M2M) communication protocol is developed by the OPC Foundation, which provides a path forward from the original OPC communications model (namely the Microsoft Windows only process exchange COM/DCOM) to a cross-platform service-oriented architecture (SOA) for process control, while enhancing security and providing an information model. Pulse Input Programming Organization Unit Quantity Transaction Record Remote Terminal Panel Remote Terminal Unit Rack with 2 CPMs installed Redundant Controller Rack with 2 Power supply slots, 2 CPM slots. Supervisory Control and Data Acquisition Universal Input/Output Module - 8 -

9 Chapter 2 - Preface 2.4 PLC Conversion Phases Legacy systems are often hard to repair and difficult to support. This increases the risk of unplanned downtimes leading to a decrease in productivity. The cost involved in getting such a system back up and running again can be high. ControlEdge Transition helps to convert legacy configuration to its equivalent recognizable format. ControlEdge Builder helps to modify the ladder logic that will be downloaded into ControlEdge Processor. Honeywell uses both ControlEdge Transition and ControlEdge Builder to process into separate phases that propel the migration process. For more information refer to ControlEdge Transition Online Help Consulting for Migration and Conversion The idea to migrate from one platform to another should solve the query like the focus of the migration. The focus of the migration can be only migrating the controller, periphery, single machine, a manufacturing line or a whole plant. The time and the efficiency of the present system also be explained in this phase. To clear all these queries a site survey check list is provided in ControlEdge Transition Site Survey and Follow Up This is the second step following consulting for migration and conversion. A site survey is conducted to get detailed list of the installed set up. The information acquired is used to overcome the limitation of the original concept and enhance it. The result will be discussed with the user and engineer. The checklist for the site survey is available in the ControlEdge Transition Hardware Conversion After the site survey and loops of follow ups, effective, efficient and appropriate ControlEdge hardware is identified based on the existing components. The process of conversion is then put forward. The Bill of Material in ControlEdge Transition tool provides legacy hardware ControlEdge PLC CPM will be the default hardware after the conversion Software Conversion The software conversion is completed through a tool which converts legacy software Configuration to the. The tool for migrating the legacy files is ControlEdge Transition. The legacy system files are converted as XML output which if required can directly be imported to ControlEdge Builder for loading into the processor

10 Chapter 2 - Preface System/ Product Training Understanding the new system, efficiently operating the system and maintenance is essential for a complete and successful migration. To make the task easy, Honeywell offers product and system training for the new system to familiarize the user, in operation and maintenance of the system. To schedule a conversion project, or learn more about the services offered, contact your local Honeywell sales office or authorized distributor. NOTE All the above-mentioned services are subject to extension, cancellation or local availability. The costs for some of these services are on a case-by-case basis, depending on complexity and project size

11 CHAPTER 3 HARDWARE CONVERSION 3.1 Introduction This chapter provides the user with the required guidance to select the best hardware as a replacement for the existing Rockwell equipment. Users can refer to the figures and tables sections below to understand the difference between PLC-5, SLC 500 and its ControlEdge equivalents and the way conversions of the hardware perform

12 Chapter 3 - Hardware Conversion 3.2 PLC-5, SLC 500 and and Memory PLC-5 Controllers to PLC-5 controllers come with different memory sizes and network connections. The PLC-5 controllers offer different communication options, while maintaining the same functions. has a rack-based modular hardware design with control processor modules that plug onto different rack options depending on system configuration requirement. It is tightly integrated with Honeywell s market leading Field Device Manager (FDM) and FDM Express The table below provides a complete list of Rockwell PLC-5 Controllers and its respective catalogue number, and a possible replacement with catalogue number. Table 3.1 PLC-5 Controllers to Equivalents PLC 5 Category Catalogue Number ControlEdge Catalogue Number 1785-L11B, 1785-L20B, Enhanced PLC-5 Controllers 1785-L30B, 1785-L40B, 1785-L60B, 1785-L80B 1785-L20E, Ethernet PLC-5 Controllers 1785-L40E, 1785-L80E 1785-L20C15, 1785-L40C15, 900CP ControlNet PLC-5 Controllers 1785-L46C15 Protected, 1785-L80C L26B, 1785-L46B, Protected PLC-5 Controllers 1785-L46C15 Protected, 1785-L86B NOTE PLC-5 Controller supports Ethernet/IP, ControlNet, DeviceNet, Serial Network, Data Highway Plus, Remote I/O and Universal Remote I/O. does not have one to one allocation for PLC communication. It supports two types of communication namely, MODBUS TCP and OPC UA

13 Chapter 3 - Hardware Conversion SLC 500 Controllers to The SLC 500 controllers offer a wide range of choices in memory, I/O capacity, instruction set, and communication ports to allow user to tailor a control system to the user s exact application requirements. These products have a strong history to rely upon which covers hundreds of thousands of installations in a broad range of applications. The table below provides a complete list of Rockwell SLC 500 Controllers and a possible ControlEdge PLC CPMs' replacement. Table 3.2 SLC 500 Controllers to Equivalents Controller Catalogue Number SLC 5/ L L514 SLC 5/ L L531 SLC 5/ L L L CP1 SLC 5/ L L L551 SLC 5/ L L553 Catalogue Number 900CP NOTE SLC 500 Controller supports Ethernet/IP, ControlNet, DeviceNet, Serial Network, Data Highway Plus, Remote I/O, DH-485 Network and Universal Remote I/O. ControlEdge Controller does not have one to one allocation for PLC communication. It supports two types of communication namely, MODBUS TCP and OPC UA

14 Chapter 3 - Hardware Conversion PLC-5 to Maximum Memory Different Rockwell s PLC-5 Controllers have maximum memory from 8000 to words. has maximum memory as 256MB for programming where 5 MB is open for user. The table below provides Rockwell s PLC-5 Controller and s data for Max Memory Words. Table 3.3 Comparison between PLC-5 and Max Memory PLC 5 Category Enhanced PLC-5 Controllers Ethernet PLC-5 Controllers ControlNet PLC-5 Controllers Protected PLC-5 Controllers Catalogue Number 1785-L11B, 1785-L20B, 1785-L30B, 1785-L40B, 1785-L60B, 1785-L80B 1785-L20E, 1785-L40E, 1785-L80E 1785-L20C15, 1785-L40C15, 1785-L46C15 Protected, 1785-L80C L26B, 1785-L46B, 1785-L46C15 Protected, 1785-L86B Max Memory (words) 8000, 16000, 32000, 48000, 64000, , 48000, , 48000, 48000, , 48000, 48000, ControlEdge PLC CPM 900 CP1 Max Memory (MB) 256MB memory for programming. (5MB open for user)

15 Chapter 3 - Hardware Conversion SLC 500 to Maximum Memory SLC 500 Controllers have maximum memory of 1000 up to words depending upon the catalogues. has maximum memory as 256MB for programming where 5 MB is open for user. The table below provides Rockwell s PLC-5 Controller and s data for Max Memory Words. The table below provides SLC 500 Controller and s data. Table 3.4 Comparison between SLC 500 and ControlEdge Max Memory SLC500 Catalogue Number SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 L511, L514 Max Memory (Words) L L531, L532, L533 L541, L542, L543 L551, L552, L , 16000, , 32000, , 32000, ControlEdge PLC CPM 900 CP1 Max Memory (MB) 256MB memory for programming. (5MB open for user)

