Integrated Architecture:

Putting the Pieces Together

using ControlLogix
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Integrated Architecture: Putting the
Pieces Together using ControlLogix
Hands-On Lab

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WELCOME TO THE INTEGRATED ARCHITECTURE: PUTTING PIECES TOGETHER HANDS-ON LAB (70
MINUTES) 6

WHAT IS INTEGRATED ARCHITECTURE? __________________________________________ 6

ABOUT THIS HANDS-ON LAB __________________________________________________ 6
LAB MATERIALS ___________________________________________________________ 7
DOCUMENT CONVENTIONS ____________________________________________________ 9

LAB 1: CREATING AN RSLOGIX 5000 PROJECT FOR THE LOGIX CONTROLLER _______________ 10

ABOUT THIS LAB __________________________________________________________ 10

LAUNCHING RSLOGIX 5000 AND CREATING A NEW PROJECT FILE _____________________ 11
LAUNCHING RSLOGIX 5000 AND CREATING A NEW PROJECT FILE _____________________ 11
CONFIGURING LOCAL I/O____________________________________________________ 12
CONFIGURING LOCAL ETHERNET/IP COMMUNICATIONS _____________________________ 14
CONFIGURING DISTRIBUTED I/O ON THE ETHERNET/IP NETWORK______________________ 15

LAB 2: ADDING A DRIVE TO THE CONTROL SYSTEM ___________________________________ 21

REVIEWING THE SITUATION __________________________________________________ 21

ADDING THE POWERFLEX70E DRIVE TO THE I/O CONFIGURATION _____________________ 21
VIEWING THE PRE-DEFINED DATA STRUCTURE FOR THE I/O DEVICES ___________________ 22
CREATING ALIASES WITH RSLOGIX 5000 SOFTWARE_______________________________ 25

LAB 3: DOWNLOADING AND TESTING THE PROJECT ___________________________________ 29

DOWNLOADING THE PROJECT ________________________________________________ 29

TESTING YOUR CODE ______________________________________________________ 29
EXECUTING SIMPLE DRIVE COMMANDS VIA RSLOGIX 5000 __________________________ 30

LAB 4: CONTROLLING THE DRIVE FROM A VERSAVIEW TERMINAL ________________________ 32

ABOUT THIS LAB __________________________________________________________ 32

LAUNCHING RSVIEW STUDIO PROGRAMMING SOFTWARE ___________________________ 32
CONFIGURING COMMUNICATIONS ______________________________________________ 33
EDITING AN HMI DISPLAY TO CONTROL THE DRIVE ________________________________ 35
TESTING THE HMI APPLICATION_______________________________________________ 42
CREATING A RUNTIME APPLICATION AND DOWNLOADING TO THE VERSAVIEW TERMINAL ____ 44
DOWNLOAD YOUR PROJECT TO THE VERSAVIEW CE TERMINAL AND TEST THE APPLICATION _ 45
LAB 5: INTEGRATING OLDER TECHNOLOGY IN REMOTE LOCATIONS _______________________47

REVIEWING THE SITUATION __________________________________________________47

EXTRATASK _____________________________________________________________53

LAB SUMMARY 54

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Welcome to the Integrated Architecture: Putting Pieces
Together Hands-On Lab (70 minutes)
What is Integrated Architecture?
Integrated Architecture is a concept that allows automation components to be used as stand-alone
control devices or combined together as an integrated system based on a common set of enabling
technologies.
Integrated Architecture brings together an outstanding range of pre-integrated components and
systems to help todays manufacturing enterprises across a wide range of industries. The Integrated
Architecture technologies are the core of a robust system:
ƒ LOGIX is the Control Platform based on the same control engine embedded in scale-able
controllers using a single programming environment
ƒ NETLINX is the Communication Platform based on the Open Networks integrated to Control,
Configure & Collect data
ƒ VIEWANYWARE is the Visualization Platform. This technology is a unified, scalable and
extensible HMI platform using a single development environment.
ƒ FACTORYTALK is the Information Platform. This technology integrates control systems and
connects the enterprise with the production facility
Integrated Architecture provides all the control you need in one package!
Distributed Control Functionality for:
ƒ Global Access to data
ƒ Deterministic control
ƒ Distributed HMI
ƒ Extensive library of process control algorithms (Function Blocks)
Programmable Controller Flexibility for:
ƒ An optimized maintenance & troubleshooting with the source stored in controller, tag based
ƒ Integrated Drives and Motion control
ƒ Standalone operation
ƒ Scalable architecture
ƒ Interfaces to many devices
About This Hands-On Lab
This Hand-On-Lab will introduce you to the Integrated Architecture. In this lab you will see Logix,
NetLinx, and ViewAnyware in action and learn how to configure and collect data across
EtherNet/IP. You will also design, create, and download a project to a Logix controller as well as
examine the controller tag database. This session demonstrates how easy it is to connect
ViewAnyWare HMI (Human Machine Interface) to a Logix controller and protocol and to control a
drive over EtherNet/IP.

