Converting PLC-5 or SLC 500 Logic to Logix-Based Logic
1756 ControlLogix, 1756 GuardLogix, 1769 CompactLogix,
1769 Compact GuardLogix, 1789 SoftLogix, 5069
CompactLogix, 5069 Compact GuardLogix, Studio 5000
Logix Emulate
Publication 1756-RM085E-EN-P
Reference Manual |
Original Instructions |
Converting PLC-5 or SLC 500 Logic to Logix-Based Logic
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
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Publication 1756-RM085E-EN-P - September 2020 |
This manual includes new and updated information. Use these reference tables to locate changed information.
Grammatical and editorial style changes are not included in this summary.
Global changes
This table identifies changes that apply to all information about a subject in the manual and the reason for the change. For example, the addition of new supported hardware, a software design change, or additional reference material would result in changes to all of the topics that deal with that subject.
Subject |
Reason |
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Updated tables that provide Tip, Note, and |
Formatting change. |
Important information. |
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The Legal Noticeshave been updated. |
Removed redundant information. |
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New or enhanced features
None in this version.
Publication 1756-RM085E-EN-P - September 2020 |
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Summary of Changes
Preface
Converting a PLC-5 or SLC 500 Program into a Logix Project
Studio 5000 environment .......................................................................... |
9 |
Additional resources................................................................................... |
9 |
Legal Notices ............................................................................................... |
9 |
Chapter 1 |
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Introduction............................................................................................... |
11 |
What to expect from the Project Migrator......................................... |
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Comparing PLC-5/SLC 500 architecture to Logix architecture ....... |
11 |
The conversion/migration process ..................................................... |
12 |
Preparing RSLogix 5 or RSLogix 500 files for migration ........................ |
13 |
Exporting a PLC-5 or SLC 500 Program ................................................... |
13 |
Export options...................................................................................... |
13 |
Export Option 1: Create two separate exports............................. |
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Export Option 2: Create TXT files and PC5/SLC files for export |
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at the same time............................................................................. |
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Use the Project Migrator Wizard to Convert a PLC-5 or SLC 500 |
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Program ...................................................................................................... |
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Wizard step 1 notes .............................................................................. |
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Wizard step 2 notes.............................................................................. |
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Wizard step 3 notes.............................................................................. |
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Wizard step 4 notes.............................................................................. |
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Common Syntax Errors................................................................. |
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Wizard step 5 notes.............................................................................. |
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Wizard step 6 notes.............................................................................. |
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Working with PCE Instructions................................................................ |
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Recognizing the instructions.............................................................. |
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Locating PCE instructions .................................................................. |
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Resolving PCE Instructions ............................................................... |
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Working with UNK Instructions ............................................................. |
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Configuring the Controller and Chassis ................................................. |
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Mapping the I/O ......................................................................................... |
21 |
Completing the MSG Configuration ....................................................... |
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Other Considerations................................................................................. |
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Table of Contents |
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Chapter 2 |
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Converting Program Structure |
Introduction.............................................................................................. |
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Dividing Logic into Tasks, Programs, and Routines.............................. |
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Creating a Continuous Task..................................................................... |
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Creating Event Tasks ................................................................................ |
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Creating Periodic Tasks for Selectable Timed Interrupts (STIs)........... |
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Converting Input Interrupts (DIIs/PIIs)................................................. |
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Creating a Status File ................................................................................ |
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Chapter 3 |
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Converting Data |
Introduction.............................................................................................. |
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How PLC-5 and SLC 500 files identify data table values.................. |
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How Logix files identify file types...................................................... |
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Converting Input (I) and Output (O) Data............................................... |
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Converting the Status (S) File Type .......................................................... |
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PC5 file migration ................................................................................ |
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SLC file migration ................................................................................ |
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Tags created through GSV during conversion................................... |
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Converting the Binary (B) File Type.......................................................... |
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Converting the Timer (T) File Type........................................................... |
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Conversion rules .................................................................................. |
