An introduction to Rockwell Automation's portfolio of Allen Bradley PLCs and their relative positioning.
In this post, I’ll introduce Rockwell Automation’s portfolio of Allen Bradley PLCs. After reading this post, you will know;
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The lead products in the Rockwell Automation controller portfolio are;
The Micro800 controller family is positioned for simple machines and is primarily marketed to high volume OEMs that are particularly price conscious.
The Logix 5000 portfolio is the heart of the Rockwell Automation Integrated Architecture portfolio of controls products. Logix 5000 controllers include CompactLogix controllers which are typically targeted towards standard machines and the ControlLogix controller platform for large or complex applications.
AADvance and Trusted are strictly Process Safety platforms that are not used for standard control. They are outside the scope of this post, but are often included in controller literature so they are mentioned on this overview for reference.
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Micro800 controllers are designed for low-cost, standalone machines. These economical small-size PLCs are available in different form factors based on the number of I/O points embedded in the base, with a range of features intended to address different requirements.
The Micro800 family shares programming environment, accessories, and plug-ins that allow machine builders to personalize the controller for specific capabilities.
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The Micro800 family utilizes Connected Components Workbench (abbreviated CCW) for programming.
CCW is a single software that supports Configuration, Programming, and Visualization of the major control components of a machine including safety. The same tool that programs Micro800 controllers is used to configure PowerFlex drives and Guardmaster configurable safety relays. CCW is also used to develop HMI applications for PanelView 800 HMIs. Other Rockwell Automation products are also configured in this software package.
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The Micro800 family features a set of plug-ins to add additional functionality without impacting the footprint or price of the base controller. This enables the user to buy "just enough control" for the application.
Plug-in modules include additional I/O, isolated analog I/O, communication modules, and backup memory modules, among other functionality.
Plug-ins work with the Micro820, 830, 850, and 870 but not with the Micro810.
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The Micro850 and 870 family can be further expanded through the use of 2085 Expansion I/O. These modules click firmly into the right side of a Micro850 or 870 controller to form one large brick.
This expansion I/O is more advanced, of higher density, and more expensive compared to the Plug-in I/O modules.
2085 Expansion I/O is only for use with the Micro850 and Micro870 controllers, not the other controllers in the Micro800 family.
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The Micro810 controller is a little bit different than the rest of the Micro800 family.
Micro810 controllers function as a smart relay with high current relay outputs, but with the programming capabilities of a micro PLC using the same CCW software.
The Micro810 does NOT use the plug-ins that are used by the other Micro800 models for I/O, communications, and other functionality.
The Micro810 can be equipped with an optional plug-in LCD screen with buttons for visualizing the current status and also as a secondary means for configuring the controller.
Micro800 controllers and the Connected Components Software are a low-cost, easy to implement PLC platform targeted at machine builders building small, standalone machines.
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The Micro800 family is positioned for micro sized to small sized applications.
The portfolio of Logix 5000 controllers is positioned above the Micro800 family. There are Logix controllers appropriate for small applications to the very largest automation applications with tens of thousands of I/O points.
Logix controllers are the core of Rockwell Automation's Integrated Architecture portfolio of automation control products. This is Rockwell Automation's tightly integrated portfolio of advanced control products, including Logix 5000 controllers, I/O, servos, drives, and visualization for a wide variety of automation applications.
Customers select Logix 5000 controllers for a number of reasons including;
Logix 5000 controllers are capable of multi-discipline control.
Multi-discipline control is the capability of executing multiple control disciplines in a single controller. Traditionally these different disciplines would have required separate controllers, separate software, and then added engineering effort for integration. For manufacturers, this results in architecture simplification and lower maintenance costs.
Logix 5000 controllers are scalable.
Logix can be used as the control architecture for small to large systems, all in a common design environment.
Logix 5000 controllers communicate using EtherNet/IP
EtherNet/IP, a real-time control network that utilizes standard, unmodified Ethernet and Internet Protocol. One benefit of unmodified Ethernet is that it is "IT ready", which is particularly important as more and more automation applications are connected to enterprise networks.
Logix 5000 controllers deliver real-time information
The Integrated Architecture platform, with Logix 5000 controllers at its core, enables manufacturers to turn data into actionable information, starting right where the information is born.
The Logix 5000 controller portfolio consists of several product families grouped under ControlLogix and CompactLogix.
