Allen-Bradley CompactLogix 5480 User manual

CompactLogix 5480 Controller
Catalog Number 5069-L46ERMW
User Manual
Original Instructions

Important User Information
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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
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).

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 3
Table of Contents
Preface
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
CompactLogix 5480 System Minimum Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Software Application Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 14
Controller Firmware and Logix Designer Application
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Real-time Control and Windows Environment in the
Same Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Controller Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CompactLogix 5480 System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Design a CompactLogix 5480 System . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MOD Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SA Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Uninterruptible Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Secure Digital (SD) Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replaceable Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remove the Top Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Install the Top Replacement Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Remove the Bottom Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Install the Bottom Replacement Fan . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 2
Connect to the Controller Out-of-box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Configure EtherNet/IP and USB Drivers on Your
Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Configure the EtherNet/IP Communication
Driver in RSLinx Classic Software . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Configure the Ethernet Devices Drivers in RSLinx
Classic Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Configure the USB Communication Driver . . . . . . . . . . . . . . . . . 49
Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connect an Ethernet Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connect a USB Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Set the Controller IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Multiple Ethernet Ports on Controller . . . . . . . . . . . . . . . . . . . . . . 53
Set the IP Address with the BOOTP-DHCP
EtherNet/IP Commissioning Tool. . . . . . . . . . . . . . . . . . . . . . . . . . 55
Disable BOOTP/DHCP with the BOOTP-DHCP
EtherNet/IP Commissioning Tool. . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disable BOOTP/DHCP with RSLinx Classic Software . . . . . . 59
Set the Controller IP Address with the DHCP Server . . . . . . . . 61

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Table of Contents
Set the Controller IP Address with RSLinx Classic Software . . 64
Set the Controller IP Address with the Logix Designer
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Use a Secure Digital Card to Set the Controller IP Address . . . 68
Update Controller Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Download Only Controller Firmware Files . . . . . . . . . . . . . . . . . . 69
Download Controller Firmware Files as Part of the
Windows Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Chapter 3
Start to Use the Controller Create a Logix Designer Application Project. . . . . . . . . . . . . . . . . . . . . 79
Go Online with the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Use RSWho to Specify a Communication Path to
Go Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Use a Recent Communications Path to Go Online . . . . . . . . . . . 84
Use the Controller Status Menu to Go Online . . . . . . . . . . . . . . . 84
Download a Project to the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Use the Who Active Dialog Box to Download . . . . . . . . . . . . . . . 85
Use the Controller Status Menu to Download . . . . . . . . . . . . . . . 86
Upload from the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Use the Who Active Dialog Box to Upload . . . . . . . . . . . . . . . . . . 87
Use the Controller Status Menu to Upload . . . . . . . . . . . . . . . . . . 89
Choose the Controller Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . 90
Use the Mode Switch to Change the Operating Mode . . . . . . . . 91
Use the Logix Designer to Change the Operating Mode . . . . . . 92
Change Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Use the Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Controller Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
COS Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Disable the Ethernet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Chapter 4
Use the Secure Digital Card Store to the SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Load from the SD Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Controller Power-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
User-initiated Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Other Secure Digital Card Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Chapter 5
EtherNet/IP Network Network Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
EtherNet/IP Network Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Software for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Nodes on an EtherNet/IP Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Devices Included in the Node Count. . . . . . . . . . . . . . . . . . . . . . . 118
Devices Excluded from the Node Count. . . . . . . . . . . . . . . . . . . . 118