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Converting the Counter (C) File Type....................................................... |
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Converting the Control (R) File Type........................................................ |
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Converting the Control (R) File Type to Serial Port Control................... |
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Converting the Integer (N) File Type........................................................ |
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Converting the Floating Point (F) File Type ............................................. |
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Converting the ASCII (A) File Type.......................................................... |
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Converting the Decimal (D) File Type ..................................................... |
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Converting the Block-Transfer (BT) File Type ........................................ |
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Block-transfer conversion rules.......................................................... |
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Converting the M0 and M1 File Types ..................................................... |
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Converting the Message (MG) File Type.................................................. |
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Message conversion rules.................................................................... |
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Converting the PID (PD) File Type........................................................... |
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Converting SFC Status (SC) Type ............................................................ |
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Converting the ASCII String (ST) File Type ............................................. |
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PC5 file translation............................................................................... |
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SLC file migration ............................................................................... |
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Converting the ControlNet (CT) File Type ............................................... |
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Converting Constant Values ..................................................................... |
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Converting Indirect Addresses ................................................................ |
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Converting indirect addressing on the file number......................... |
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Table of Contents |
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Converting Indexed Addresses ................................................................. |
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Addresses controlled by the processor status word S:24................... |
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Addresses that specify data in files (Logix arrays)............................ |
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Alias Creation Rules .................................................................................. |
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Converting Symbols.................................................................................. |
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No aliases created (default) ................................................................ |
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Aliases created ..................................................................................... |
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Converting Address Comments............................................................... |
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Chapter 4 |
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Converting Instructions |
Introduction............................................................................................... |
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Conversion Rules Review .......................................................................... |
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Instruction List........................................................................................... |
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Converting CAR routines ................................................................... |
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Converting FOR/NXT/BRK instructions ........................................... |
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Chapter 5 |
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Programming Conversion Errors |
Introduction............................................................................................... |
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(PCE) Messages |
PCE Messages ............................................................................................ |
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Index
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The Studio 5000 Automation Engineering & Design Environment® combines engineering and design elements into a common environment. The first element is the Studio 5000 Logix Designer® application. The Logix Designer application is the rebranding of RSLogix 5000® software and will continue to be the product to program Logix 5000™ controllers for discrete, process, batch, motion, safety, and drive-based solutions.
The Studio 5000® environment is the foundation for the future of
Rockwell Automation® engineering design tools and capabilities. The Studio 5000 environment is the one place for design engineers to develop all elements of their control system.
These documents contain additional information concerning related Rockwell Automation products.
Resource |
Description |
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Industrial Automation Wiring and Grounding |
Provides general guidelines for installing a Rockwell |
Guidelines, publication 1770-4.1 |
Automation industrial system. |
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Product Certifications webpage, available at |
Provides declarations of conformity, certificates, |
http://ab.rockwellautomation.com |
and other certification details. |
View or download publications at http://www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact the local Rockwell Automation distributor or sales representative.
Rockwell Automation publishes legal notices, such as privacy policies, license agreements, trademark disclosures, and other terms and conditions on the Legal Notices page of the Rockwell Automation website.
Publication 1756-RM085E-EN-P - September 2020 |
9 |
Preface
End User License Agreement (EULA)
You can view the Rockwell Automation End-User License Agreement ("EULA") by opening the License.rtf file located in your product's install folder on your hard drive.
Open Source Licenses
The software included in this product contains copyrighted software that is licensed under one or more open source licenses. Copies of those licenses are included with the software. Corresponding Source code for open source packages included in this product are located at their respective web site(s).
Alternately, obtain complete Corresponding Source code by contacting Rockwell Automation via the Contact form on the Rockwell Automation website: http://www.rockwellautomation.com/global/aboutus/contact/contact.page
Please include "Open Source" as part of the request text.
A full list of all open source software used in this product and their corresponding licenses can be found in the OPENSOURCE folder. The default
installed location of these licenses is C:\Program Files (x86)\Common Files\Rockwell\Help\FactoryTalk Services Platform\Release
Notes\OPENSOURCE\index.htm.