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Lab Materials
For this Hands-On lab, we have provided you with the following materials that will allow you to
complete the labs in this workbook.
Hardware
This hands-on lab uses one of the following Demo boxes:
ƒ ControlLogix Demo Box

ƒ PowerFlex 70 Drive demo box

ƒ POINT I/O Demo Box

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ƒ Gateway Demo box

ƒ PLC5 Demo Box

ƒ PanelView CE 1000H

Take a few minutes to familiarize yourself with the hardware used in this lab exercise.
Software
This hands-on lab requires the following software:
ƒ RSLogix 5000
ƒ RSLinx
Files
This hands-on lab requires the following files:
ƒ Machine_Control.apa
ƒ Utilities.doc
ƒ IA_Overview.ppt

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Document Conventions
Throughout this workbook, we have used the following conventions to help guide you through the
lab materials.
This style or symbol: Indicates:
Words shown in bold italics Any item or button that you must click on, or a menu name
(e.g., RSLogix 5000 or OK) from which you must choose an option or command. This will
be an actual name of an item that you see on your screen or
in an example.
Words shown in Courier text, An item that you must type in the specified field. This is
enclosed in single quotes information that you must supply based on your application
(e.g., 'Controller1') (e.g., a variable).
Note: When you type the text in the field, remember that you
do not need to type the quotes; simply type the words that
are contained within them (e.g., Controller1).

 FYI The text that follows this symbol is supplemental information

regarding the lab materials, but not information that is
required reading in order for you to complete the lab
exercises. The text that follows this symbol may provide you
with helpful hints that can make it easier for you to use this
product.

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Lab 1: Creating an RSLogix 5000 Project for the
Logix Controller
About This Lab
In this lab, you will be introduced to RSLogix 5000 programming software. You will do the
following:
ƒ launch RSLogix 5000 and create a new project for the Logix controller
ƒ configure the Logix controller’s I/O tree to control the I/O in the 1734 PointI/O chassis and a
PowerFlex 70 over EtherNet/IP
ƒ learn how easy it is to configure, control and collect data from a drive and Point I/O modules on
ControlNet
Below is a representation of your control system on plant-wide EtherNet/IP.

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Launching RSLogix 5000 and Creating a New Project File
In this section of the lab, you will launch RSLogix 5000 software and create a new project.

1. From the computer desktop, double-click on the RSLogix 5000 icon to launch
RSLogix 5000 software.
2. From the toolbar menu, select File > New.
3. When the New Controller dialog appears, configure the project as follows, then click OK to
accept your changes.

 FYI

Chassis Type
This field is visible only for ControlLogix and is disabled if you have chosen a
CompactLogix, DriveLogix, or FlexLogix controller type. These controllers do not
have a physical chassis, and therefore you do not need to select a chassis type. In
the case of the XLogix controllers (ControlLogix L4x), there are physical chassis but
they are fixed at specific sizes.
Slot
In the ControlLogix demo boxes, the controller is in slot 1of the chassis (slot 0 if the
left-most slot). For ControlLogix, DriveLogix, and FlexLogix, since the controller
always resides in slot 0 of the virtual backplane, this field is disabled, and slot
number 0 is displayed. For Xlogix (ControlLogix L4x) the controller doesn’t reside in
a virtual backplane, but is always in slot 0.

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Configuring Local I/O
Now it is time to configure the controller to talk to specific I/O devices. This is done by adding
modules in the I/O Configuration portion of the Controller Organizer. In order to establish
communication between devices you must enter specific data like node number, slot number,
amount of data to be scanned and the rate at which you would like it to be scanned (RPI
Requested Packet Interval). Before adding any modules, let’s review the I/O Configuration
structure.
1. From the Controller Organizer, expand the I/O Configuration folder to review the current
structure.

You will configure the 1756-OB16D module in slot 4 of the local chassis.
2. In the I/O Configuration folder, right click on 1756-Backplane and select New Module.

3. When the following window appears, expand the Digital option and select the 1756-OB16D as
shown below.

4. Select OK to accept your selection.

5. Select Major Revision 3 and click OK to proceed.

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6. When the New Module window appears, configure the Name and Slot number as shown below.

Note that the Name can be any unique IEC 1131-3 compliant alpha-numeric name that the user
wants. IEC1131-3 basically says that it must begin with an alpha character, can only be a
maximum of 40 characters long, and cannot contain certain characters like % or #.

 FYI

Electronic Keying
Electronic Keying prevents the inadvertent insertion of the wrong module in the
wrong slot. RSLogix 5000 compares the following information for the inserted module
to that of the configured slot:
Type, Vendor, Catalog Number, Major Revision and Minor Revision
Exact Match - all of the parameters described above must match or the inserted
module will reject the connection.
Compatible Module - the Module Type, Catalog Number, and Major Revision must
match. The Minor Revision of the module must be greater than or equal to the one
specified in the software.
Disable Keying – the controller will not employ keying at all.