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ControlLogix is positioned for larger, more complex applications. ControlLogix has higher I/O counts, more axes of motion, and more flexibility, such as expandable communication options.
Because of the additional value, ControlLogix is generally higher in cost as compared to CompactLogix. Historically it had higher processing power than CompactLogix, although in the most recent generation, the actual processing performance is the same.
Another difference is that ControlLogix has more features targeted at Process applications, such as HART and redundancy.
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CompactLogix controllers are targeted at small to medium-sized applications. CompactLogix is a great fit for customers looking for a smaller footprint controller, because the power supply and Ethernet ports are embedded and the platform does not use a chassis.
However, CompactLogix does not have the expandable network options of ControlLogix, nor does it have the redundancy capability required for some process control applications. In many ways, CompactLogix is more targeted at OEMs while ControlLogix is targeted at End Users.
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The term Guard means a safety version. GuardLogix is a controller that does everything that the equivalent ControlLogix controller does, plus enables safety rated control for safety applications, such as safety related machine stop based on the status of a light curtain.
Similarly, Compact GuardLogix does everything the equivalent CompactLogix does, plus the safety control.
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The term "Armor" is used for an OnMachine version of the product where the controller and EtherNet/IP communications cards are pre-installed in an enclosure that can be directly mounted on a machine. It does not have to be mounted inside an electrical panel. This concept is particularly popular with the American automotive industry. There are OnMachine versions of both the standard and safety versions of Logix.
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All Logix 5000 controllers are programmed in Logix Designer which is part of the Studio 5000 design environment.
A previous version of the Logix controller programming software was called RSLogix 5000, so you may hear that term. Studio 5000 also includes tools to architect complete systems, create a database of reusable application code, emulate Logix systems, and program PanelView 5000 HMIs.
To program Logix 5000 PLCs, you need to purchase Studio 5000 Logix Designer.
Now that the Logix 5000 platform has been introduced, let’s look at the specific features of each product family, starting with the CompactLogix System.
CompactLogix is a product name that is used for several similar controller product families. Generally speaking they are positioned above the Micro800 family and below the ControlLogix family. All CompactLogix families are rack-less, meaning that they do not have a chassis. In CompactLogix systems the controller is typically on the left side, with I/O and other expansion modules to the right. The backplane for electrical connection to expansion modules is a connector on the right side of the controller.
In the more recent generations of CompactLogix, including all the models that would be the lead products for new applications, the EtherNet/IP network communications are embedded in the controller module itself and do not require a separate communications module. These Ethernet ports are typically on the bottom of the controller module pointing down.
A project can be downloaded to the controller either remotely via the Ethernet connection or locally through the USB port.
CompactLogix controllers have an SD Card slot (behind the small door), primarily used for backing up the controls program. This SD Card can be used to quickly load the program onto a replacement controller.
The catalog number for CompactLogix controllers starts with 1769 or 5069.
There are a many different CompactLogix models, enabling users to select the most cost effective solution that meets the needs of the application. This does mean that product selection is a bit complicated.
Two of the main things that differentiate models within a given product family are the amount of user memory for storing the application and the number of network connected devices. Typically these reflect the size of the application.
Another differentiation between models is Integrated Motion. This is a simple application question - if Motion (in other words, Servo) Control is required, the customer buys a CompactLogix model that includes this functionality. If the application does not require Motion, the customer can buy a less expensive model that does not include the Motion control functionality. In every other way, the two models would function the same.
Similarly, many CompactLogix models offer a Compact GuardLogix version that includes Integrated Safety. In this case the selection is a bit more complicated, as safety applications are often handled external from the controller.
One example of external safety is the use of monitoring safety relays. With regards to CompactLogix selection, the important question will be whether the application could benefit from the use of Integrated Safety, where the Compact GuardLogix handles the safety control in addition to the standard control.
Another factor that drives selection between CompactLogix product lines is which local I/O is preferred. Different CompactLogix models utilize different local I/O platforms.
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This image above graphically shows the relative positioning of the CompactLogix product lines.
One functionality difference is that each product line to the right is capable of controlling more axes of motion (when the Integrated Motion model is selected) as compared to the less expensive product lines to the left.
Another difference is that each product line to the right has a higher maximum User Memory size.
