In this chapter, we will introduce the CompactLogix platform by exploring its genesis and evolution since its initial launch in 2001. We will explore the myriad different versions and form factors that are available within the CompactLogix product line and their typical use cases. The CompactLogix product line is by far the most confusing of the Rockwell Automation family due to the wide range of low-cost products and confusing naming conventions. I will attempt to unravel this product line throughout this chapter.

This chapter will cover the following topics:

• Introducing CompactLogix controllers
• Navigating the CompactLogix controller family
• CompactLogix deprecated controllers
• CompactLogix 5370 controllers
• CompactLogix 5380 controllers
• CompactLogix 5480 controllers
• Identifying compatible products

In the first section of this chapter, we will introduce the CompactLogix family of controllers and provide an overview of its history.

Technical requirements

To complete this chapter, you need to create a Rockwell Automation support account by going to https://www.rockwellautomation.com/account/create-account.

Creating an account is free, and the material we will refer to in this chapter is publicly available to anyone who has registered with Rockwell Automation.

You will also need a copy of RSLogix or Studio 5000 to program your project. You can either purchase this from your local distributor or request a time-limited trial version. You can find a local distributor for Rockwell Automation products at https://locator.rockwellautomation.com/.

Introducing CompactLogix controllers

In 2001, Rockwell Automation first shipped the L43 CompactLogix (Bulletin 1768) controllers, targeted at small- to medium-size automation solutions. At launch, the CompactLogix Controller was intended as the long-term replacement for the SLC-500 controller family. The CompactLogix control platform was designed with an emphasis on the controller software. As the CompactLogix hardware evolves with improved performance and additional features, the logic can easily be migrated to new hardware and firmware versions.

Unlike the SLC-500 platform, the CompactLogix controllers can be programmed using the same RSLogix 5000 (Logix Designer) software suite that is used with ControlLogix. In 2006, the CompactLogix L43 was launched with integrated motion support. In 2008, Rockwell Automation released the low-cost CompactLogix L23 (Bulletin 1769) controllers with embedded I/O and the L3x modular (Bulletin 1769) controllers.

In 2009, Compact GuardLogix, an SIL 3 certified controller with the L43S and L45S CPU supporting integrated safety was added to the Logix family. The 1769 CompactLogix modules do not have a chassis like the ControlLogix modules do. The 1769 CompactLogix modules can connect together using a DIN rail (which stands for "Deutsches Institut fur Normung rail") can be screwed in directly to a panel. In 2016, the latest generation of CompactLogix controllers was announced, the Bulletin 5069 CompactLogix 5380 Controllers.

The following table provides a high-level overview of the evolution of the CompactLogix family of controllers:

In the next section, we will discuss the various form factors and features that comprise the CompactLogix family of controllers in greater detail.

Navigating the CompactLogix controller family

CompactLogix embodies a wide-ranging series of controller solutions, which can be a challenge to navigate for those who are new to the platform. CompactLogix controllers represent a low-cost solution for industrial automation problems that still have the power of the Studio 5000 development environment behind them. CompactLogix controllers come in many different fit-for-purpose form factors that we will detail in this chapter.

There are more factors to consider when selecting a CompactLogix controller due to their modular nature and the wide range of form factors available, such as the following:

• Supported Logix Designer software versions
• Cabinet size restrictions
• CompactLogix form factors/I/O module scalability
• Processing requirements of your current application and future expansion
• Memory requirements of your current application and future expansion

The CompactLogix product line is broken down into the following five categories:

• 1768 CompactLogix controllers
• 1769 CompactLogix L3x controllers
• 1769 CompactLogix 5370 controllers
• 5069 CompactLogix 5380 controllers
• 5069 CompactLogix 5480 controllers

The various model numbers for CompactLogix don't follow an incremental model numbering scheme, which is often a point of confusion.

The following CompactLogix controller table illustrates the release timeline of the various CompactLogix controller model numbers:

Bulletin 1768 CompactLogix controllers (no longer supported by Rockwell Automation):

Bulletin 1769 L23x packaged controllers with embedded I/O (no longer supported by Rockwell Automation):

Bulletin 1769-L3x modular controllers (no longer supported by Rockwell Automation):

Bulletin 1769 CompactLogix 5370 controllers:

Bulletin 5069 CompactLogix 5380 controllers:

Bulletin 5069 CompactLogix 5480 controllers:

It is also important to consider that some of the CompactLogix 5370 controllers are slated as direct replacements for some of the older CompactLogix controllers (although the older controllers are still available for purchase):

• 5370 1769-L24 replaces 1769-L23.
• 5370 1769-L3x replaces 1769-L3x.