7. Click OK twice to close the Module Profile configuration window.

8. Verify that your I/O structure on the appears as follows:

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 Note that the controller in slot 1 appears after you’ve configured the first module and is shown in
the I/O tree as part of the local chassis. The I/O Configuration structure in RSLogix 5000 V15
shows you the exact physical hardware setup of your local chassis.
Configuring Local EtherNet/IP Communications
In this section of the lab, you will configure EtherNet/IP communications in your local chassis by
adding the 1756-ENBT module to the I/O Configuration.
1. In the I/O Configuration folder, right click on 1756-Backplane and select New Module.

2. When the following window appears, expand the Communications option and select the 1756-
ENBT as shown below.

3. Select OK to accept your selection.

4. Select Major Revision 3 and click OK to proceed.

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5. When the New Module window appears, configure the Name and Slot number as shown below.

6. Before existing this dialog, configure the IP Address as 192.168.1.x+10 where x is the number
of your student station (note that you can find the IP Address of the ENBT by looking on the
scrolling LED display on the faceplate of the module in your chassis).
7. Click OK to accept your changes.
Configuring Distributed I/O on the EtherNet/IP Network
The next step will be to configure the Ethernet I/O structure in the I/O Configuration of your
controller. Let’s begin by configuring the distributed EtherNet/IP device.
1. From the Controller Organizer, right click on the Ethernet and select New Module.

2. From the list that appears, expand the Communications option, select the 1734-AENT module,
and then click OK.

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3. Configure the module Name, Chassis Size, and IP Address as shown below:

 FYI

Chassis Size
Select the appropriate number of modules connected to the communication adapter,
between 1 and 8. In our POINT I/O chassis we have 7 modules so the chassis size is
7.
Comm Format
We will cover the topic of Comm Format shortly. For now just leave it set for Rack
Optimization.

4. Click OK to review the Requested Packet Interval.

5. Leave the default value and click OK to close the window.

 FYI

Requested Packet Interval (RPI)

The RPI is the rate that the user requests the data be moved to or from the module.
The minimum and maximum RPI values are shown parenthetically to the right of the
box/spin control. The RPI is entered by the user.

You are now ready to configure the Distributed POINTI/O.

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6. Right click on the PointIO 7 Slot Chassis and select New Module.

7. Select the 1734-IB2 from the Digital directory and select OK.

8. Configure the module as follows, then click on the Change button.

9. From the Electronic Keying pull-down menu, select Disable Keying, then click OK twice to
close the configuration.
Now you’ll configure an Analog Input POINT I/O module.

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10. Right click on the PointIO 7 Slot Chassis and select New Module.

11. Select the 1734-IE2V from the Analog directory and select OK.

12. Configure the module as follows, then click on the Change button.

13. From the Electronic Keying pull-down menu, select Disable Keying, then click OK.

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14. Click on the Configuration tab.

RSLogix 5000 allows you to configure your module directly from the I/O Configuration instead of
doing it from the Controller tag database! You have the possibility to configure each analog
channel independently. The scaling of the Engineering Units does not have to be completed
programmatically anymore – it can be configured from the module wizard.
15. Go the Alarm Configuration tab.
RSLogix 5000 allows you to directly set the process alarms within the module configuration.

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16. Set the limits as shown below, then click OK to exit the configuration.

17. Verify that your I/O Configuration appears as follows:

18. From the toolbar menu, select File > Save.

Your control system is coming together nicely! Let’s review the tasks you’ve completed so far:
ƒ Created a project and configured the controller
ƒ Configured remote Ethernet communications
ƒ Configured local I/O
ƒ Configured distributed I/O
You decide that adding I/O devices to your Integrated Architecture control system is a piece of
cake. Now your manager informs you that you have a new responsibility – updating the outdated
conveyor system in your production cell.

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Lab 2: Adding a Drive to the Control System
Reviewing the Situation
You are now faced with a project involving updating the drives on the conveyor system in your
production cell. You review the current system and realize that the older drive (not a Rockwell
Automation drive, of course) has experienced a transistor failure. After making some phone calls,
you realize it’s cost prohibitive to fix (not to mention that the parts to fix it have been obsoleted).
You work with your local distributor who is able to supply you with a drive to meet your application
requirements: a PowerFlex 70E made by Rockwell Automation. He assures you that this drive can
be added to your Integrated Architecture control system with just a few clicks of your mouse and
says you don’t even have to write any code to make the drive operational. You decide to try it out –
after all, your manager expects the conveyor to be fully operational when he comes to work in a
couple hours.
In this section, you’ll experience the ease of adding a drive to your Integrated Architecture control
system. To demonstrate this, you’ll be working with the PowerFlex 70E drive at your student
station. In this lab you will:
ƒ Configure local EtherNet/IP communications
ƒ Add a PowerFlex 70 drive to the EtherNet/IP network
ƒ Configure the drive in RSLogix 5000
ƒ Execute common commands to control the drive

Adding the PowerFlex70E Drive to the I/O Configuration

1. In the I/O Configuration folder, right click on Ethernet and choose New Module.

2. Expand the Drives selection to view the list of available devices.

3. Select the PowerFlex 70E as shown below and click OK to accept your change.

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4. When the Module Properties window appears, configure the Name as PF70E.