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Chapter 1
Converting a PLC-5 or SLC 500 Program into a Logix Project
The RSLogix Project Migrator converts a PLC-5 or SLC 500 import/export file (PC5 or SLC extension) into a complete import/export file (L5K extension).
This manual describes the RSLogix Project Migrator. This chapter describes the pre-migration file preparation and post-migration examples and tasks.
IMPORTANT The Project Migrator converts only ladder instructions. SFC and structured text files are not converted.
The Project Migrator can be downloaded from the Rockwell Automation website.
The goal of the Project Migrator is to reduce the amount of work involved in migrating a PLC-5 or SLC 500 program to a Logix project. The Project Migrator automatically converts the program logic, but it is not the complete solution. Depending on the application, you may need to do additional work to make the converted logic work properly.
The Project Migrator produces a syntactically correct import/export file, but the exact intent of the original application could be lost. This loss could be due to differences in rules. (For example, rules of precedence, rules of indexed addressing, or rules of I/O addressing). When there is an error in the migration, the Project Migrator records the error in the rung of the Logix routine in which it occurred. You can use that error message to analyze and fix the error.
IMPORTANT After running the conversion process, the resulting import/export file still requires further manipulation. You must map the I/O and use BTD, MOV, or CPS instructions to place this mapped data into the structures created by the conversion process.
The Logix architecture differs in several ways from that of the PLC-5 and SLC 500 processors. The Project Migrator converts this legacy architecture as it best fits into the Logix architecture. Because of the architectural differences, you may have to rework the converted Logix project to make sure it operates properly.
The most significant differences in architecture are listed in the following table:
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Architectural issue |
Comparison |
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CPU |
The PLC-5 and SLC 500 processor is based on 16-bit operations. Logix |
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controllers use 32-bit operations. The Project Migrator converts legacy logic |
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into its 32-bit equivalent. |
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operating system |
The PLC-5 and SLC 500 processors support individual program files that |
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can be configured as selectable timed interrupts (STIs) or input interrupts |
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(DIIs/PIIs). In addition, the PLC-5 processor supports multiple main control |
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programs (MCPs). A Logix controller combines these into it’s task, program, |
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and routine organization. The Project Migrator converts the legacy program |
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types into appropriate Logix tasks. |
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input and outputs |
The PLC-5 and SLC 500 processor map I/O memory into I and O data table |
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files. The I/O data is updated synchronously to the program scan so you |
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know you have current values each time the processor begins a scan. A |
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Logix controller references I/O which is updated asynchronously to the |
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logic scan. For a Logix controller, use the synchronous copy (CPS) |
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instruction to create an I/O data buffer to use for static values during logic |
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execution and update the buffer as needed. |
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After the conversion is complete, you must add instructions to copy the I/O |
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data into the I and O arrays. Do this at the beginning or ending of a program |
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to buffer the data so that it is presented synchronously to the program |
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scan. |
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data |
The PLC-5 and SLC 500 processors store all data in global data tables. You |
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access this data by specifying the address of the data you want. A Logix |
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controller supports data that is local to a program and data that is global to |
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all the tasks within the controller. A Logix controller can also share data |
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with other controllers, and instead of addresses, you use tags to access the |
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data you want. |
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Each PLC-5 and SLC 500 data table file can store several words of related |
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data. A Logix controller uses arrays to store related data. The Project |
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Migrator converts the PLC-5 and SLC 500 data table files into Logix arrays. |
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s |
The PLC-5 and SLC 500 s are based on their 16-bit architecture and can |
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have different time bases. A Logix controller is based on its 32-bit |
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architecture and only supports a 1 msec time base. The Project Migrator |
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converts the legacy s as they best fit into the Logix architecture. Converted |
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s might require rework to make sure they operate properly. |
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communications |
The PLC-5 processor supports block-transfer read and write (BTR and BTW) |
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instructions, ControlNet I/O (CIO), and message (MSG) instructions. The SLC |
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500 processor supports block-transfer read and write (BTR and BTW) |
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instructions and MSG (MSG) instructions. The Logix 5000 controllers support |
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MSG instructions of various types. You will need to verify and complete all |
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MSG instructions after migration. |
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The entire conversion process involves the following steps:
Conversion step |
Page |
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Preparing RSLogix 5 or RSLogix 500 files for Migration on page 13 |
9 on page 13 |
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Exporting a PLC-5 or SLC 500 Program on page 13 |
9 on page 13 |
Using the Project Migrator Wizard to Convert a PLC-5 or SLC 500 Program |
13 on page 16 |
on page 16 |
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Working with PCE Instructions on page 19 |
16 on page 19 |
Working with UNK Instructions on page 20 |
17 on page 20 |
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Converting a PLC-5 or SLC 500 Program into a Logix Project |
Conversion step |
Page |
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Configuring the Controller and Chassis on page 20 |
18 on page 20 |
Mapping the I/O on page 21 |
19 on page 21 |
Completing the MSG Configuration on page 22 |
20 on page 22 |
The rest of the chapter describes these steps in detail.