In the next section, we will explore the various CompactLogix deprecated controller series.

CompactLogix deprecated controllers

Now that we have introduced the CompactLogix product line, it is time to dive into the wide range of form factors and varying features available. In this first section, we will discuss the CompactLogix controllers that have reached the end of their life cycle and are no longer supported by Rockwell Automation. It is important to identify these controllers as it is still quite common to encounter them operating in the field today.

First, we will introduce the L43 and L45 controllers in the following section.

Bulletin 1768 – L43 and L45

The CompactLogix L43 and L45 controllers were first introduced in 2001 and have subsequently been replaced by the 5370 and 5380 CompactLogix controllers. The L43 and L45 platforms featured the following:

• A compact flash memory card
• An Ethernet port
• A serial RS-232 port
• 1769/1768 modules (can only be placed to the right of the power supply)
• A power supply module

The following illustration depicts the L43 and L45 CompactLogix series controller with power supply and I/O modules:

As of July 2020, the Bulletin 1768-L43 and 1768-L45 CompactLogix controllers have been discontinued and are no longer available for sale. Rockwell Automation recommends migrating to the newer CompactLogix 5370 or CompactLogix 5380 control platform.

In the next section, we will detail the L23x controller, which is also no longer being produced by Rockwell Automation.

Bulletin 1769 – L23x

The L23x CompactLogix controller is a highly compact controller featuring embedded I/O. The L23x controller has been discontinued and replaced by the 5370 and 5380 CompactLogix controllers.

The L23x platform featured the following:

• A serial RS-232 port
• An Ethernet port (only on E models)
• Embedded I/O
• An embedded power supply module

The following illustration shows the L23E featuring an embedded network card and its embedded I/O points:

L23x CompactLogix controllers have been discontinued and are no longer available for sale. Rockwell Automation recommends migrating to the newer CompactLogix 5370 or CompactLogix 5380 control platform.

In the next section, we will discuss the CompactLogix L3x modular controllers.

Bulletin 1769 – L3x modular controllers

The L3x CompactLogix controller is a modular controller platform featuring replaceable I/O cards similar to the ControlLogix platform. The L3x controller has been discontinued and replaced by the 5370 and 5380 CompactLogix controllers.

The L3x platform featured the following:

• A CompactFlash memory card
• A serial RS232, or ControlNet, or Ethernet port
• 1769 modules that can be placed to the left or right of the power supply module
• A power supply module

The following illustration depicts the L3x controller, its power supply, and I/O modules:

L3x CompactLogix controllers have been discontinued and are no longer available for sale. Rockwell Automation recommends migrating to the newer CompactLogix 5370 or CompactLogix 5380 control platform.

In the following section, we will introduce the modern line of embedded I/O CompactLogix controllers, the 5370 controllers.

CompactLogix 5370 controllers

In 2012, Rockwell Automation released the 5370 L1, L2, and L3 (Bulletin 1769) controllers, which provided a low-cost, Ethernet/IP-enabled, high-performance controller in a 40 percent-smaller form factor. The 5370 CompactLogix controllers represent the fourth-generation CompactLogix series release. The CompactLogix 5370 series controller provides many of the same enhancements that the ControlLogix 5570 (Series 7, L7) provided over the ControlLogix 5560 (Series 6, L6), including the following:

• Twice the performance capability due to a more powerful dual-core CPU
• Adoption of modern SDRAM memory
• The replacement of the 9-pin serial port with a USB 2.0 port (programs transfer 200 times faster over USB 2.0 than the serial port)
• The replacement of the CompactFlash memory card with a Secure Digital(SD) memory card
• Added the Energy Storage Module(ESM) and removed the need for a lithium battery
• Makes use of existing 1769 I/O modules
• Integrates motion control over Ethernet

The ability to store program comments and tag descriptions on the controller (with firmware V21 and above)

Now that we have introduced the newer 5370 line of CompactLogix controllers, we will explore the L1, L2, and L3 form factors that are available.

Bulletin 1769 5370 – L1

The CompactLogix 5370 L1 controller is a significantly smaller direct replacement for the L23 CompactLogix controllers with embedded I/O. One of the more interesting aspects of the L1 is that its embedded I/O module is only available with the built-in digital I/O.