Datalinks
A Datalink is a type of pointer used by PowerFlex drives to transfer data to and from
the controller. Datalinks allow specified parameter value(s) to be accessed or
changed without using explicit messages. When enabled, each Datalink consumes
either four bytes or eight bytes in both input and output image table of the controller.
The type of drive determines the size of Datalinks.

5. Before proceeding, configure the IP address as 192.168.1.x+30 where x is the number of your
student station (for example, if the number of your student station is 5, then the IP address of
your ENBT is 192.168.1.35).
6. Click on the Change button and set the Electronic Keying to Disable Keying.
7. Click OK to exit the configuration and verify that your I/O configuration appears as follows:

Congratulations! In just a few clicks of the mouse, you have added a complex piece of hardware to
your control system and it’s ready to be started without any further configuration.
You have completed the Logix configuration! Let’s review some important benefits of working with
Logix and the Integrated Architecture.

Viewing the Pre-Defined Data Structure for the I/O Devices

When a communications or I/O device is configured in the I/O Configuration, the RSLogix 5000
software automatically generates the Module-Defined Tags native to that module.
The RSLogix 5000 controller automatically creates the Controller-Scoped Tags required for each
configured I/O module and each tag is a structure of multiple fields that uses the following format:
Location:Slot:Type.Member.SubMember.Bit
Let’s see why this is a strengths of the Integrated Architecture.
1. From the Controller Organizer, double-click on Controller Tags.

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 The following screen appears:

2. Locate and expand the PF70E:I data structure to view the tags that were automatically created
when you added the PowerFlex 70 E drive to the I/O Configuration.
Notice that the tag names correlate to the Logic Status bits and Feedback word. These
status/feedback bits can be used in the ladder code for monitoring your drive status.

3. Locate and expand the PowerFlex70E:O data structure to view Logic Command Bits and
Reference word, which were created automatically by adding the PowerFlex 70E to the I/O
Configuration.
4. Take a close look. Can you identify a tag that you think would start the drive? Stop the drive?
Clear a fault? No code is required to execute these commands in the drive!!! As you can see,
within RSLogix5000, you have the ability to configure and control your drive without writing even
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 1 line of code! You can start the drive by simply triggering the start bit of the module defined tag
structure of the drive that you just added in the IO Configuration! We will do that from the
PanelView Plus.Everything is centralized in one location to optimize your development time.

5. Collapse the structure for PF70E:I and PF70E:O in preparation for reviewing local and
distributed I/O module-defined tags.
6. Expand the Local:4:C, Local:4:I, and Local:4:O structures as shown below.

Notice that the input and output data is already available for use – no programming is required
to read or write values! The tags were automatically generated when you added the 1756-
OB16D module to the I/O Configuration.
7. From the toolbar menu, select File > Save.

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Creating Aliases with RSLogix 5000 Software
After looking at the data tags of the Point I/O digital input module you think that the syntax
(Distributed_ControlPanel_7:1:I.0) is not the most explicit name for the first digital input bit of the
module. Not to worry - RSLogix 5000 allows you to create aliases that tie tag addresses to physical
I/O points or other tag addresses!

 FYI
What is an alias?
An Alias tag lets you create one tag that represents another tag.
Both tags share the same value
When the value of one of the tags changes, the other tag reflects the change
Use Aliases in the following situations:
Program logic in advance of wiring diagrams
Assign a descriptive name to an I/O device
Provide a simpler name for a complex tag
Use a descriptive name for an element of an array

Let’s take a look at an example:

A pushbutton is wired on the digital input of the 1734-IB2/C module (in the POINT I/O demo box)
and this button commands the startup of your simulated machine. Would it be better to use a tag
named Start_Machine instead of Distributed_ControlPanel_7:1:I.Data.0? RSLogix 5000 allows
you to do this!
1. From the Controller Organizer, right click on the Controller Tags folder and select New Tag. As
it’s shown bellow:

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2. When the Tag Properties dialog appears, configure the tag as follows (note that the Alias For
tag should be Distributed_ControlPanel_7:I.Data[1].0).

3. Click OK to close the window.

You just simply created an alias tag which can be reused everywhere in your program! Any
time this Alias tag is used in code, it will point to Distributed_ControlPanel_7:1:I.Data.0. Let’s
test it out by writing a simple rung of code and downloading the project to the controller.
4. From the Controller Organizer, double-click on MainRoutine to open the ladder editor.
5. From the ladder toolbar, click on the Examine On (XIC) button as shown below.

The instruction will now appear on Rung 0.

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6. Now click on the Output Energize (OTE) button.

7. Verify that your rung appears as follows:

8. Double-click on the ? above the XIC instruction and select the Start_Machine tag from the list
so that your rung appears as follows:

Let’s create a tag that indicates that your machine is running. To do this, we’ll alias a tag to an
output point on the output combo card in your ControlLogix demo box.
9. Right click on the ? above the OTE instruction and select New Tag.
10. Configure the tag as shown below and click OK to accept your changes.