16 Chapter 3 - Hardware Conversion 3.3 PLC-5, SLC 500 and I/O Chassis The PLC-5 programmable controller requires a chassis to contain the various modules. Chassis are available in sizes of 1, 2, 4, 8, 12, and 16 module slots. There are some controllers which supports redundant power supply in PLC-5. NOTE A Chassis in PLC-5 is normally a full frame to support the CPU I/O. A Rack is a pluggable component limited in length only by the maximum I/O of the PLC which is manufacturer dependent. SLC 500 controllers are available in sizes of 4,7, 10, 13 module slots. They do not have redundant power supply option. In, I/O Slot provides the carrier for I/O modules. The I/O Slot Rack also provides one CPM/EPM slot for control of local I/O modules. I/O Slot Rack supports various lengths for customers. There are 5 types of I/O slot racks. Among them, the 8 I/O slot rack and 12 I/O slot rack have redundant power supply option, and power status module is required. The other three have 4, 8, 12 I/O slots and have non-redundant power supply option. The table below lists the different I/O Slot Rack available for. Table 3.5 ControlEdge I/O Rack Honeywell and/or Supplier Part Number (Optional)Model Number 900RR R R R R08R R12R-0200 Part Description Redundant CPM Rack (Assembly) 4 I/O Slot Rack Non-Redundant Power (Assembly) 8 I/O Slot Rack Non-Redundant Power (Assembly) 12 I/O Slot Rack Non-Redundant Power (Assembly) 8 I/O Slot Rack Redundant Power (Assembly) 12 I/O Slot Rack Redundant Power (Assembly) The figures below are of all types of I/O slot racks used in. Figure 3.1 Redundant CPM Rack, Assembly

17 Chapter 3 - Hardware Conversion Figure Slot I/O Rack with Non-Redundant Power supply Figure Slot I/O Rack with Non-Redundant Power supply Figure Slot I/O Rack with Non-Redundant Power supply Figure Slot I/O Rack with Redundant Power supply

18 Chapter 3 - Hardware Conversion Figure Slot I/O Rack with Redundant Power supply Dimensions of PLC-5, SLC 500 Chassis mount and Chassis mount Figure 3.7 PLC-5 Controller-Resident chassis mounted AREA RESERVED FOR DISCONNNECT, TRANSFORMER, CONTROL RELAYS, MOTOR STARTERS, OR OTHER USER DEVICES 153 mm (6 in.) 51 mm (2 in.) 102 mm (4 in.) 102 mm (4 in.) 51 mm (2 in.) WIRING DUCT 153 mm (6 in.)

19 Chapter 3 - Hardware Conversion Figure 3.8 PLC-5 Remote I/O and Extended-local I/O four chassis mounted in two rows and two columns AREA RESERVED FOR DISCONNNECT, TRANSFORMER, CONTROL RELAYS, MOTOR STARTERS, OR OTHER USER DEVICES 153 mm (6 in.) 102 mm (4 in.) 51 mm (2 in.) 153 mm (6 in.) 51 mm (2 in.) WIRING DUCT 102 mm (4 in.) 102 mm (4 in.) WIRING DUCT 153 mm (6 in.) Figure 3.9 SLC slot Modular Chassis FRONT VIEW LEFT SIDE VIEW 70 (2.76) 11 DIA (0.433) 5.5 DIA (0.217) 1.0 (0.04) (3) 158 mm (6.22 in.) (2) (1) 140 (5.51) 140 (5.51) 171 (6.73) 171 (6.73) 14 (0.55) 5.5 DIA (0.217) 215 (8.46) 235 (9.25) 45 DIA (1.77) 145 (5.71) 261 (10.28) mm (in.) (1) DIMENSIONS FOR 1746-P1 POWER SUPPLY (2) DIMENSIONS FOR 1746-P2, -P3, -P5, -P6, -P7 POWER SUPPLIES (3) DIMENSIONS FOR 1746-P4 POWER SUPPLY

20 Chapter 3 - Hardware Conversion Figure 3.10 SLC slot Modular Chassis FRONT VIEW LEFT SIDE VIEW 175 (6.89) 11 DIA (0.433) 5.5 DIA (0.217) 1.0 (0.04) (3) 158 mm (6.22 in.) (2) (1) 140 (5.51) 171 (6.73) 171 (6.73) 140 (5.51) 14 (0.55) 5.5 DIA (0.217) 320 (12.60) 340 (13.39) 45 (1.77) 145 (5.71) 366 (14.41) mm (in.) (1) DIMENSIONS FOR 1746-P1 POWER SUPPLY (2) DIMENSIONS FOR 1746-P2, -P3, -P5, -P6, -P7 POWER SUPPLIES (3) DIMENSIONS FOR 1746-P4 POWER SUPPLY Figure 3.11 SLC slot Modular Chassis FRONT VIEW LEFT SIDE VIEW 1.0 (0.04) 11 DIA (0.433) 5.5 DIA (0.217) 140 (5.51) 55 (2.17) (3) 158 mm (6.22 in.) (2) (1) 140 (5.51) 171 (6.73) 140 (5.51) 5.5 DIA (0.217) 140 (5.51) 435 (17.13) 14 (0.55) 145 (5.71) 455 (17.91) 481 (18.94) mm (in.) (1) DIMENSIONS FOR 1746-P1 POWER SUPPLY (2) DIMENSIONS FOR 1746-P2, -P3, -P5, -P6, -P7 POWER SUPPLIES (3) DIMENSIONS FOR 1746-P4 POWER SUPPLY

21 Chapter 3 - Hardware Conversion Figure 3.12 SLC slot Modular Chassis FRONT VIEW 11 DIA (0.433) 5.5 DIA (0.217) 105 (4.13) 140 (5.51) 5.5 DIA (0.217) (3) 158 mm (6.22 in.) (2) 140 (5.51) (1) 171 (6.73) 14 (0.55) 5.5 DIA (0.217) 140 (5.51) 540 (21.26) 560 (22.05) 586 (23.07) mm (in.) (1) DIMENSIONS FOR 1746-P1 POWER SUPPLY (2) DIMENSIONS FOR 1746-P2, -P3, -P5, -P6, -P7 POWER SUPPLIES (3) DIMENSIONS FOR 1746-P4 POWER SUPPLY LEFT SIDE VIEW 1.0 (0.04) 140 (5.51) 171 (6.73) 145 (5.71) Figure 3.13 Chassis size (dimension) of Figure 3.14 ControlEdge I/O Rack with Redundant Power Supply Dimension Comparison

22 Chapter 3 - Hardware Conversion Dimension Comparison between PLC-5 I/O Chassis and Chassis The table below compares the dimensions of PLC-5 I/O Chassis and I/O Chassis. I/O Chassis occupies smaller space than PLC-5 I/O Chassis. Table 3.6 PLC-5 I/O Chassis and ControlEdge PLC I/O Chassis Comparison

23 Chapter 3 - Hardware Conversion PLC-5 Cat no A1B A2B Description Chassis for 1771 I/O Module Chassis for 1771 I/O Module No. Dimensions I/O Approx (in.) Slots HxWxD 4 Slots 8 Slots A3B A3B Chassis for 1771 I/O Module Chassis for 1771 I/O Module 12 Slots 12 Slots ControlEdge PLC Cat no. 12.4x9.0x R x 14.0 x x 19.0 x x 19.0 x R R08R R R12R Description 4 I/O slot Rack 8 I/O slot Rack 8 I/O slot Rack (redundant power support) 12 I/O slot Rack 12 I/O slot Rack (redundant power support) No. I/O Slots 4 Slots 8 Slots 8 Slots 12 Slots 12 Slots Dimensions Approx (in.) HxWxD 5.4x10.5x x16.5x x20.9x x22.5x x26.9x A4B Chassis for 1771 I/O Module 16 Slots 12.4 x 24.0 x PSC AM AM2 Power Supply Chassis I/O chassis with integral remote I/O adapter and power supply I/O chassis with integral remote I/O adapter and power supply 4 Slots 1 Slot 1 Slot 12.2 x 8.0 x x 2.7 x x 5.1 x NOTE There is no one-one equivalent it has be substituted with different Chassis

24 Chapter 3 - Hardware Conversion Dimension Comparison between SLC 500 I/O Chassis and Chassis The table below compares the dimensions of SLC 500 I/O Chassis and ControlEdge PLC Chassis. Chassis has a slot for Redundant CPM Rack which edges it from SLC I/O and 12 I/O slots racks have redundant power supply option, and power status module is required for Chassis. The SLC 1746 modular chassis houses the processor or I/O adapter module and the I/O modules. Table 3.7 CPM Comparison of Dimension between SLC 500 I/O Chassis and ControlEdge PLC SLC 500 Cat no A4 Description 4-Slot Chassis A A A13 7-Slot Chassis 10-Slot Chassis 13-Slot Chassis No. Dimensions I/O Approx (in.) Slots HxWxD Cat no x 6.8 x R x 6.8 x 5.8 in 15.9 x 6.8 x 5.8 in 20.1 x 6.8 x 5.8 in 900CP Description No. I/O Slots Dimensions Approx (in.) HxWxD 4 I/O slot Rack 4 Slots 5.4x10.5x6.0 Redundant CPM Rack R R08R R R12R Slot 5.4x10.3x6.0 8 I/O slot Rack 8 Slots 5.4x16.5x6.0 8 I/O slot Rack 8 (redundant Slots power support) 12 I/O slot Rack 12 Slots 12 I/O slot Rack 12 (redundant Slots power support) 5.4x20.9x x22.5x x26.9x