The L1 CompactLogix controller features the following:

• An SD memory card
• Two Ethernet ports
• A USB 2.0 port
• Embedded point I/O modules
• Expandable with 6- or 8-point I/O modules
• Embedded power supply
• Integrated motion control

The following is an illustration of the L1 form factor CompactLogix 5370 controller with embedded I/O terminals:

In the next section, we will introduce the L2 form factor of the fourth generation CompactLogix controller.

Bulletin 1769 5370 – L2

The CompactLogix 5370 L2 controller is another direct replacement for the CompactLogix controllers with embedded I/O. Unlike the L1 controller, the L2 controller comes in multiple embedded I/O form factors: digital inputs, combination digital and analog inputs, high-resolution analog inputs, and universal inputs.

The L2 CompactLogix Controller features the following:

• An SD memory card
• Two Ethernet ports
• A USB 2.0 port
• Embedded 1769 I/O modules
• Expandable with 4 x 1769 I/O modules
• Embedded power supply
• Integrated motion control

The following is an illustration of the L2 CompactLogix form factor:

In the next section, we will introduce the L3 form factor of the CompactLogix 5370.

Bulletin 1769 5370 – L3

The fourth generation CompactLogix 5370 L3 controllers are a direct replacement for the CompactLogix L3x line. The CompactLogix L3 form factor supports all of the 1769 I/O modules, power supplies, and cables previously used with the L32E and L35E controllers.

The L3 series controller features the following:

• An SD memory card
• Two Ethernet ports
• A USB 2.0 port
• 8 to 30 1769 I/O modules
• 1769 modules can be placed to the left or right of the power supply
• A power supply module
• Comes in 1 MB, 2 MB, and 3 MB versions
• Safety version available
• Phase Manager supported
• Alarm instructions supported (ALMA, ALMD)
• Supports Studio 5000 version 20+

The following is an illustration of the L3 CompactLogix form factor:

In the next section, we will introduce the L8 processor-based CompactLogix 5380 controllers.

CompactLogix 5380 controllers

In 2016, Rockwell Automation introduced the 5380 CompactLogix (Bulletin 1769) controllers, which feature the same processor as the ControlLogix L8 series controllers.

The 5380 series controllers feature the following improvements over the 5370 series:

• A 20% increase in memory capacity
• 5-20 times faster scan times and task switching
• The task monitor is now built into 5380 web pages
• Safety, Phase Manager, and Application lifecycle management (ALM) support to be added in future
• Supports Studio 5000 version 28+

The following illustration depicts a CompactLogix 5380 L3 CPU:

In the next section, let's take a look at the powerful 5380-L3 controller.

Bulletin 1769 5380 – L3

The CompactLogix 5380 series represents the fifth generation of CompactLogix controllers. The CompactLogix 5380 L3 controller is a powerful, expandable, and compact form factor Process Automation Controller (PAC).

The 5380 series features include the following:

• LED status indicators
• A run mode switch
• An SD card slot
• A USB port
• A four-digit digital status display
• Processor and field power connections
• Comes in 1 MB, 2 MB, 3 MB, and 4 MB versions
• No memory reserve required – 100% of the memory can be used for applications

The following is an illustration of the CompactLogix 5380 controller:

In the following section, we will introduce the Compact GuardLogix controller.

CompactLogix GuardLogix

The Compact GuardLogix form factor of the 5370 L3 controllers provides integrated safety and integrated motion in a single compact controller. The GuardLogix L3 controllers support integrated safety up to SIL 3, PLe Cat.4. Safety systems and GuardLogix are outside the scope of this book, but it is important to know they are available and their function within control systems.

The following is an illustration of the CompactLogix GuardLogix controller:

When programming safety-related functions, CompactLogix GuardLogix only supports ladder logic. However, CompactLogix GuardLogix controllers are fully capable of performing non-safety-related functions using the other International Electrotechnical Commission (IEC) languages similar to a normal CompactLogix controller.

In the next section, we will introduce the CompactLogix 5480 hybrid controller and Windows-based solution in a compact form factor.

CompactLogix 5480 controllers

The CompactLogix 5480 controllers provide a unique hybrid controller and an industrial computer running Windows 10 (IoT Enterprise) in a single device. The 5480 controller features many of the same features of the L3 series controller, with the added benefit of also being able to run Windows 10 to support a Human Machine Interface (HMI) (such as FactoryTalk), run Studio 5000, or connect data to the Microsoft Azure IoT cloud. A monitor, mouse, and keyboard can be plugged directly into the controller thanks to the integrated display port and USB 3.0 connections. The CompactLogix 5480 controller utilizes the same powerful ControlLogix L8 processor that the ControlLogix L8 and the CompactLogix 5380 controllers take advantage of.