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11. Verify that your rung of code appears as follows:

12. Add a branch around the Start_Machine instruction and place and XIC on the branch level.
13. Double-click on the ? above the XIC and select the Motor_Running tag so that your run
appears as follows:

14. Add an Examine if Open (XIO) to the rung as shown below and create an aliased tag called
Stop_Machine (alias to Distributed_ControlPanel_7:I.Data[1].1).
15. Verify that your rung appears as follows:

You added the branch level to act as a latch for the momentary Start_Machine input. Without
the Stop_Machine instruction, you have no mechanism to stop the machine.
It’s time to download the project to your controller!

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Lab 3: Downloading and Testing the Project
Downloading the Project
1. From the toolbar menu in RSLogix 5000, select Communications > Who Active.
2. When the Who Active window appears, browse to the controller at your student station (use IP
Address 192.168.1.x+10 where x is the number of your student station), then click Download.
3. Go into Remote Run mode on the controller by toggling the keyswitch to RUN then back to
REM.
4. On the controller faceplate, verify that the I/O OK LED is solid green as shown below:

We are now online with the controller and we should point out a few things:
ƒ Where the display says Rem Run it is indicating the state of your controller. It could also
indicate Program or Test. The color (Blue for Program or Rem Program, Green for Run or Rem
Run, Red for Faulted) will also match the state of the controller.
ƒ The picture of the controller key will mimic the actual key position. Toggle the keyswitch on the
controller to different positions and watch what happens.
ƒ The I/O Not Responding graphic will mimic the I/O LED on the front of the controller; both
should currently be solid green.
Testing Your Code
In this section of the lab, you will test the ladder code of your simulated machine.
1. Make sure you’re viewing the MainRoutine in the ladder editor.
2. Notice the green power flow bars.
This indicates that the controller is scanning your code.

3. On the POINT I/O demo box, press the DI0 green pushbutton and verify that your
Machine_Running bit gets latched in (you should also note that the red pushbutton LED
labeled DO8 is illuminated in your ControlLogix demo box).

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4. Stop the machine by depressing the DI1 green pushbutton in the POINT I/O demo box.
Now that you have experienced the power of tag aliasing, let’s take a look at how you can execute
simple drive commands right from the RSlogix 5000 Controller Tags database.

Executing Simple Drive Commands via RSLogix 5000

1. Verify that the PORT, MOD, and NET A indicators on the PowerFlex drive are solid green and
that the STS LED indicator on the faceplate of the drive is blinking green (if not, press the red
reset button on the HIM).
2. If you’re not already viewing controller tags, double-click on the Controller Tags from the
controller organizer.

3. Click on the Monitor Tags tab at the lower left corner of the tag database.

4. Locate the PF70E:O.DriveLogixRslt.Start tag and enter a 1 into the value field, then click
Enter.
The drive will start running in the forward direction.

5. Enter a 0 into the PF70E:O.DriveLogixRslt.Start value field, then click Enter.

Notice that the drive started on an OFF > ON transition of the Start Command and will continue
to run until a Stop Command is initiated.
6. Locate the PF70E:O.DriveLogixRslt.Stop tag and enter a 1 into the value field, then click
Enter.
The STS LED on the PowerFlex 70 will flash yellow to indicate that a Stop command has been
initiated. The drive will stop.
7. Enter a 0 into the PF70E:O.DriveLogixRslt.Stop value field, then click Enter.
The yellow flashing changes to green flashing.
Try this same procedure for the direction (Forward and Reverse) bits:
8. Enter a 1 into the PF70E:O.DriveLogixRslt.Reverse value field.
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 Notice that the drive motor doesn’t move; you must now enable the drive by toggling the Jog bit.
9. Change the value of the PF70E:O.DriveLogixRslt.Jog tag to 1, then click Enter.
10. Try the same exercise with the PF70E:O.DriveLogixRslt.Forward bit.
11. When finished exercising the drive, ensure that all bits are de-energized and minimize your
RSLogix 5000 project.
Excellent! With just a few clicks of the mouse, the drive has been added to your Integrated
Architecture control system and is now running successfully! You plan on recommending
PowerFlex drives for all others that need replacement (or for new conveyor system startups) in the
future. You just know that your manager will put you in for a raise since this will save your company
lots of time and money.
But, how will the operator control the drive (and review status information)? After all, it’s not like he
(or she) will have a computer running RSLogix 5000 right there on the production floor. Let’s see
how we can add an Operator Interface to the control system to address this issue.

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Lab 4: Controlling the Drive from a VersaView
Terminal
About This Lab
Eager to impress, you go the extra mile and enthusiastically research options for an operator
interface that will seamlessly tie into the Integrated Architecture. Again, you work with your local
distributor who is able to supply you with an operator interface that will meet your application
requirements: a VersaView CE 1000H made by Rockwell Automation. He assures you that this
device can be added to your Integrated Architecture control system with little effort. You decide to
try it out – after all, your manager expects the conveyor to be fully operational when he comes to
work in an hour and your distributor has never steered you wrong in the past.
This lab demonstrates how easy it is to connect ViewAnyWare HMI (Human Machine Interface) to a
RA controller and protocols as well as benefits of application re-use and implementation
commonality. As you complete the exercises in this hands-on session, you will understand how to
develop RSView Machine Edition applications to communicate with a controller and network.
Launching RSView Studio Programming Software
In this section of the lab, you will launch the RSView Studio software. This software will allow you
to program and connect the VVCE terminal to the Logix controller.