25 Chapter 3 - Hardware Conversion 3.4 PLC-5, SLC 500 and I/O Modules An I/O group is an addressing unit that corresponds to an input image-table word (16 bits) and an output image-table word (16 bits). An I/O group can contain up to 16 inputs and 16 outputs; and it can occupy 2-, 1-, or 1/2-module slots for addressing purposes. An I/O rack is an addressing unit that corresponds to 8 input image-table words and 8 output image-table words. A rack contains 8 I/O groups. Depending on I/O chassis size and I/O group size, an I/O rack can occupy a fraction of an I/O chassis, a full I/O chassis, or multiple I/O chassis. support various I/O Modules catalogues. PLC-5 supports 67 catalogues and SLC 500 supports 42 I/O modules catalogue. supports 6-8 catalogues. However, has two distinct advantages among its competitors: It has Universal I/O (UIO) which can act as any channel based on the configuration of the channel. HART enabled Universal I/O for greater configuration flexibility. For more information on PLC-5 to equivalent modules, refer to Appendix A

26 Chapter 3 - Hardware Conversion 3.5 PLC-5, SLC 500 I/O Channels for controller Comparison between PLC-5 and Maximum Total I/O Channels for controller PLC-5 controllers come with different I/O channels. It varies from 512 any mix or 384 in out to 3072 any mix or 3072 in out. In, 4608 I/O Channels could be assigned in one (pair) PLC controller. (The value 4608 comes from full 32 channels used in all 144 Digital modules). Maximum 500 Digital I/O channels can run at 50ms loop latency time in one (pair) PLC Controller. does not guarantee all points with 50ms loop latency time once beyond 500 Digital I/O Points. The table below provides PLC-5 Controller and s data for Max Total I/O Channels

27 Chapter 3 - Hardware Conversion Table 3.8 Comparison between PLC-5 and Max Total I/O Channels PLC-5 Category Enhanced PLC 5 Controllers Ethernet PLC 5 Controllers ControlNet PLC 5 Controllers Catalogue Number 1785-L11B, 1785-L20B, 1785-L30B, 1785-L40B, 1785-L60B, 1785-L80B 1785-L20E, 1785-L40E, 1785-L80E L20C15, L40C15, L40C15, L46C1 Protected, Max Total I/O Channels for Controller 512 any mix or 384 in out, 512 any mix or 512 in out, 1024 any mix or 1024 in out, 2048 any mix or 2048 in out, 3072 any mix or 3072 in out, 3072 any mix or 3072 in out 512 any mix or 512 in out, 2048 any mix or 2048 in out, 3072 any mix or 3072 in out 512 any mix or 512 in out (complement), 2048 any mix or 2048 in out (complement), 2048 any mix or 2048 in out, 2048 any mix or 2048 in out (complement), 3072 any mix or 3072 in out (complement) ControlEdge PLC CPM 900 CP1 Max Total I/O Channels for Controller 4608 I/O Channels could be assigned in one (pair) PLC controller. (The value 4608 is comes from full 32 channels used in all 144 Digital modules). 1 Maximum 500 Digital I/O channels can run at 50ms loop latency time in one (pair) PLC Controller L80C15 Protected PLC 5 Controllers 1785-L26B, 1785-L46B, L46C15 Protected, 1785-L86B 512 any mix or 512 in out (complement), 2048 any mix or 2048 in out (complement), 2048 any mix or 2048 in out (complement), 3072 any mix or 3072 in out (complement) NOTE 1 does not guarantee all points with 50ms loop latency time once beyond 500 Digital I/O Points

28 Chapter 3 - Hardware Conversion Table 3.9 Channels Comparison between SLC 500 and Max Total I/O SLC500 Catalogue Number SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 L511, L514 L524 L531, L532, L533 L541, L542, L543 L551, L552, L553 Max Total ControlEdge I/O Channels Max Total I/O Channels for Controller PLC CPM for Controller 4 to to CP I/O Channels could be assigned in one (pair) PLC controller. (The value 4608 is comes from full 32 channels used in all 144 Digital modules). 1 Maximum 500 Digital I/O channels can run at 50ms loop latency time in one (pair) PLC Controller. NOTE 1 will not guarantee all points with 50ms loop latency time once beyond 500 Digital I/O Points

29 Chapter 3 - Hardware Conversion 3.6 Power Supply PLC-5 Power Supply The 1771 power supplies provide 5V dc power directly to the chassis backplane. These power supplies occupy one or two slots in a The table below covers majority of the PLC-5 hardware. Redundancy is available for greater availability. Table 3.10 PLC-5 power supply Cat No. Input Voltage, Nom 1770-P1 120V ac or 220/240V ac Backplane Output Current Real Input Power, Max Location of Slots N/A 20W Stand Alone 1771-P4S 120V ac 8 +5V dc 59W 1771-P5 24V dc 8 +5V dc 57W 1771-P5E 24V dc (has selectable power-loss 8 +5V dc 57W delay) 1771-P4S1 100V ac 8 +5V dc 56W 1771-P6S1 200V ac 8 +5V dc 56W 1771-P4R 120V ac 8 +5V dc 59W 1771-P6R 220V ac 8 +5V dc 59W 1771-P6S 220V ac 8 +5V dc 56W 1771-P PS7 120V ac or 220V ac 120V ac or 220V ac 1771 Chassis, 1 slot 1771 Chassis, 2 slots 1771 Chassis, 2 slots 1771 Chassis, 1 slot 1771 Chassis, 1 slot 1771 Chassis, 1 slot 1771 Chassis, 1 slot 1771 Chassis, 1 slot 16 +5V dc 108W Standalone 16 +5V dc (total output power including user is 100 W max) 171W 1771-P10 125V dc 51W Standalone 1771 Chassis, 2 slots

30 Chapter 3 - Hardware Conversion SLC 500 Power Supply The SLC system features three AC power supplies and four DC power supplies. For AC power supplies, 120/240 volt selection is made by placing the jumper to match the input voltage. SLC power supplies have an LED that illuminates when the power supply is functioning properly. Table 3.11 SLC 500 power supply Cat No. Line Voltage User Current Capacity Inrush Current, max P / V AC, V DC 20 A Hz 1746-P / V AC, V DC 20 A Hz 1746-P V DC - 20 A 1746-P / V AC, 1 24V DC (1) 45 A Hz 1746-P V DC V DC 20 A 1746-P V DC V DC 20 A 1746-P V DC, isolated Power Supply There are two variants of power supply i.e. 58W 24VDC and 110/240VAC on. Table /240VAC Power Supply (900P ) Cat No. 900P P Voltage 90 to 264 V AC, 47 to 63 Hz 21 to 29V DC Power Supply Hold up time 115V AC, 60HZ maximum Load 20 24V DC, maximum Load Inrush Current Input rating Output rating 40 Amps peak-topeak for 120 ms at 130 VA 58W 240 V AC 30A for 29V DC 72.5W 58W NOTE The table is not one to one comparison. It has data of the variants on power supply