The following illustration depicts the hybrid CompactLogix 5480 controller:

The CompactLogix 5480 features the following:

• An instance of Windows 10 IoT Enterprise running on an integrated industrial PC
• A 64 GB SSD drive for running Windows 10 IoT Enterprise
• Supported in Studio 5000 Logix Designer version 32
• Includes three 1 GB Ethernet/IP ports
• Includes a 1 GB Ethernet port as a dedicated Windows 10 network interface
• Supports up to 31 local Bulletin 5069 compact I/O modules
• Integrated DisplayPort for high-definition industrial monitor connectivity
• Two USB 3.0 ports for OS peripherals and expanded data storage capabilities

Now that we have covered the wide range of CompactLogix devices that are compatible with Logix/Studio 5000, in the next section, we will review how to identify compatible products using the tools available on the Rockwell Automation website.

Identifying compatible products

As we have highlighted in this chapter, there are several different product lines of CompactLogix, each with its own unique set of controller, modules, and chassis. One challenge that integrators are faced with is selecting components that are compatible with their CompactLogix product line. Fortunately, Rockwell Automation has come to the rescue in the form of a compatibility listing feature on their website.

Next, we will take a quick look at how to find compatible products for any of the CompactLogix controllers using the Compatibility & Downloads section of the Rockwell Automation website:

1. First, let's navigate to https://compatibility.rockwellautomation.com.
2. Next, we enter in the Bulletin number and model of the CompactLogix controller we wish to search for in the Search PCDC text field and then click the search icon. Let's enter the Bulletin number 5069-L330 and then press the search icon:

3. The search results will display a number of different models of the 5069-L330 CompactLogix controller. We will focus on the 5069-L330ER controller. The green square icon beside the 5069-L330ER tells us that this model is still fully supported by Rockwell Automation.
4. A gray icon would tell us that there are some life cycle messages related to this product to be aware of. A red icon would indicate that this product is no longer supported by Rockwell Automation.
5. Click on the Show More link:

6. Next, click on the Compatible Products link.
7. We can now view the Rockwell Automation products, I/O modules, and software compatible with the 5069-L330ER model:

We have now learned how to use the Compatibility & Downloads section of the Rockwell Automation website to find software and products that are compatible with a particular Compact Logix controller.

Summary

In this chapter, we learned about the full line of CompactLogix controllers available within Rockwell Automation's Integrated Architecture system. We learned about the CompactLogix 5480 hybrid controllers and their unique position in the industrial computing marketplace. We now have an understanding of the controller solutions available within the Integrated Architecture system and are capable of making solution architecture decisions. We have also learned how to use Rockwell Automation's online resources to identify the modules that are compatible with our solution.

In the next chapter, we will introduce Rockwell Automation's SoftLogix platform, a PC-based ControlLogix controller.

Further reading

For more information about the CompactLogix series of controllers and modules, please refer to the Rockwell Automation documents:

• CompactLogix 5380, Compact GuardLogix 5380, and CompactLogix 5480 Controllers Specifications:https://literature.rockwellautomation.com/idc/groups/literature/documents/td/5069-td002_-en-p.pdf
• Legacy 5370 1769 Series CompactLogix Controller Specifications:https://literature.rockwellautomation.com/idc/groups/literature/documents/td/1769-td005_-en-p.pdf

Questions

The following questions can be used to test your retention of the concepts introduced in this chapter. You can find the answers to these questions in the back of the book under Assessments.

1. What size of automation system does the CompactLogix series of controller target?
2. In what year was the CompactLogix series of controller first launched?
3. Which series of ControlLogix controller features an integrated industrial computer offering a display port connection, two USB 3.0 connections, and a dedicated 1 GB Ethernet connection?
4. Where can we find products and I/O modules that are compatible with a particular controller?
5. Which series of CompactLogix controller replaced controllers such as the 1769-L23 and 1769-L32?
6. In what year didRockwell Automation introduce the (Bulletin 1769) 5380 CompactLogix controllers that feature the same processor as the ControlLogix L8 series?
7. What CompactLogix controllers support safety systems with integrated safety up to SIL 3, PLe CAT 4?