Before using the Project Migrator, it’s best to prepare the RSLogix5 and RSLogix 500 files.
•To save memory, remove unused references from the PLC-5 and SLC 500 application files. The following options are available for you in RSLogix 5 or RSLogix 500 software:
•Delete unused memory. (Tools> Delete Unused Memory)
•Delete unused addresses. (Tools> Database>Delete Unused Addresses)
•To help avoid syntax errors that the Project Migrator will not convert if encountered in the PC5 file, remove SFC and STX routines.
Before you can convert PLC-5 or SLC 500 logic to its Logix equivalent, you must first export the logic to an ASCII text file with a PC5 extension for a PLC-5 file or a SLC extension for an SLC 500 file.
If you elect to convert comments and symbols, you also need the TXT file, which is the standard 6200 programming software format for a documentation file.
Use the RSLogix 5 or RSLogix 500 export procedure to produce two types of files:
•Database files (TXT). These files contain the application’s symbols, address comments, instruction comments, and rung comments. Three TXT files are produced.
•<program name>.txt - Address Comment and Symbols
•<program name>1.txt - Instruction Comments (These are ignored by the Project Migrator.)
•<program name>2.txt - Rung Comments (These are ignored by the Project Migrator. Rung comments within PC5/SLC file are used.)
•Program file format (PC5 or SLC). This file contains an application’s data, RLL statements, and rung comments.
There are a few ways that you can export files for migration using RSLogix 5 or RSLogix 500 software as described on the following pages.
For this option, you export the PC5/SLC files and then export the TXT file.
First, create the PC5 or SLC files for export, using the following steps.
1.In RSLogix 5 or RSLogix 500, select File>Save As. The Save Program As dialog box appears.
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2. |
In the Save in field, select the program you want to export. |
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By default, the software points to the Project folder for the destination. |
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You can enter a different destination directory. |
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In the Save As type field, select the Library Files format (PC5 or SLC). |
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Check the ‘Save data base as external file’ checkbox so that the |
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comments and symbols are included in the export. |
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Click Save. The Export PC5 Format or the Export SLC5000 dialog box |
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appears. |
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On the export format dialog box, use the following steps. |
a. Select Complete Program Save. b. Select all the export options.
c. Click OK.
Then create a TXT file for export, using the following steps.
1.In RSLogix5 or RSLogix 500, from the Tools menu, choose Database > ASCII Export.
The Documentation Database ASCII Export dialog box appears.
2. Select the AB 6200 tab, make your selections, and then click OK.
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The Select Export Destination Directory dialog box appears.
3.Under Directories, select the directory where the PC5 or SLC file resides.
4.Accept the warning about comments and symbols. Click OK.
RSLogix 5 programming software stores PLC-5 programs using RSP file extensions. RSLogix 500 programming software stores SLC 500 programs using RSS file extensions.
To create both files for export at the same time, use the following steps.
1.In RSLogix 5 or RSLogix 500, select File>Save As.