31 Chapter 3 - Hardware Conversion 3.7 Network Communication PLC-5 allows information exchange between a range of devices and computing platforms and operating systems through EtherNet/IP, ControlNet, DeviceNet, Serial Network, Data Highway Plus, Remote I/O. SLC 500 allows information exchange between a range of devices and computing platforms and operating systems through EtherNet/IP, ControlNet, DeviceNet, Data Highway Plus, DH-485, Universal Remote I/O and Serial Networks. allow information exchange between a range of devices and computing platforms and operating systems through MODBUS TCP and OPC UA. does not have mapping for each network however Supports MODBUS TCP and OPC UA EtherNet/IP The TCP/IP Ethernet network is a local-area network designed for the high-speed exchange of information between computers and related devices. With its high bandwidth (10 Mbps to 100 Mbps), an Ethernet network allows many computers, controllers, and other devices to communicate over vast distances. An Ethernet network provides enterprise-wide systems access to plant-floor data. With an Ethernet network, user can maximize communication between a wide variety of equipment. This network uses TCP and UDP over an IP based network. It allows for general I/O control, data exchange between controllers (C2C), connectivity to enterprise systems, integration of safety devices and motion control systems. ControlNet The ControlNet network is an open, high-speed, deterministic network used for transmitting timecritical information. It provides real-time control and messaging services for peer-to-peer communication. A ControlNet network combines the capabilities of existing Universal Remote I/O and DH+ networks. User can connect a variety of devices to this network, including personal computers, controllers, operator interface devices, drives, I/O modules. ControlNet networks also support the transfer of non-critical data, such as program uploads, downloads, and messaging. This real-time control network provides transport methods for time- critical I/O and interlocking data as well as for programming and configuration data. Typical applications include: General I/O control Data exchange among controllers (C2C) DeviceNet Backbone to multiple distributed DeviceNet networks The DeviceNet network is an open, low-level communication link that provides connections between simple industrial devices like sensors and actuators to high-level devices like controllers. This open network offers inter-operability between like devices from multiple vendors, based on standard Controller Area Network (CAN) technology. With a design focused on low volume data from and to devices DeviceNet offers real time operation for distributed devices with few I/O points, data and power over the same physical media, direct connection of devices

32 Chapter 3 - Hardware Conversion Serial Network The PLC-5 serial port is configurable for RS-232, RS-423, or RS-422A and SLC 500 SLC 5/03, SLC 5/04, and SLC 5/05 processors have a serial port which is configurable for RS-232 compatible serial communication compatible serial communication. To communicate using the DF1 protocol, such as modems, communication modules, programming workstations, or other serial devices, send and receive ASCII characters, such as ASCII terminals, bar-code readers, and printers and to communicate using DH-485 protocol use the serial port to connect devices. Data Highway Plus The Data Highway Plus (DH+) network is a local area network designed to support remote programming and data acquisition for factory-floor applications. User can also use DH+ communication modules to implement a small peer-to-peer network. User can use a DH+ network for data transfer to other controllers or high-level computers and as a link for programming multiple controllers. PLC-5 and SLC 500 controller can communicate over a DH+ network with other controllers and with a workstation. The DH+ network supports daisy-chain and trunkline-dropline configurations. Remote I/O This I/O has strength and versatility. The remote I/O network supports many third-party devices. Typical applications range from simple I/O links with controllers and I/O, to links with a variety of other devices. User connect devices through remote I/O adapter modules or built-in remote I/O adapters. DH-485 Network (Only for SLC-500) The DH-485 communication network allows devices on the plant floor to share information. Through the network, application programs can monitor process and device parameters and status, including fault and alarm detection, perform data acquisition., perform supervisory control functions and upload/download PLC programs over the network. Universal Remote I/O (RIO) Network The Universal Remote I/O network supports several products. In addition to 1746 I/O, the Universal Remote I/O network supports numerous third-party devices. The applications it supports range from simple I/O links with controllers and I/O, to links with a wide variety of other types of devices. User connect devices through remote I/O adapter modules or builtin remote I/O adapters. Using the Universal RIO Network instead of direct-wiring a device over a long distance to a local I/O chassis reduces installation, start-up, and maintenance costs by placing the I/O closer to the sensors and actuators Network Communication MODBUS TCP A Modbus Messaging Implementation Guide provided by Schneider Automation outlines a modified protocol specifically for use over TCP/IP. MODBUS TCP is equal to the PLC Controller (pair) quantity which enabled MODBUS TCP protocol

33 Chapter 3 - Hardware Conversion Item Device Function Multi-Master support Ethernet support Serial support Slave connection per CPM Master connection per CPM Specification Master and Slave Yes Maximum Number of Registers per CPM as slave 8000 Ethernet Network Connection OPC UA MODBUS TCP, Configurable TCP port number Via device server/protocol converter 64 per port 16 per port 10/100 Base-T, RJ-45 OPC is implemented in server/client pairs. The OPC server is a software program that converts the hardware communication protocol used by a PLC into the OPC protocol. An OPC UA server shall support 10 clients. Item Device Function Generic OPC information models Specification Server and Client Data Access (DA) Technology specific information models PLCOpen V1.0 Number of OPC UA Client per CPM 10 Number of OPC UA Server per CPM 10 Number of variable for one CPM acting as OPC UA Server 2000 Number of variable for one CPM acting as OPC UA Client 500 MDIS Server support Yes NOTE Connects to Human-Machine Interface (HMI) through MODBUS and OPC UA protocols. UOC does not operate as an OPC UA client. Therefore, there is no specification for a maximum client point count Network Topology The topology of a network is simply arrangement of computers and devices on the wire, and how they pass their information. There are several types of network topology. uses two types of network topology: Ring Topology Star Topology Ring Topology The workstations are connected in a closed loop configuration in ring topology. Adjacent pairs of workstations are directly connected. Other pairs of workstations are indirectly connected, the data passing through one or more intermediate nodes. The formation resembles a ring structure thus the name Ring Topology is given to this type of network. Figure 3.15 Ring Topology

34 Chapter 3 - Hardware Conversion The advantages of Ring Topology are: Cable faults are easily located, making troubleshooting easier Ring networks are easy to install Star Topology In Star Topology, all computers/devices connect to a central device called central hub. Each host or computer is individually connected to the central hub. The formation resembles a star thus the name StarTopology is given to this type of network. Figure 3.16 Star Topology

35 CHAPTER 4 FEATURES AND ARCHITECTURE 4.1 Key Features of Figure 4.1 The key features of the include: First PLC with HART enabled Universal I/O for greater configuration flexibility. Tight integration with Experion, Honeywell s best-in-class Distributed Control System (DCS), Supervisory Control and Data Acquisition (SCADA) system, and safety system. Tight integration with Honeywell s market leading Field Device Manager - FDM and FDM Express. Tight integration with Honeywell s new Panel PC Experion Panel PC. Native controller redundancy. Optionally redundant power supplies. Two variants of power supplies: 58W 24VDC and 110/240VAC. Leverages Honeywell s LEAP project methodology and Universal I/O for greater configuration flexibility. I/O racks of diverse sizes. Integration with third-party systems and devices such as motors, drivers, and compressors. Connects to Human-Machine Interface (HMI) through Modbus and OPC UA protocols. Compatible with leading open network standards such as Modbus and OPC UA. Powerful IEC programming environment

36 Chapter 4 - Features and Architecture Best-in-class cyber security capabilities like built-in Control Firewall, Secure boot, Secure Communication to ensure the safety of the system, personnel and critical information. Project Upload feature supported. Easier Firmware upgrade/downgrade process. 4.2 Architectural differences between PLC-5, SLC 500 and CPU OS PLC-5 The PLC-5 Processor is based on 16-bit Operations. Program execution is determined primarily using main control Programs (MCPs). In addition, selectable timed interrupts (STIs) or Input Interrupts (DIIs/PIIs) are available. Processor maps I/O memory into I and O Input data table files. The I/O data is updated and synchronously to the program scan so you Output know you have current values each time the processor begins a scan Data Time The PLC-5 only knows global data, which are stored in global data tables. Each PLC-5 data table can store several words of related data Time variables in the PLC-5 processors are stored in Timer files, which are 16-bit wide and have selectable time bases of 10ms and 1s. 32-bit Dual-core ARM processor Program execution is determined primarily through the tasks. ControlEdge supports various tasks like Default, Event, Cyclic and System. Processor populates I/O data into variables those are created during Channel assignment. Data structure is defined for each channel type. ControlEdge knows global and local data. Global data can be accessed across POUs. Local data can be accessed with in POUs. User defined data type allow declaration of structures as data types. Times are 32 BIT wide and supports duration in ms