1. From the computer desktop, double-click on the RSView Studio icon to launch
RSView Studio software.
2. Select Machine Edition and then click Continue.

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3. Click on the Existing tab, select Machine_Control, then click Open.

Configuring Communications
In this part of the lab we will setup the communication requirements for the system in RSLinx
Enterprise. RSLinx Enterprise is a communications product (server) that links networks and
devices to Microsoft Windows 2000-, XP-, and CE-based applications. In this application we must
provide a link for the HMI device to communicate and receive data from a Logix controller.
1. From the Application Explorer, expand the RSLinx Enterprise directory and double-click on
Communication Setup.

The RSLinx Enterprise Configuration Wizard will open.

Next you will create a device shortcut. In RSLinx Enterprise, a device shortcut represents a specific
path to a controller. Device shortcuts provide a “roadmap/directions” for the HMI device to the
Logix controller. After creating this mapping, the HMI terminal will know where to look for the
information required in the application.
2. In the Communication Setup window, click Add to add a new shortcut.

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The following screen will appear:

 FYI

In the Communication Setup window, there are 2 tabs: Local and Target.
The Local tab displays a view of the system from this workstation's (the
development computer's) perspective. That is, it reflects the view of the network from
the RSLinx Enterprise server on this workstation. It will show all the devices that are
currently online on the network.
The Target tab displays the offline configuration from the perspective of the HMI
device that will be running the application. It will provide the roadmap/directions from
the HMI device to the controller that it will need to communicate with.

3. Make sure you’re on the Local tab, enter the name IA, and press Enter.
4. Click on the + sign next to EtherNet and locate your Logix controller using IP Address
192.168.1.x+10 where x is the number of your student station).

5. Make sure that the IA shortcut is highlighted, click on your controller, and then click Apply.
6. Click the Copy button to copy the shortcut from the Local to Target tab, then click OK to accept
your changes.
7. When the following warning appears, click Yes to proceed.

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 FYI

You have now created a device mapping (communication link) from the computer
you are working on, to the Logix controller at your student station. It is now
necessary to provide this same mapping (communication link) for the HMI terminal
on the target tab of the communication setup. This will be accomplished in the
following steps.

Editing an HMI Display to Control the Drive

The goal of this section is to control the drive from the HMI.
1. From the Application Explorer, expand the Graphics and Displays folders.
2. Double-click on Main Screen to open the display for editing.

The following display appears:

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3. Double-click on the START DRIVE pushbutton to open its properties.
4. Go to the Connections tab and you should see the following window:

5. Click on the ellipsis under Tag.

This will launch the tag browser and will allow you to select a tag for the Tag / Expression line.

 FYI

A Tag is defined by the Logix controller as a named area of the controller’s memory
where data is stored.
You can browse for the Tag / Expression or you can enter it manually.

6. From the Tag Browser, right click on Machine_Control and select Refresh All Folders.

This will add the shortcut that was created in the Communication Setup to the Folders section
and allow you to browse online with the Logix controller.
7. Verify that the Tag Browser appears as follows:

After refreshing, the IA shortcut that was created earlier will appear in the Folders section of the
tag browser. The next few steps will instruct you how to view all the tags and folders located in
the Logix controller you are online with.
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8. Click on the + next to the IA folder to view its contents.

9. Expand the Online folder by clicking the + along side the folder.
The following screen appears:

It looks exactly the same than the Controller Tags database! In fact, you are directly accessing
the ControlLogix controller memory without writing any code! We now want to select the
module-defined tag that will allow us to start the drive.

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10. Click on the PF70E:O tag in the left side frame as shown below.

Notice that the tags that are part of the module-defined structure for PF70E:O appear in the
right side frame.

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11. Click on DriveLogixRslt_Start in the right side frame.

Notice that the Selected Tag window has been populated with your tag selection.
12. Click OK to assign this tag to the momentary pushbutton object.
The tag that was selected will show up in the value section under Tag / Expression.

13. Click OK to save and exit the Momentary Pushbutton Properties.

By clicking OK you are creating a connection from the momentary Push Button to the
ControlLogix controller.

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14. Using the same procedure, assign the Stop tag to the STOP DRIVE button and the ClearFault
tag to the CLEAR FAULT button.

 FYI

There are 2 ways that the commanded frequency of the drive can be changed: via
the potentiometer in the demo box or from a network command. If the drive is
configured to receive the signal from the network, you could assign a tag to a
Numeric Input Enable button to allow you to change the commanded frequency of
the drive. Because the drive at your station is currently configured to receive the
signal from the potentiometer (which is used in another lab exercise), you will simply
be reading the output frequency instead of changing it from your display.

15. Double-click on the Numeric Display.

16. Click on the Connections tab and click on the ellipsis under Expn.

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17. When the following screen appears, click on the Tags button to launch the Tag Browser.

18. From the PF70E:I data structure, select the OutputFreq tag as the data you wish to display,
then click the Arithmetic button to select Multiply as shown below.