The Save Program As dialog box appears. The example below shows the Save As dialog box from RSLogix 5.
2.In the Save as type field, select X5 or ACH to activate the "Export database" checkbox.
3.Check the "Export database" checkbox.
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4.Under Export file type, select one of the following, depending on the programming software you are using.
•For RSLogix 5, select A.B. 6200
•For RSLogix 500, select A.P. S.
5.In the Save as type field, change the file type from X5 or ACH to PC5 or SLC. Even though the A.B. 6200 format is dimmed, the database will be exported in that format.
6.Click Save. The Export PC5 Format or the Export SLC 500 Format dialog box appears.
7.On the export format dialog box, use the following steps.
d.Select Complete Program Save.
e.Select all the export options.
f.Click OK.
Once you have the ASCII text file of the PLC-5 or SLC 500 program file, you can convert the logic to its Logix equivalent. In the Logix Designer application, use the following steps.
1. From the Tools menu, choose RSLogix Project Migrator.
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2. The wizard appears. Use the wizard to walk through steps 1 through 7.
•To start, select one of the option buttons.
•For PLC-5 to Logix... button - Select this option to browse for PC5 files.
•For SLC-500 to Logix... button - Select this option to browse for SLC files.
•To use a different TXT file name than the program file name, clear the
Documentation file(s) associated with the logic file use the same name checkbox. Browse to the first database file name (TXT).
•RSLogix 5 or RSLogix 500 can also be launched from the wizard. To do so, click the Launch RSLogix 5 or the Launch RSLogix 500 icon at the top of the dialog box.
For this to work, the software must be installed on the same computer as the Project Migrator.
•Browse to the file to be migrated.
•Click Next.
Select or clear the check box for the following option:
•Create Alias Tag for existing PLC-5/SLC Symbols -- This option creates alias tags for all symbols found in the database files. Otherwise the symbols are added as address comments to converted legacy file types.
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•Click Migrate. Since every PLC-5 and SLC500 application is unique, there may be syntax errors.
•If syntax errors occur during migration, they appear in the Status Log pane and include the line at which the error occurred. Choose one these actions to deal with errors:
•Edit the error immediately and click Save & Retry to restart the migration.
•Examine the original application to decide if the area where the syntax error is occurring is something that can be deleted permanently or if it is something that can be removed and then later be recreated in the Logix Designer application.
•Edit the PC5, SLC, and TXT files using a text editor such as Notepad.
•Review the table that follows for the most common syntax errors and their descriptions.
•Specify a file name and folder destination for the migrated file. The default file name is the same as the legacy file with an .L5k extension, and the default folder location is the same as the location of the legacy file.
•Select the Logix controller and version of the Logix Designer application. The version selected should correspond to a version of the Logix Designer application that is supported on the PC.
•Click Next.
The Project Migrator might run into syntax errors within the program and database files. If so, you must correct the errors to continue the conversion. The following table describes common migration errors.
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Syntax Error |
Description |
How to Fix the Error |
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Invalid symbol name |
The Project Migrator expects the symbol names to be |
Search for symbol names that are not alphanumeric. |
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alphanumeric. |
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RSLogix 5 and RSLogix 500 software enforce these rules, but |
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using the 6200 software or manually editing the database |
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files may cause these rules to be broken. |
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" (quote) within a " (quote) |
Quotes are used to denote the start and end of string values |
Either remove the quote or make it a double quote |
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or rung/instruction/address comments. |
(""). The Project Migrator will translate the double |
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If a rung/instruction/address comment contains a quote, the |
quote as a single quote in the Logix Designer |
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Project Migrator does not recognize that it is not the end of |
application. |
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the string. |
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% within a % |
% characters are used to denote the start and end of |
Remove the extra % or make it a double %. The |
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comments within the program file and occasionally in |
Project Migrator will treat the double %% as |
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database files. |
consecutive comments. |
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This type of comment is ignored by the Project Migrator. If a |
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comment contains another %, the Project Migrator does not |
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recognize that it is not the end of the comment. |
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Syntax Error |
Description |
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How to Fix the Error |
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Errant characters |
The program or database file contains a random character |
Remove the errant characters. |
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or two that does not fit the syntax of the program or |
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database files. This is more common with manually-edited |
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files than a direct export from RSLogix 5 or RSLogix 500. |
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Invalid rung syntax |
The rung has invalid syntax, such as unmatched |
Check and fix the rung syntax. |
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Working with PCE
Instructions
Step 5 appears only for SLC and MicroLogix migrations. Select an I/O migration option:
•Keep existing I/O in a separate rack - Keeps the legacy I/O modules as they exist in the .SLC file, attaching them remotely via EtherNet in a legacy chassis.