37 CHAPTER 5 CONVERTING THE PROGRAM STRUCTURE The uses a different execution model than the PLC-5 processor. The supports 3 different Program Organization Units (POUs). Types are: Functions Functions Blocks (FBs) Programs Each POU consists of two parts: The variables declaration part and the code body part. Both are designated as 'Worksheets'. In the declaration part, all local variables are declared. The instruction or code body part of a POU contains the instructions, programmed in the desired programming language. 5.1 Function POUs Functions are POUs with multiple input parameters and exactly one output parameter. Return values can be single data types. Within a function you can call another function but not a Function Block or Program. Ex: Type Conversion function: INT_TO_REAL 5.2 Function Block POUs Function Blocks are POUs with multiple input/output parameters and internal memory. The value a function block returns, depends on the value of its internal memory. Ex: Counter function: CTU 5.3 Program POUs Program POUs usually contain a logical combination of function/function block calls. The behavior and use of programs are as function blocks. Programs have input and output parameters and they can have an internal memory. Programs must be associated to Tasks

38 Chapter 5 - Converting the Program Structure 5.4 Programing languages in supports 5 different program languages, 2 are textual and 3 graphical language. They are: Instruction List (IL) - Textual Language Structured Text (ST) Textual Language Function Block Diagram (FBD) - Graphical Language Ladder Diagram (LD) - Graphical Language Sequential Function Chart (SFC) - Graphical Language 5.5 Tasks Tasks determine the time scheduling of the programs associated with them. Following are different tasks available in. Default Task: The default task is the task with the lowest priority (lower than cyclic tasks) and is not time scheduled. After executing it completely the system waits for a defined idle time. If then no cyclic task or any other task with a higher priority must be processed, the default task is executed again automatically. This means that the default task is always executed (apart from the necessary pre-defined idle period between two invocations), as long as no task with a higher priority runs Cyclic tasks are activated in a certain time interval and the program is executed periodically. System tasks are called automatically by the PLC operating system if an error or a change of the operational state of the PLC occurs. They are also known as system programs or SPGs. Event or interrupt tasks are activated if a certain event has happened. Each task has a certain priority. In so called preemptive scheduling systems, an active task with low priority is interrupted immediately, when a task with higher priority becomes active due to a certain event. In systems with non-preemptive scheduling, task interruptions by tasks with higher priority are not possible. 5.6 Variables Scope of Variables The scope of a variable determines in which POUs it can be used. Possible scopes are local and global. The scope of each variable is defined by the location where it is declared (local or global variables worksheet) and the variable keyword used for the declaration Local variables If a variable can be only used within one POU it is called a local variable. In those cases, it is declared in the variables worksheet of the corresponding POU using one of the variable declaration keywords VAR, VAR_INPUT or VAR_OUTPUT Global variables If a variable can be used within the whole project it is called a global variable. It must be declared using the keyword VAR_GLOBAL in the global declaration and as VAR_EXTERNAL in each POU where it is used

39 Chapter 5 - Converting the Program Structure Symbolic Variables Symbolic variables are declared with a symbolic name and a data type. An initial value is optional. The programming system stores a symbolic variable to a free memory area in the PLC memory which is not known to the user. Symbolic variables can be declared as retentive variables using the keyword 'RETAIN' Directly represented and located variables Located variables are declared using a symbolic name and a logical address. Directly represented variables are declared without a symbolic name but also with a logical address. Both directly represented and located variables are stored at the declared logical address and it is up to the application programmer to check that no memory address is used twice. A location declaration consists of the keyword AT, the percent sign "%", a location prefix, a size prefix and the name of the logical address The table below shows the location and size prefix for directly represented and located variables: Location Prefix I Q M X B W D L Description Physical Input Physical Output Physical address in the PLC memory. Single bit size (only with data type BOOL) Byte size (8 bits) Word size (16 bits) Double word size (32 bits) Long word size (64 bits)

40 CHAPTER 6 CONVERTING THE DATA PLC-5 controller typically stores data in several globally accessible Data files. Each of the data files contains a collection of variables of a single data type. Worthy examples of these are the I/O data table files, which contain an array of words since, the PLC-5 processor supports only up to 16-bit datatypes, while the system supports 16-bit datatypes and 64-bit datatypes. The table that follows shows the file conversions at a glance. PLC-5 Data file type O I S B T C R N F A D BT MG PD SC ST Constants Indirect Addressing Indexed Addressing Data Type Digital output (modules) Digital input (modules) Global variables Bool Time and Bool INT and Bool N.A. INT REAL N.A. N.A. N.A. N.A. N.A. N.A. String Constants N.A. N.A. SLC500 Data file type O I S B T C R N F Data Type Output modules Input modules Global variables Bool Time and Bool INT and Bool N.A. INT REAL

41 Chapter 6 - Converting the Data 6.1 PLC-5, SLC 500 and files identifying data table values The import/export files use DATA statements to identify file types, as shown in the example below: DATA <file_reference>:<last_element_number> <data_value> The following table describes the fields for the example given above: Fields file_reference last_element_ number data_value Specifies to file type size of the file The conversion process uses this value to determine the number of elements to place in the array used for this file. contents of the file The import/export files use DATA statements to identify file types, as shown in the example below: DATA <file_reference>_<last_element_number> <data_value> NOTE The expression : is separator for where as _ is a place holder on the for easy identification I/O Addressing in PLC-5, SLC 500 and ControlEdge PLC CPM Different addressing schemes for I/O data for PLC-5, SLC 500 and are: Controller PLC-5 processor SLC 500 processor processor I/O Addressing Base 8 (octal) Base 10 (decimal) Pre-defined structure for I/O modules

42 Chapter 6 - Converting the Data 6.2 Converting Input (I) and Output (O) data The conversion of the Input and Output data table files is necessary, due to the different addressing schemas. It is important to understand the difference in addressing them. In the the input and output data table files have 16-bit wide elements whereas in I/O data is referred using variable names. PLC-5 and SLC 500 original address I:006 O:010 I:021/04 O:035/14 Comment Addresses the 7th word of the Input data table file Addresses the 11th word of the Output data table file Addresses the 5th bit in the 18th word of the Input data table file Addresses the 13th bit in the 30th word of the Output data table file converted address Channel details can be accessed using unique Tag names of pre-defined I/O structures that was assigned during I/O Channel Configuration. Channel Properties varies based on Channel Type

43 Chapter 6 - Converting the Data 6.3 Converting the Binary (B) file type A Binary file is translated by converting 16-bit values into 16 variables or a single word depending on the addressing method used as shown in the table below. This method of conversion lets instructions that manipulate Binary files work correctly. The tag name is Bx (where x is the PLC-5 or SLC 500 data table file number). Description Specifying the element number and bit within that element Addressed using sequence numbering original address converted address B3:1/2 B3_1.X2 Word B3/17 B3_17 BOOL ControlEdge PLC CPM Data Type

44 Chapter 6 - Converting the Data 6.4 Converting the Timer (T) file type Timers in the processors consist of a 16-bit preset value, a 16-bit accumulator value, and a time base of 1s or 10ms. It also has MNEMONIC bits such as EN, TT and DN. The conversion process for the Timer (T) type converts to equivalents of the MNEMONIC bits to PRE, ACC, EN and DN. The converted time on is always in s (second). The table that follows shows a comparison of the PLC-5/SLC 500 and the : Table 6.1 PLC-5/SLC 500 and Comparison - TON PLC-5/SLC 500 Mnemonic Description ControlEdge PLC CPM Mnemonic Description PRE Preset Value: contains the time value the timer should accumulate. PT Present time interval for the delay. Data type is TIME ACC Accumulator Value: contains the accumulated time ET Elapsed time interval. Data type is TIME EN Timer Enabled Bit: Indicates timer is enabled and true when rung goes true. IN TON/TOF function blocks IN pin. TT Timer Timing Bit: Indicates that timer operation is in progress. Doesn t exist _ DN Timer Done Bit: Indicates that timing operation is completed. Preset is equal to Accumulated value. Q TON/TOF function block Q pin