19. Enter a value of 0.00397 as the multiplication factor.

This will scale the value so you can view the data in Hertz (Hz).

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20. Verify that the Tag / Expression information appears as shown below, then click OK to accept
your configuration.

21. Save changes to the display by clicking the Save icon.

You’re getting close to having everything operational before your manager arrives at work. Before
downloading the application to the VersaView terminal, you decide to use the handy testing
functionality in the RSView Studio development environment. This is a nice tool for troubleshooting
and testing your application without having to actually download the application to a terminal.
Testing the HMI Application
1. Verify that the PORT, MOD, and NET A indicators on the PowerFlex drive are solid green and
that the STS LED is blinking green.
This indicates that the drive is healthy. If the drive is experiencing a fault condition, press the
red reset button on the HIM.

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2. Click the Play button to test run the application.
This will allow you to verify that the tag you assigned to the numeric display is valid and that the
buttons you configured control the drive.

3. Press the START DRIVE button and verify that the motor starts spinning in your demo box.
Note that the STS LED on the drive faceplate is solid green indicating that the drive is running;
also note that the motor speed is displayed on the HIM on the front panel of the drive.
If the connection is valid, live data should appear in the numeric display as shown here.

4. Stop the drive by clicking the STOP DRIVE button.

Note that the motor speed goes to 0 Hz.
5. Stop the application by clicking the Stop button.

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Creating a Runtime Application and Downloading to the VersaView
Terminal
Before you can download your application to the terminal, you must create a run-time application.
When you create the run-time application, RSView Studio compiles all of the necessary application
information into a single file with the extension .mer. This file can then be used by the PanelView
Plus or VersaView CE terminal to run the application.
1. From the toolbar menu, select Application > Create Runtime Application.

2. Save the file as Machine_Control.mer, then click Save.

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 The following dialog box will appear as the software compiles the application.

Download Your Project to the VersaView CE Terminal and Test the

Application
1. From the toolbar menu, select Tools > Transfer Utility.

2. When the following screen appears, click the ellipsis to browse to the Machine_Control.mer file
you just created.

3. From the Select Destination Terminal window, browse through the Ethernet network to locate
the VersaView CE 1000H terminal at your student station (use IP Address 192.168.1.x+20
where x is the number of your student station).

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4. Click Download.
The file is now being transferred to the VVCE.
5. From the desktop of the VersaView CE terminal, use your finger to double-click on the RSView
ME Station icon.
6. Press the Load Application button.
7. Select your application (Machine_Control.mer) from the list, then press Load.
8. Select Yes at the next prompt, then press Run Application.
9. Test your application.
10. Press the Shutdown Application button on the terminal when testing is complete.
Your manager arrives on the production floor 20 minutes after you have the conveyor operational.
He’s very impressed with the work you’ve done, but raises a concern……….he just came from a
meeting with the Plant Manager and was informed that production of other similar products from
your facility in Wichita are being transferred to your facility and the first parts must be in production
within a 6 month timeframe. A duplicate of the production cell you just migrated to an Integrated
Architecture control system is needed and there’s so little time – especially considering that lead
time on some of the conveyor system parts is over 3 months. Your manager insists that he needs to
dedicate more engineering resources and get them trained on the new control system so they can
help with this new project.
You quickly put your manager at ease by informing him that all the work you just completed is
completely scaleable and transferable – all the way from the HMI level down to the device level. All
the HMI screens you have created and the code you wrote can easily be ported over to the new
production cell - and the new conveyor system doesn’t even have to be functional (or there at all)
for the control system to be complete. You manager is perplexed. “Whatever do you mean?” You
inform your manager that since you have just implemented an IA control system (and the new
production cell is very similar), you already know what field devices are needed and where they
need to be. You tell him that using the Integrated Architecture strategy means doing work only
once, so that engineering resources can be allocated elsewhere because all the work has been
completed already - all you have to do is simply re-map the alias tags and reassign device shortcuts
in the HMI and you’re done.
Your manager is so impressed with your work that he gives you 1 more challenge.

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Lab 5: Integrating Older Technology in Remote
Locations
Reviewing the Situation
The Plant Manager indicated that senior management needs to be able to make business decisions
based on real-time data from the production floor – specifically in the Utilities area of the plant.
When discussing this challenge with you, your manager raises concerns about having the ability to
access that data from the new Integrated Architecture control system you have put together – after
all, the control technology used in the Utilities area is 20 years old. You assure him that with an
Integrated Architecture control system the data is just as accessible in the older controller as in the
latest technology controllers. He promises you the raise you want if you make it work (and make
him look good to senior management).
Your plant now appears as shown below with plant-wide EtherNet/IP and legacy network DH/RIO in
the Utilities area.

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1. From the computer desktop, double-click on RSLinx Classic to open the software (note that it
may already be open in the system tray).
2. From the toolbar menu, select DDE/OPC > Topic Configuration as shown below.

The following window will appear:

Note that a topic called IA is visible in the Topic List. This was automatically created by RSLinx
when you downloaded your project to the Logix controller.
3. Select the New button.
A NEW_TOPIC entry will appear as shown below.

