Rockwell Automation ControlLogix 5570 and 5560 controllers

After the upgrade is completed, the controller automatically restarts and the confirmation status screen displays the new firmware version (such as "Rev 30.011").

(2) AutoFlash upgrade

Create a project in Logix Designer, click on "Who Active" to find the target controller, and select "Update Firmware".

Select the firmware file path and version, confirm that the controller is in "Remote Program" mode and there are no uncleared faults, and click "Update".

During the upgrade process, the progress is displayed (5570 points for "update count/block count", 5560 only displays "block count"), and the firmware version is verified after completion.

3. Memory and storage configuration

5570 series: SD cards are used to store project and fault logs, supporting three modes: "power on load", "load when memory is damaged", and "user triggered load". Locking the SD card can prevent firmware from being overwritten.

5560 series: The CompactFlash card needs to be configured with the "store/load" parameter in Logix Designer, supporting program backup and recovery. When replacing the battery, ensure that there is a backup in the card to prevent data loss.

Communication network configuration

1. Supported communication protocols and modules

The controller supports multiple types of industrial networks and requires corresponding communication modules. The core configuration is as follows:

Network type, communication module model, core function, maximum number of connections/bandwidth limit

EtherNet/IP 1756-ENBT/EN2TR/EN3TR supports production and consumption tags, I/O control, and HMI communication. 1756-EN3TR supports 256 movements in 128 axes (EN2T/EN2TR); 128 (ENBT)

ControlNet 1756-CNB/CN2/CN2R/CN2RXT deterministic real-time communication, supporting 64 redundant media (CN2R/CN2RXT) (CNB/CNBR); 128 (CN2/CN2R)

DeviceNet 1756-DNB connects distributed I/O and drivers, supports scanning list configuration with 124 DINT input/123 DINT output

Data Highway Plus (DH+) 1756-DHRIO/DHRIOXT connects PLC-5/SLC controllers, supporting 32 sites at 57.6/115.2/230.4 kbps rates

HART 1756-IF8H/OF8H analog I/O+digital signal superposition, supports direct connection to HART transmitter for device diagnosis

2. Key steps for communication configuration

(1) EtherNet/IP configuration

Add modules such as 1756-EN2T in the "I/O Configuration" of Logix Designer and set the IP address (supporting BOOTP/DHCP allocation).

Configure "Production/Consumption Tags": Production tags need to specify the number of consumers, while consumption tags need to match the production tag data type and RPI (Request Packet Interval).

Remote I/O configuration: Reduce the number of connections through "rack optimization connections", and a single connection can cover the entire remote rack I/O.

(2) Serial Communication (5560 Series)

Connect the 1756-CP3 serial port cable, configure the "RS-232 DF1 device driver" in RSLinx, and select the "Logix 5550/CompactLogix" device type.

Supporting protocols: DF1 master-slave/point-to-point/wireless modem, DH-485, ASCII, Modbus (requiring MSG instruction programming), ASCII protocol requires configuring buffer size (1-4096 bytes) and termination characters.

Programming and Application Development

1. Control program structure

The Logix 5000 control program consists of a three-level structure of "task program routine", with the following core rules:

Tasks (up to 32):

Continuous task (1): lowest priority, utilizing idle CPU time for cyclic execution.

Periodic task: Execute at set intervals (0.1~2000000ms), priority 1~15 (highest 1).

Event task: triggered by triggering conditions (such as I/O status changes, consumption tag triggers) for execution.

Program (up to 1000 per task, V24+): Contains local tags, parameters, main routines, fault routines, supports "scheduled execution" (executed in sequence) and "unplanned execution" (only verified and not running).

Routine: executable code written in a single programming language, supporting ladder diagrams (LD), function block diagrams (FBD), structured text (ST), and sequential function diagrams (SFC).

2. Core programming functions

(1) Production/Consumption Tags (Interlock Data)

Production label: One controller releases data, and multiple controllers (up to 32) consume it simultaneously. It must be on the same network (not bridged across networks), and the data type and array dimension must be consistent.

Connection calculation: The production label occupies "number of consumers+1" controller connection, the consumption label occupies 1 connection, and the communication module occupies an additional 1 connection.

(2) MSG instruction (message communication)

Supports types such as "CIP Data Table Read/Write", "PLC-5/SLC Communication", "General CIP", etc. It can cache connections (optimize speed during repeated execution, up to 32 cache connections) or non cache connections (release connections after execution).

Block Transfer requires the configuration of a "request/response" data area, which is suitable for high-speed counters, frequency converters, and other devices.