45 Chapter 6 - Converting the Data Table 6.2 PLC-5/SLC 500 and Comparison - TOF PLC-5/SLC 500 Mnemonic Description ControlEdge PLC CPM Mnemonic Description PRE Preset Value: contains the time value the timer should accumulate. PT Present time interval for the delay. Data type is TIME ACC Accumulator Value: contains the accumulated time ET Elapsed time interval. Data type is TIME EN Timer Enabled Bit: Indicates timer is enabled and true when rung goes true. IN TON/TOF function blocks IN pin. TT Timer Timing Bit: Indicates that timer operation is in progress. Doesn t exist _ DN Timer Done Bit: Indicates that timing operation is completed. Preset is equal to Accumulated value. Q TON/TOF function block Q pin

46 Chapter 6 - Converting the Data 6.5 Converting the Status (S) file type A Status file is translated by converting 16-bit values into 16 variables or a single word depending on the addressing method used as shown in the table below. This method of conversion lets instructions that manipulate Status files work correctly. The tag name is Sx (where x is the PLC-5 or SLC 500 data table file number). Description Specifying the element number and bit within that element Addressed using sequence numbering original address converted address S3:1/2 S3_1.X2 Word S3/17 S3_17 BOOL ControlEdge PLC CPM Data Type

47 Chapter 6 - Converting the Data 6.6 Converting the Integer (N) file type The conversion process first checks whether the integer bit has been accessed in the program. In the case where it has been accessed as a bit, the integer is converted to word data type. In other case integer is not accessed as a bit then it is converted to integer data type. The tag name is Nx (where x is the PLC-5 or SLC 500 data table file number). original address converted address N11:0 N11_0 INT N11:1/8 N11_1.X7 Word Type 6.7 Converting the Floating Point (F) file type The conversion process converts F file type into its equivalent real data file. The tag name is Fx (where x is the PLC-5 or SLC 500 data table file number). The table below shows an example F address and its ControlEdge equivalent: original address converted address F8:3 F8_3 Real Type

48 Chapter 6 - Converting the Data 6.8 Converting the String (ST) file type The conversion process converts ST to its equivalent String data type. The tag name is STx (where x is the PLC-5 data table file number). The table below shows an example ST address and its equivalent: original address converted address ST8:3 ST8_3 String Type 6.9 Unsupported Data types for ControlEdge PLC do not map one to one for the following variables mentioned in the table below for data file type. converts them to word. PLC-5 Data file type R PLC-5 original address R5:1 R5:1/EN ControlEdge PLC CPM Converted Address R5_1 R5_1_EN Data Type Converted to word A A18:0 A18_0 Converted to word C C5:1 C5:1/CU C5_1 C5_1_CU Converted to word D D32:0 D32_0 Converted to word BT MG PD SC Indirect Addressing Indexed Addressing BT5:1 BT5:1/EN BT5_1 BT5_1_EN Converted to word Converted to word Converted to word Converted to word Converted to word Converted to word SLC 500 Data file type SLC 500 original address ControlEdge PLC CPM Converted Address Data Type A A18:0 Converted to word C R C5:1 C5:1/CU R5:1 R5:1/EN C5_1 C5_1_CU R5_1 R5_1_EN Converted to word Converted to word Converting the Control (R) file type The conversion process creates word for each structure element. The tag name is Rx (where x is the PLC-5 or SLC 500 data table file number). There is not corresponding structure ControlEdge thus, for each element a separate variable is assigned in

49 Chapter 6 - Converting the Data original address converted address R5:1 R5_1 Word R5:1/EN R5_1_EN Word R5:1/DN R5_1_DN Word ControlEdge PLC CPM Data Type NOTE In source system R5:1/EN represents a variable R5:1. In two variables are created

50 Chapter 6 - Converting the Data Converting the Counter (C) file type The conversion process creates a single dimension array of COUNTER structures for the C file. The tag name is Cx (where x is the PLC-5 or SLC 500data table file number). The table below shows a comparison of the PLC-5/SLC 500 counter and the counter: original address converted address C5:1 C5_1 Word C5:1/CU C5_1_CU Word C5:1/DN C5_1_DN Word Data Type NOTE In source system C5:1/CU represents a variable C5:1. In two variables are created

51 Chapter 6 - Converting the Data

52 CHAPTER 7 CONVERSION OF SYSTEM SOFTWARE AND STANDARD FUNCTIONS 7.1 Introduction This chapter lists the more commonly used PLC-5 instructions, explains how the equivalent is done in ControlEdge. 7.2 PLC5 Instruction to ControlEdge Instruction Mapping Relay-Type Instruction Examine On (XIC) Normally Open Contact If you find an ON condition at bit I:012/07 in the input table, set this instruction true. This bit corresponds to input terminal 7 of a module in I/O group 2 of I/O rack 1. If the input circuit is true, the instruction is true. If the state of the C004 is on then value is copied from left to right. Examine Off (XIO) Normally Closed Contact If you find an OFF condition at bit I:012/07 in the input table, set this instruction true. This bit corresponds to input terminal 7 of a module in I/O group 2 of I/O rack 1. If the input circuit is false, the instruction is true. If the state of the C004 is off then the value is copied from left to right

53 Chapter 7 - Conversion of System Software and Standard Functions Energize (OTE) Coil Turn ON bit O:013/01 of the output image table if the rung is true. Turn it OFF if the rung is false. This bit corresponds to output terminal 01 of The Boolean value is copied from left to right and a module in /O group 3 of I/O rack 1. to the associated variable. Latch (OTL) SET Coil Turn ON bit O:013/01 of the output image table if the rung is true. This bit corresponds to output terminal 1 of a module in I/O group 3 of I/O rack 1. The Boolean value is copied from left to right and the associated variable is set if the left link Is true. Unlatch (OTU) RESET Coil Turn OFF bit O:013/01 of the output image table if the rung is true. This bit corresponds to output terminal 1 of a module in I/O group 3 in I/O rack 1. The Boolean value is copied from left to right and the associated variable is Re-set if the left link Is true

54 Chapter 7 - Conversion of System Software and Standard Functions Timer Instructions: Timer On Delay (TON): Timers in the PLC-5 processors consist of a 16-bit preset value, a 16-bit accumulator value, and a time base of 1s or 10ms. Turn an output on or off after the timer has been on for a preset time interval. If the input IN Changes from false to true, switching on is delayed for the duration of the time interval applied to the input PT. After PT has passed Q is set to true. ControlEdge present value should be derived based on Preset and Time base value that is configured in PLC-5. Timer Off Delay (TOF): Timers in the PLC-5 processors consist of a 16-bit preset value, a 16-bit accumulator value, and a time base of 1s or 10ms. Turn an output on or off after its rung has been off for a preset time interval. If the input IN Changes from false to true, switching off is delayed for the duration of time interval applied to the input PT. After PT has passed, Q is set to FALSE

55 Chapter 7 - Conversion of System Software and Standard Functions Using Counters: Count Up (CTU): The CTU Instruction counts upward over a range of to Each time the rung goes from false to true, the CTU instruction increments accumulated value by one count. The accumulated value of counter is retentive. The count is retained until reset by a reset instruction (RET) that has same address as the counter. When accumulated value equal or exceeds present value, the CTU Instruction sets a done bit DN. In case of raising edge at input CU and RESET is false, CV is increased by one count. If the final value of counter (PV) is achieved, Q is set to TRUE and function block stops counting. Count Down (CTD): The CTD Instruction counts downward over a range of to Each time the rung goes from false to true, the CTD instruction decrements the accumulated value by one count. The accumulated value of counter is retentive. The count is retained until reset by a reset instruction (RET) that has same address as the counter. The done bit. DN is set as long as the accumulated value equal or greater than present value Compare Instructions: Equal to (EQU): In case of raising edge at input CD and RESET is false, CV is decremented by one count. If the final value of counter (0) is achieved, Q is set to TRUE and function block stops counting. Use the EQU instruction to test whether two values are equal. Sources A and B can either be values are addresses that contain values

56 Chapter 7 - Conversion of System Software and Standard Functions The rung goes to true, if the value of N7:5 is equal to the value of N7:10 If the value in V00_1 is equal to value in V00_2 then Sets Output to true. Greater than or Equal to (GEQ): Use the GEQ instruction to test whether one value is greater than or equal to another value. Sources A and B can either be values are addresses that contain values. The rung goes to true, if the value of N7:5 is greater than or equal to the value of N7:10 If the value in V00_1 is Greater than or equal to value in V00_2 then Sets Output to true