4. Change the name of the topic to Utilities and then press the Enter key.

Now that we have added the new control area, we just have to tell the software where it is in the
plant. We do that by simply “drilling down” through our plant architecture in the same way that you
would “drill down” through the file system on your computer using Windows Explorer. In our case
our path from the computer is as follows (we’ll do this in the following pages):
ƒ Out Ethernet port on your computer onto the Ethernet network
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ƒ To ControlLogix Ethernet module
ƒ Across the ControlLogix backplane to the Data Highway Plus communications module
ƒ Out the Data Highway Plus network
ƒ Into the PLC-5
Let’s start by selecting the Ethernet network.
5. In the right side pane, click on the + next to the Ethernet network as shown below.

Now we can see all the devices on the Ethernet network. All we have to do is select the one we
want. In our case the device we need to travel through is the Ethernet module at IP address
192.168.1.103 (we are going to bridge through the Gateway demo box to the Utilities area).
6. Select the + next to the Ethernet module at IP Address 192.168.1.103.
7. Now select the + next to the Backplane, 1756-A10/A entry as shown below.
You have now gone into the ControlLogix chassis through the Ethernet module and onto the
backplane. Note that you can now see all the modules in the backplane as shown below.

Notice there is a 1756-DHRIO/B module in slot 4 of the chassis. This is a communication card that
connects the chassis to a Data Highway Plus network. We are now going to travel out of the
chassis and over the Data Highway Plus network to a PLC-5 controller.
8. Click the + next to the 1756-DHRIO/B entry, then click on the + next to CH A, Data Highway
Plus (we are using channel A of the module. It also has a second network port, channel B).

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9. Finally, select the PLC-5/80E at node address 04 as shown below.

10. Now that we have identified the Controller we wish to get data from, select the Done button to
complete the configuration.
11. Select the Yes button to the prompt to update the topic.
Now any time we want to get data from that controller, all we have to do is select Utilities from
our list. Let’s go ahead and paste the data into Microsoft Word now.
12. From the toolbar menu, select Edit > Copy DDE/OPC Link.
The following window appears:

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13. Expand the RSLinx OPC Server until you can see Online under Utilities as shown below:

14. Select the + next to Online to expand it as shown below:

Notice that the memory structure of traditional controllers looks a little different than the latest
controllers. That is what is being displayed here. No problem though, it will still work in the
Integrated Architecture.

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15. Click on the N7 file entry on the left side and then select the N7:0 data point from the window
on the right as shown below:

Then click here

First click
here

16. Click the OK button to accept your selection, then minimize the RSLinx software.
17. From the computer desktop, open the Working Folder double-click on the Utilitites.doc file.
18. The following is a simple example of how you can pull data into a tool most of us use everyday:
Microsoft Word. Let’s see how easy it is.

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19. Double-click in the empty cell next to Network Power Consumption so that your screen appears
as follows:

20. From the toolbar menu, select Edit > Paste Special.
21. Make sure to select the Paste Link radio button and Unicode Text in the window and then
select the OK button.

That’s all there is to it! You now have data coming in from a remote location in the plant from
controllers that were purchased in the 80’s. It is that easy because it is truly integrated. Basically, if
you know how to use Windows Explorer you know how to define data to be collected from
anywhere in your plant. The concept is the same, except that instead of expanding folders on a
computer, you are navigating through multiple networks from the office and out onto the plant floor.
ExtraTask
There is a PowerFlex 40 drive on DeviceNet in your Integrated Architecture control system. Using
the procedure above, see if you can go retrieve the output frequency of the device and place it in
your report.
Hint:
When creating your topic in RSLinx, after selecting the target device for the topic, click on the Data
Source tab and select DeviceNet as the Processor Type before completing your topic
configuration.

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 Lab Summary
In this lab, you have worked through some exercises that demonstrated the power and flexibility of
the Integrated Architecture. You completed the following tasks:
ƒ Created a new RSLogix 5000 project
ƒ Configured a Logix controller
ƒ Configured local and distributed I/O
ƒ Configured EtherNet/IP communications
ƒ Reviewed module-defined tags
ƒ Configured aliased tags and wrote code using those aliases
ƒ Added a complex device (PowerFlex 70) to the IA control system with just a few clicks of the
mouse
ƒ Downloaded and tested your project
ƒ Executed simple drive commands without writing any code
ƒ Seamlessly integrated HMI into your control system
ƒ Downloaded your HMI project to the VVCE terminal and tested your project updates
ƒ Created a communication path to an area in your plant (Utilities) that was using 20 year old
technology and showed how easy it is to bring that data into a simulated MES system
By completing these tasks, you have experienced some of the enabling technologies that make the
Integrated Architecture a superior control system:
ƒ FactoryTalk
ƒ ViewAnyWare
ƒ Logix
ƒ Netlinx
Integrated Architecture was designed to help you:
ƒ Reduce time to Market by providing you the ability to gain a competitive edge by getting
products to market faster.
ƒ Improve Plant Uptime by providing solutions that allow you to keep plants running at maximum
capacity.
ƒ Optimize Manufacturing by providing offerings to help you increase yield and maximize use of
production resources.

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