The CompactLogix 5370 L1 and 5370 L2 product lines feature embedded I/O right in the controller module, in addition to the ability to add local expansion I/O. Other CompactLogix product lines do NOT have embedded I/O, meaning the controller relies on some combination of local expansion I/O and remote I/O connected over a network.
The different product lines utilize different local expansion I/O platforms. The 5370 L1 controller uses 1734 Point I/O for local expansion I/O. The Point I/O backplane connects directly to the 5370 L1. The 5370 L2 and 5370 L3 product lines use the traditional 1769 Compact I/O for local I/O. The 5380 product line utilizes the Compact 5000 High Performance I/O for local I/O.
There are Integrated Safety versions of the 5370 L3 and 5380 controllers. They are called Compact GuardLogix 5370 and 5380, respectively. There are not safety versions of the L1 and L2 controllers.
There are also older CompactLogix product lines that are not shown here.
There is a published CompactLogix Selection Guide that provides many more details about the specific functionality of each product line and individual catalog number. Always check the posted version of this document for the latest information.
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Now that we've discussed the CompactLogix controllers, let's move on to the ControlLogix platform.
ControlLogix is a chassis-based controller that requires some type of communications and I/O.
Modules that provide this functionality are installed into a chassis, like the one shown above.
The power supply is on the left.
A controller can be installed in any slot in the chassis and multiple controllers can be installed in a single rack.
Some of the newest ControlLogix controllers have an EtherNet/IP communication port built in, but it is more common for the communications to be on a separate, dedicated module that is connected to the controller via the chassis backplane.
I/O for the system can be in the local chassis or it can be distributed I/O that is connected to the controller via a control network, such as EtherNet/IP.
There are modules that provide other specific functions, such as redundancy for highly critical applications and Model Predictive Control for advanced tuning of process applications.
Most Rockwell Automation products intended to be installed as modules in a ControlLogix rack have catalog numbers that start with 1756, including the controllers, the communications cards, and the local I/O.
ControlLogix controller model names start with 55 followed by a number indicating the model generation and a fourth digit indicating the specific model. Examples include 5573 and 5585.
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Many ControlLogix and GuardLogix models have a specialized version called -XT for extreme environments.
The primary technical differences are a wider temperature range and improved protection against corrosive environments. Notice that the chassis includes larger spacing between the modules for improved airflow. This is just one of many design modifications to achieve the wider temperature range. The improved protection against corrosive environments is achieved by conformal coating of the electronics.
There are many 1756 network and I/O modules.
These can be installed in chassis with or without a ControlLogix controller. If there is no controller in a given chassis, that chassis would typically be remote I/O for a Logix controller connected via a network.
There are network modules available for many common automation networks.
There is a wide variety of types of I/O modules to meet many different application requirements.
There are specialty modules for dedicated functions, such as a Compute Module which is basically an industrial computer in the rack, a Model Predictive Control module for advanced process applications, and a network security module.
There are even third party modules that provide functionality not covered by the Rockwell Automation product line.
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Now that each of the lead products have been discussed, the image above reiterates how they're positioned relative to each other.
The Micro800 is an entry level controller platform with free software targeted at volume OEMs with significant price sensitivity.
CompactLogix and ControlLogix are a common platform with a common design software. This software is called Logix Designer and it is part of the Studio 5000 design environment.
There is very little overlap between the target applications for the Micro800 family and the Logix controller family.
CompactLogix is a collection of related products. They are sometimes referred to as "Mid-range" and are typically targeted at standard machines, although some newer controllers in this family are high performance and quite capable of advanced applications.
While there is some capability overlap, ControlLogix is generally positioned above CompactLogix. It has more network options and specialty functionality. Some functions that are often required for Process applications are only available in the ControlLogix platform, such as redundancy.
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As well as the lead products discussed in this post, there are some older Allen Bradley PLC products lines that you may encounter.
These products are either older or already obsolete, but they each have a very large install base.
The MicroLogix was the previous generation of micro controller and it is very popular with OEMs. Some MicroLogix models have been obsolesced but others are still available to buy and fully supported.
The MicroLogix shares programming software with another product called the SLC, short for Small Logic Controller. You will often here the product called "SLICK". It was designed for applications similar to what would be covered by CompactLogix today. Like the MicroLogix, some SLC models are still sold and supported today, while a larger part of the product line has been obsolesced.
The PLC-5 was introduced in the mid-1980s and only recently made obsolete. It still enjoys a huge install base.
After reading this post, you should be able to;