57 Chapter 7 - Conversion of System Software and Standard Functions Greater than (GRT): Use the GRT instruction to test whether one value is greater than another value. Sources A and B can either be values are addresses that contain values. The rung goes to true, if the value in N7:5 is greater than the value in N7:10 If the value in V00_1 is Greater than to value in V00_2 then Sets Output to true Less than or Equal to (LEQ): Use the LEQ instruction to test whether one value is less than or equal to another value. Sources A and B can either be values are addresses that contain values. The rung goes to true, if the value in N7:5 is less than or equal to the value in N7:10 If the value in V00_1 is Less than or equal to value in V00_2 then Sets Output to true

58 Chapter 7 - Conversion of System Software and Standard Functions Less than (LES): Use the LES instruction to test whether one value is less than another value. Sources A and B can either be values are addresses that contain values. The rung goes to true, if the value in N7:5 is less than to the value in N7:10 If the value in V00_1 is Less than to the value in V00_2 then Sets Output to true Not Equal to (NEQ): Use the NEQ instruction to test whether two values are not equal. Sources A and B can either be values are addresses that contain values. Rung goes to true, if the value in N7:5 is not equal to value in N7:10 If the value in V00_1 is Not equal to the value in V00_2 then Sets Output to true

59 Chapter 7 - Conversion of System Software and Standard Functions Compute Instructions: Arc Cosine (ACS): (Enhanced PLC-5 Processors Only) Use the ACS instruction to take the arc cosine of the source (in radians) and store the result (in radians) in destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Always resets ControlEdge If the rung is true, take the arc cosine of the value in F8:19 and store the result in F8:20. Calculates the ARC Cosine of the Source value and store the result in Destination

60 Chapter 7 - Conversion of System Software and Standard Functions Addition (ADD): Use the ADD instruction to add one value (Source A) with another value (Source A) and place the result in destination. Updating Arithmetic status flag for ADD Instruction: Carry (C)- Sets if carry generated; otherwise resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, add the value in N7:3 to the value in N7:4 and store the result in N7:20. Add the value in V00_1 to the value in V00_2 and store the result in Output Arc Sine (ASN): (Enhanced PLC-5 Processors Only) Use the ASN instruction to take the arc sine of the source (in radians) and store the result (in radians) in destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Always resets If the rung is true, take the arc Sine of the value in F8:17 and store the result in F8:18 Calculates the Arc Sine of the Source value and store the result in Destination variable

61 Chapter 7 - Conversion of System Software and Standard Functions Arc Tangent (ATN): (Enhanced PLC-5 Processors Only) Use the ATN instruction to take the arc tangent of the source (in radians) and store the result (in radians) in destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the arc tangent of the value in F8:21 and store the result in F8:22 Calculates the Arc Tangent of the Source value and store the result in Destination variable. Clear (CLR): Use the CLR instruction to set the all the bits of word to ZERO. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-always resets Sign (S)-always resets If the rung is true, Clear all of the bits in in N7:3 to ZERO. Clears the variable connected to the input Destination to zero, if the Clear input is set to true. Supported Data types are SINT, INT, DING,REAL

62 Chapter 7 - Conversion of System Software and Standard Functions Cosine (COS): (Enhanced PLC-5 Processors Only) Use the COS instruction to take the cosine of the source (in radians) and store the result (in radians) in destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the cosine of the value in F8:13 and store the result in F8:14 Calculates the Cosine of the Source value and store the result in Destination variable. Divide (DVD): Use the DVD instruction to divide one value with another value and store the result in destination. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-Sets if division by zero or if overflow generated; otherwise resets Zero (Z)-Sets if result is zero, otherwise resets; undefined if overflow is set Sign (S)-Sets if result is negative, otherwise resets; undefined if overflow is set If the rung is true, divide the value in N7:3 with the value in N7:4 and store the result in N7:20. Divide the value in V00_1 with the value in V00_2 and store the result in Output

63 Chapter 7 - Conversion of System Software and Standard Functions Natural Log (LN): (Enhanced PLC-5 Processors Only) Use the LN instruction to take the natural log of the value in the source and store the result in destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the natural log of the value in N7:0 and store the result in F8:20 Calculates the Natural log of the source value and store the result in Destination variable. Log to the base 10 (LOG): (Enhanced PLC-5 Processors Only) Use the LOG instruction to take the log base 10 of the value in the source and store the result in the destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the log base 10 of the value in N7:2 and store the result in F8:3 Calculates the log base 10 of the source value and store the result in Destination variable

64 Chapter 7 - Conversion of System Software and Standard Functions Multiply (MUL): Use the MUL instruction to multiple one value with another value and store the result in destination. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-Sets if overflow generated; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, multiply the value in N7:3 with the value in N7:4 and store the result in N7:20. Multiply the value in V00_1 with Value in V00_2 and store the result in Output Negate (NEG): Use the NEG instruction to change the sign of the value. If user negates a negative value result is positive. If user negate a positive value result is negative. Updating Arithmetic status flag for CLR Instruction: Carry (C)- Sets if the operation generates a carry. Overflow (V)-Sets if overflow generated; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the opposite sign of the value at N7:3 and store result in N7:20. Negates the Source value and stores the result in destination variable

65 Chapter 7 - Conversion of System Software and Standard Functions Sine (SIN): (Enhanced PLC-5 Processors Only) Use the SIN instruction to take the sine of a number and store the result in the destination. Updating Arithmetic status flag for ACS Instruction: Carry (C)- Always resets Overflow (V)-Sets if overflow generated; otherwise resets. Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the sin of the value in F8:11 and store the result in F8:12 Square Root (SQR): Calculates of the SIN of the Source value and stores the result in Destination variable. Use the SQR instruction to take the square root a value and store the result in destination. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets. Overflow (V)-Sets if overflow generated during floating point to integer conversion; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-always resets If the rung is true, take the square root of the value in N7:3 and store result in N7:20. Take the square root of the value in V00_1 and store the result in Output Subtract (SUB): Use the SUB instruction to subtract one value from another value and store the result in destination value. Updating Arithmetic status flag for CLR Instruction:

66 Chapter 7 - Conversion of System Software and Standard Functions Carry (C)- Sets if borrow generated; otherwise resets Overflow (V)-Sets if underflow generated; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, subtract the value in N7:3 with the value in N7:4 and store result in N7:20. Subtract the value in V00_1 with the value in V00_2 and store the result in output Tangent (TAN): (Enhanced PLC-5 Processors Only) The TAN instruction calculates the tangent of source number and store the result in destination. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-Sets if overflow generated; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the tangent of value in F8:15 and store the result in F8:16 Take the tangent of the value in V00_1 and store the result in Output

67 Chapter 7 - Conversion of System Software and Standard Functions X to the power of Y (XPY) (Enhanced PLC-5 Processors Only) Use XPY instruction to raise a value (Source A) to the power (Source B) and store the result in destination. Updating Arithmetic status flag for XPY Instruction: Carry (C)- always resets Overflow (V)-Sets if overflow generated; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, take the value in N7:4, raise it to the power of value in N7:5, and stores result in destination N7:6 AND Operation (AND): Calculates the exponentiation of the Base value with Exponent value and stores result in Output variable. Use the AND instruction to perform an AND operation using the bits in value from another value and store the result in destination value. instruction to subtract one Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if most significant bit is set; otherwise resets If the rung is true, AND the value in N9:3 with the value in N10:4 and store result in N12:3 AND the value in V00_1 with the value in V00_2 and store the result in Output

68 Chapter 7 - Conversion of System Software and Standard Functions NOT Operation (NOT): Use the NOT instruction to perform an NOT operation using the bits in source address and store the result in destination value. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if most significant bit is set; otherwise resets If the rung is true, NOT the value in N9:3 and stores result in N10:4 NOT the value in V00_1 and store the result in Output OR Operation (OR): Use the OR instruction to perform an OR operation using the bits in the two sources (constants and addresses). Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if most-significant bit is set; otherwise resets If the rung is true, OR the value in N9:3 with the value in N10:4 and stores result in N12:3 OR the value in V00_1 with the value in V00_ 2 and store the result in output