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Table of Contents
EtherNet/IP Network Topologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
DLR Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Linear Network Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Star Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Integrated Architecture Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
EtherNet/IP Network Communication Rates . . . . . . . . . . . . . . . . . . 123
Socket Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Chapter 6
Connect to Different EtherNet/IP
Network Levels
Available Network Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Connect to an Enterprise-level Network . . . . . . . . . . . . . . . . . . . . . . . 129
Connect to a Device-level Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Ports A1 and A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Port B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
EtherNet/IP Modes with Ports A1 and A2 . . . . . . . . . . . . . . . . . . . . . 131
Dual-IP Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Linear/DLR Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Overlapping IP Address Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Configure the EtherNet/IP Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Configure Dual-IP Mode in the Logix Designer Application . 136
Configure Dual-IP Mode in RSLinx Classic Software. . . . . . . . 138
Configure Linear/DLR Mode in the Logix Designer Application .
140
Configure Linear/DLR Mode in RSLinx Classic Software . . . 142
Change the EtherNet/IP Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Change the EtherNet/IP Mode in the Logix Designer Application
145
Change the EtherNet/IP Mode in RSLinx Classic Software . . 147
Internet Protocol Configuration in Logix Designer Application . .
150
Port Configuration in RSLinx Classic Software . . . . . . . . . . . . . 151
Controller Functionality Considerations . . . . . . . . . . . . . . . . . . . 152
DNS Requests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
DNS Request Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
SMTP Server. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Use Socket Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Send Message Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Software Display Differences for EtherNet/IP Modes . . . . . . . . . . . 155
Chapter 7
Use I/O Modules Local I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Add Local I/O Modules to a Project . . . . . . . . . . . . . . . . . . . . . . . 159
Electronic Keying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Remote I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Add Remote I/O Modules to a Project . . . . . . . . . . . . . . . . . . . . . 166

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Table of Contents
Add to the I/O Configuration While Online . . . . . . . . . . . . . . . . . . . 175
Modules and Devices That Can Be Added While Online . . . . 176
Determine When Data Is Updated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Input Data Update Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Output Data Update Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Chapter 8
Develop Control Applications Elements of a Control Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event Task with Compact 5000 I/O Modules . . . . . . . . . . . . . . 184
Task Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Scheduled and Unscheduled Programs . . . . . . . . . . . . . . . . . . . . . 187
Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Parameters and Local Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Programming Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Add-on Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Extended Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Access the Module Object from an Add-On Instruction . . . . . . . . . 193
Create the Add-On Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Monitor Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Connection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Controller Communication Interaction with Control Data. . . . . . 195
Produce and Consume (Interlock) Data. . . . . . . . . . . . . . . . . . . . . . . . 197
Requested Packet Interval (RPI) of Multicast Tags . . . . . . . . . . 198
Send and Receive Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Determine Whether to Cache Message Connections . . . . . . . . 200
Monitor I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Determine If I/O Communication Has Timed Out . . . . . . . . . 201
Determine If I/O Communication to a Specific I/O
Module Has Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Automatic Handling of I/O Module Connection Faults . . . . . 202
Sample Controller Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Chapter 9
Develop Motion Applications Motion Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Motion Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Program Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Obtain Axis Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

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Table of Contents
Chapter 10
Commercial Operating System System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Clock Synchronization with Logix Control Engine. . . . . . . . . . 212
Functions Like a Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Memory Dedicated to Windows-based Activities. . . . . . . . . . . . 213
Ports Dedicated to Windows-based Activities. . . . . . . . . . . . . . . 214
Use the Reset Button with the COS . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Data Exchange Between the COS and Logix Control Engine . . . . 221
FactoryTalk Linx Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
FactoryTalk Linx Gateway Software. . . . . . . . . . . . . . . . . . . . . . . . 221
Restrictions With the COS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
State Changes on the COS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Methods of Changing the COS State. . . . . . . . . . . . . . . . . . . . . . . 223
Security Settings on the COS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
COS Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Install Software Application from External Network . . . . . . . . 225
Inactivity Lock and Screen Saver Settings . . . . . . . . . . . . . . . . . . . 226
Password Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Account Lockout Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Internet Explorer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Removable Media Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Driver Signature Enforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Use the Operating System Utilities Tool to Reinstall
the COS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Maintain Power to Controller After Successful
COS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Use the Windows Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Considerations Before You Use the Windows Kit . . . . . . . . . . . 234
Obtain Windows Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Install the Windows Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Chapter 11
Troubleshoot the Controller Controller Diagnostics with Logix Designer Application . . . . . . . . 241
Warning Symbol in the I/O Configuration Tree . . . . . . . . . . . . 242
Controller Status after a Module Fault . . . . . . . . . . . . . . . . . . . . . 242
Categories on I/O Module Properties Dialog Box . . . . . . . . . . . 244
Notification in the Tag Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Fault Information in Controller Properties Dialog Box . . . . . . 248
Port Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Advanced Time Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