•Replace all I/O with equivalent newer models - Displays a list of all I/O modules detected in the legacy file. Select the desired converted I/O module, onto which the Project Migrator maps the legacy I/O. Manually verify compatibility with the chosen output module. You can opt to create a placeholder tag rather than selecting an I/O module. When you select this option you must manually add the desired I/O and handle any copying operations from the migrated output file.
When the migration is complete, click Exit to close the Project Migrator, or click Launch RSLogix 5000 to open the Logix Designer application and import the migrated project.
The Project Migrator inserts a Possible Conversion Error (PCE) instruction within the appropriate ladder rung to help you identify possible errors with the conversion. To complete the conversion process, you will want to locate, analyze, and fix any discrepancies using the PCE instructions.
For a list of PCE instruction errors, see Appendix A Programming Conversion Errors (PCE) Messages on page 65
Text is appended to the rung comments that have the PCE instruction. The message text begins with asterisks (*) and the words "Generated by Translation Tool", and ends with asterisks.
An example of a PCE instruction follows:
*** Generated by Translation Tool: Source and destination types may differ *** ";
N: PCE(120, PCE011) COP(I1_008, N23[0], 4);
You can also locate all of the PCE instructions by verifying the logic. The Verify > Controller task compiles the Logix program and checks for errors. This is an easy way to see where all the PCE instructions are because the error checking will point them out. To locate the PCE instructions, use the following steps.
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Chapter 1 |
Converting a PLC-5 or SLC 500 Program into a Logix Project |
Working with UNK
Instructions
Configuring the Controller
and Chassis
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1. From the Logic menu, choose Verify > Controller.
The bottom of the screen displays the results.
2. Double-click the error shown in the error window to go directly to the rung where the error resides.
Once you import the converted Logix project, find each PCE instruction. A PCE instruction highlights a possible conversion error. Delete each PCE instruction and replace it with the appropriate, corrected logic.
The Project Migrator converts some PLC-5 and SLC 500 instructions that have no equivalent in the Logix architecture. Once you import these instructions into the Logix project, they appear as UNK instructions. You must delete each UNK instruction and replace it with the appropriate corrected logic.
Once you have resolved any errors, continue the conversion process by using the Controller Properties dialog box in the Logix Designer application to assign the chassis size and slot number of the controller. Use the steps that follow.
1.Click the Controller Properties icon to open the Controller Properties dialog box.
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Chapter 1 |
Converting a PLC-5 or SLC 500 Program into a Logix Project |
2. Select Properties. The Controller Properties dialog box appears.
3.Configure the controller by specifying the slot number of the controller and the chassis size.
4.Click OK.
5.Continue to use the Controller Organizer to specify the I/O modules and other devices for the controller. The example that follows shows how to specify the I/O module.
g.Select the backplane.
h.Right-click and select New Module.
The file structure in a Logix controller is tag-based. To facilitate the conversion, the Project Migrator creates tags and arrays of tags to align and map the PLC-5 files. For example:
PLC-5 address |
Maps to: |
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N7:500 |
N7[500] |
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N17:25 |
N17[25] |
R6:100 |
R6[100] |
I:002 |
I[2] |
O:001 |
O[1] |
The tags created for physical I/O (For example, I.2) are empty at the end of the conversion process.
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