69 Chapter 7 - Conversion of System Software and Standard Functions Exclusive OR Operation (XOR): Use the XOR instruction to perform an exclusive OR operation using the bits in the two sources (constants and addresses). Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if most-significant bit is set; otherwise resets If the rung is true, XOR the value in N9:3 with the value in N10:4 and stores result in N12:3 XOR the value in V00_1 with the value in V00_2 and store the result in Output

70 Chapter 7 - Conversion of System Software and Standard Functions Conversion Instructions The Conversion instructions convert integer to BCD and convert BCD to Integer. For example, use TOD and FRD for signals to/from BCD I/O devices, for display purpose, or for number compatibility with PLC-2 family processors. Convert to BCD (TOD): Use the TOD instruction to convert an integer value to a BCD Value. Updating Arithmetic status flag for TOD Instruction: Carry (C)- always resets Overflow (V)-Sets if integer value is outside the range ; otherwise resets Zero (Z)-Sets if destination value is negative or Zero; otherwise resets Sign (S)-always resets If the rung is true, Convert the value in N7:3 to a BCD value and store the result in D9:3 Convert the value in V001 to a BCD value and store the result in Output variable. NOTE The mapping may not work as mentioned as an equivalent data type is not available

71 Chapter 7 - Conversion of System Software and Standard Functions Bit Modify and Move Instruction Move (MOV): The MOV is an output instruction that copies data from source to destination. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-Sets if overflow generated during floating point-to-integer conversion; otherwise resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets ControlEdge If the rung is true, MOV instruction copies data in source address N7:0 to destination address N7:2 MOVE instruction copies the value from V00_1 to V00_2 Masked Move (MVM): The MVM is an output instruction that copies to source to a destination, and allow portions of data to be masked. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets If the rung is true, MVM instruction copies data in source address N7:0 to destination address N7:2 and allows portion of the data to be masked. MVM instruction copies data in Source to Destination and allows portion of the data to be masked

72 Chapter 7 - Conversion of System Software and Standard Functions Shift Register Instructions: Bit Shift Left (BSL), Bit Shift Right (BSR): The Bit shift instruction shifts all bits within the specified addresses with one bit position with each false- to-rung transaction. Updating Arithmetic status flag for CLR Instruction: Carry (C)- always resets Overflow (V)-always resets Zero (Z)-Sets if result is zero; otherwise resets Sign (S)-Sets if result is negative; otherwise resets Performs the bitwise left shift operation on InPutValue. N specifies the No. of bits to be If the rung is true, BSL instruction shifts 58 bits in Bit File B3, starting with 16 th shifted. Result is stored in Output bit, to the left one bit position. The last bit shifts Variable. out at bit position 73 into the UL Bit. Source bit, bit 12 of input word 22, shifts into the first bit position, bit 16 of bit file B3. NOTE Custom Logic to be written to insert a source bit at starting position to map equal to PLC-5 and SLC 500. ControlEdge PLC Performs the bit-wise right shift operation on InPutValue. N specifies If the rung is true, BSR instruction shifts 38 bits in Bit File B3, starting the No. of bits to be with the highest bit position 69, to the right one bit position. The lowest bit shifted. Result is stored (bit 32) shifts out of the bit array into the.ul Bit. Source bit, bit 06 of in Output Variable. input word 23, shifts into the highest bit position 69 NOTE Custom Logic to be written to insert a source bit at starting position to map equal to PLC-5 and SLC

73 Chapter 7 - Conversion of System Software and Standard Functions Using FIFO and LIFO Instructions: Use FIFO Instructions, First in First Out and LIFO Instructions, Last in - First out in pairs to store and retrieve data in prescribed orders. FIFO Instructions: When rung goes from false to true, Processor sets EN Bit and loads the source element (N60:1) into next available elements in the stack as pointed to by the control signatures position. If a rising edge at input FIFO_Load is detected the variable connected to Source will be written to the FIFO buffer. Unloads the data from first elements stored in the FIFO stack into the destination word at N60:2. At the same time the processor shifts all data in the stack one position towards the first word. If a rising edge at input FIFO_Unload is detected, the first value which has been written to the FIFO buffer is moved to the variable connected to Destination. The Position will be decreased by one and the written value will be removed from the FIFO buffer. PLC5- Mnemonic Description EN EU DN EM Enable Bit is set: when rungs make false-to-true rung transaction to indicate that the instruction is enabled. Enable Unload Bit is set: when rung conditions are true to indicate that instruction is enabled. Done Bit is set: to indicate that the stack is full. DN bit inhibits loading the stack until there is room. Empty bit is set: to indicate that stack is empty. Do not enable the LIFO or FIFO Unload commands if the EM Bit is set. ControlEdge PLC Mnemonic Doesn t exist Full Empty Set to true if FIFO Buffer is full Set to true if FIFIO Buffer is empty

74 Chapter 7 - Conversion of System Software and Standard Functions LIFO Instructions: ControlEdge When rung goes from false to true, Processor sets EN Bit and loads the source element (N70:1) into next available elements in the stack as pointed to by the control signatures position. If a rising edge at input LIFO_Load is detected the variable connected to Source will be written to the LIFO buffer Unloads the data starting from the last word elements stored in the LIFO stack into the destination word at N70:2. If a rising edge at input LIFO_Unload is detected the last value which has been written to the LIFO buffer is moved to the variable connected to Destination. The Position will be decreased by one and the written value will be removed from the LIFO buffer

75 Chapter 7 - Conversion of System Software and Standard Functions Program Control Instructions Jump (JUMP) and Label (LBL): Use JUMP and LBL instruction in pairs to skip portions of the ladder program. Jump: Label: The Processor jumps over the successive rungs until it reaches the rung that contains the LBL instruction with the same number. Jump and label must have the same name. The Processor jumps over the successive rungs until it reaches the rung that contains the Label ASCII Instructions The ASCII instructions read, write, compare and convert ASCII strings. These instructions are only supported by Enhanced PLC-5 Processor. ASCII String to Integer (ACI): Use the ACI instruction to convert an ASCII string to an integer value between -32,768 and 32,767. Updating Arithmetic status flag for CLR Instruction: Carry (C)- the carry was generated while converting the string to an integer Overflow (V)-the integer value was outside of the valid range Zero (Z)-the integer value is Zero Sign (S)-the integer value is negative Convert the string in ST38:90 and store the result in N7:123 Convert the string in V00_1 and store the result in Output

76 Chapter 7 - Conversion of System Software and Standard Functions ASCII String Concatenate (ACN): ACN instruction appends Source B to end of the Source A and store the result in the Destination. If the result is more than 82 characters then only first 82 characters are written to the destination bit and error bit (S:17/8) is set. Concatenate the string in ST37:42 with string in ST38:91 and store the result in ST52:76 Append the string in Second_string to the end of the string in First_String and store the result in Output. ASCII String Extract (AEX): Use AEX instruction to create a new string by taking a portion of an existing string. Extract 10 characters starting at the 42 nd character of ST38:40 and store the result in ST52:75. Extracts a substring from the middle of a string connected to Input_String. The number of characters to be extracted is connected to the input L. Extraction begins at character Position P. Result is stored in Output string

77 Chapter 7 - Conversion of System Software and Standard Functions ASCII Integer to String (AIC): Use AIC instruction to convert an integer value (between -32,768 and 32,767) to and ASCII string. Convert the value 867 to a string and store the result in ST38:42. Changes the value connected to the IN put parameter to string and store the result in Output. Valid format string for INT Data type is %d. ASCII String Search (ASC): Use the ASC instruction to search an existing string (search string) for an occurrence of source string. Search the string in ST52:80 starting at the bit 35 character, for the string found in ST38:40. In this example result stored in N10:0. This function detects the position of the Search_ String connected to IN2 with a given string connected to Input_String IN1. ASCII String Compare (ASR): Use the ASR instruction to compare two ASCII strings. The system looks for a match in length and upper/lower case. If two strings are identical then rung is true; otherwise rung is false. If the string in ST37:42 is identical to the string in ST38:90, set output bit to true Compares the character string connected to Input IN1 with IN2 and Sets Output to true if IN1 is equal to IN2, otherwise Output is set to false