Simatic S7 to Logix5000 Application Conversion Guide.pdf

Simatic S7 to Logix5000

Application Conversion Guide

Application Solution

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Appli-

cation, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office

or online at http://literature.rockwellautomation.com ) describes some important differences between solid state equipment and hard-wired

electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons re-

sponsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application

of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements as-

sociated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the ex-

amples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in

this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Identifies information about practices or circumstances that can cause an explosion in a

hazardous environment, which may lead to personal injury or death, property damage, or

economic loss.

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death,

property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and

recognize the consequence

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that

dangerous voltage may be present.

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that

surfaces may reach dangerous temperatures.

Allen-Bradley, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Table of Contents

Preface

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Conversion versus Translation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PLC Logic Conversion Services Provided by Rockwell Automation . . 9

Service Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

One-stop PLC Program Conversion Services . . . . . . . . . . . . . . . . . 9

Service Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Services Offered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Basic Conversion Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Conversion Plus Initial Clean-up Package . . . . . . . . . . . . . . . . . . . 10

Additional Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Additional Program Conversions Available . . . . . . . . . . . . . . . . . . 11

Chapter 1

Hardware Conversion

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

S7 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

S7 Local I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Selection and Configuration of S7 I/O Components . . . . . . . . . . 14

Logix Local I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Selection and Configuration of Logix I/O Components . . . . . . . 18

S7 Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Configuration of S7 Profibus DP Remote I/O . . . . . . . . . . . . . . . 21

Logix Distributed I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Configuration of Logix Distributed I/O . . . . . . . . . . . . . . . . . . . . 22

Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Networks in S7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Networks in Logix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Conversion of HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Conversion of Systems Containing Distributed Controllers . . . . . . . . 32

Hardware and Software Implementation . . . . . . . . . . . . . . . . . . . . 32

Connecting Siemens and Rockwell Automation Devices . . . . . . . . . . 34

Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Distributed Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 2

Logix Features that May Not be

Familiar to S7 Users

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

S7 Organization Blocks Compared to Logix Tasks . . . . . . . . . . . . . . . 36

Organization Blocks in S7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Tasks in Logix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Task Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Tags Not Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Data Areas in S7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Data in Logix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

I/O and Alias Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Programming Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Logix Ladder Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Logix Structured Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Logix Function Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Logix Sequential Function Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Conversion of STEP 7 Code to Logix . . . . . . . . . . . . . . . . . . . . . . 55

Arrays not Pointers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Add-On Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Add-On Instruction Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Backing Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

The Common Industrial Protocol (CIP). . . . . . . . . . . . . . . . . . . . . . . . 58

Viewing the Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Data Exchange between Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Send / Receive in STEP 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Produced / Consumed Tags in Logix. . . . . . . . . . . . . . . . . . . . . . . 60

User-Defined Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Asynchronous I/O Updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

The DINT Data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Phase Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Phase Management in STEP 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

PhaseManager in Logix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Coordinated System Time (CST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Timestamped Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Scheduled Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

No Temporary Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

No Accumulators or Special Registers needed . . . . . . . . . . . . . . . . . . . 66

Chapter 3

Conversion of System Software

and Standard Functions

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Logix System Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Date and Time Setting and Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Read System Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Handling of Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Status – Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Status – Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Status – for OBs and Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Conversion Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

String Handling Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Examples of System Function Calls . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Disabling Interrupts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Read System Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Get Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Module Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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Get Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Chapter 4

Conversion of Typical Program

Structures

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Conversion Code Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Ladder Logic Translation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Jumps and Decision Making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

User Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Pointers and Arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

State Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

STEP 7 State Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

STEP 7 Temporary Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Block Copy, COP and CPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Mathematical Expressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Other Topics Related to Programming. . . . . . . . . . . . . . . . . . . . . . . . 120

Scope of Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

OBs, Tasks, and Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

A Larger Example - Control Module . . . . . . . . . . . . . . . . . . . . . . . . . 121

Components of the CM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

User Data Type Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

The Add-On Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Add-On Instruction Local Data . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Call-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Chapter 5

Common Mistakes when

Converting to Logix

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Not Selecting Appropriate Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 129

Underestimating Impact of Task Scheduling . . . . . . . . . . . . . . . . . . . 130

Performing Translation Instead of Conversion . . . . . . . . . . . . . . . . . 130

Not Using the Most Appropriate Logix Languages . . . . . . . . . . . . . . 130

Implementation of Incorrect Data Types – DINT versus INT . . . . 131

Add DINTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Add INTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Timing Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

User Code Emulating Existing Instructions . . . . . . . . . . . . . . . . . . . . 132

User Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

COP Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Incorrect Usage of COP, MOV, and CPS . . . . . . . . . . . . . . . . . . . . . 133

Incorrect Usage of CPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Not Handling Strings in Optimal Way . . . . . . . . . . . . . . . . . . . . . . . . 133

Extensive Usage of Jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Not Using Aliased Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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