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Table of Contents
Controller Diagnostics with RSLinx Classic Software . . . . . . . . . . . 256
General Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Port Diagnostics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Connection Manager Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
USB Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Controller Webpages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Home Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Faults Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Tasks Webpage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Diagnostics Webpages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Ethernet Port Webpages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Advanced Diagnostics Webpages . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Browse Chassis Webpage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Other Potential Issues to Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . 272
Continuous Task Sends Output Data at High Rate. . . . . . . . . . 272
Immediate Output Instructions Issued at High Rate. . . . . . . . . 273
Integrated Motion On an EtherNet/IP Network Traffic
Priority Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Appendix A
Status Indicators 4-Character Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
General Status Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Major Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
I/O Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Controller Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
OK Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
RUN Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
FORCE Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
FAN 1/2 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
SD Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
EtherNet/IP Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
NET A1, A2, and B1 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
LINK A1, A2, and B1 Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . 287
SPEED X1 Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
LINK X1 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Power Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
MOD Power Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
SA Power Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Thermal Monitoring and Thermal Fault Behavior . . . . . . . . . . . . . . 290
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 9
Preface
This manual explains how to use the CompactLogix™ 5480 controllers.
Make sure that you are familiar with the following:
• Use of a controller in a Logix 5000™ control system
• Use of an EtherNet/IP™ network
• Use of Rockwell Automation® software, for example:
– Studio 5000 Logix Designer®
– RSLinx® Classic
– ControlFLASH™
– FactoryTalk® Linx
• Use of Windows 10 IoT Enterprise LTSB 64-bit operating system;
referred to as the COS (commercial operating system) throughout the
rest of this publication
If you use the COS, we recommend that you use the following resources
to become more familiar with how to use a COS:
–Windows 10 IoT platform powers the intelligent edge from
Microsoft® Corporation, available at: https://www.microsoft.com/
en-us/windowsforbusiness/windows-iot
– Rockwell Automation Knowledgebase articles that describe how to
use the Windows 10 operating system with Rockwell Automation
products. The Knowledgebase is available at:
https://rockwellautomation.custhelp.com/
IMPORTANT The CompactLogix 5480 controller has a licensed, pre-installed COS
on it.
You are not required to use the COS on the controller.

10 Rockwell Automation Publication 5069-UM002A-EN-P - January 2019
Preface
Additional Resources The following documents contain additional information concerning related
products from Rockwell Automation.
Table 1 - Additional Resources
Resource Description
CompactLogix 5480 Controller
Specifications Technical Data,
publication 5069-TD002
Provides specifications for CompactLogix 5480 controllers.
CompactLogix 5480 Controllers
Installation Instructions, publication
5069-IN019
Describes how to install a CompactLogix 5480 controller.
CompactLogix System Selection
Guide, publication 1769-SG001
Provides information about how to design and select components for a
CompactLogix system.
Compact 5000 I/O Modules and
EtherNet/IP Adapters Specifications
Technical Data, publication 5069-
TD001
Provides specifications, wiring diagrams, and functional block diagrams for
Compact 5000™ I/O modules and EtherNet/IP adapters.
Replacement Guidelines: Logix 5000
Controllers Reference Manual,
publication 1756-RM100
Provides guidelines on how to replace the following:
• ControlLogix® 5560/5570 controller with a ControlLogix® 5580
controller
• CompactLogix 5370 L3 controllers with a CompactLogix 5480 controller
Compact 5000 Digital I/O Modules,
publication 5000-UM004
Provides information on how to install, configure, and operate Compact
5000 digital I/O modules.
Compact 5000 Analog I/O Modules
User Manual, publication 5000-
UM005
Provides information on how to install, configure, and operate Compact
5000 analog I/O modules.
Compact 5000 High-speed Counter
Module User Manual, publication
5000-UM006
Provides information on how to install, configure, and operate a
Compact 5000 high-speed counter modules.
EtherNet/IP Communication Modules
in Logix 5000 Control Systems User
Manual, publication ENET-UM004
Describes how to use 5000 Series EtherNet/IP communication modules.
Ethernet Design Considerations
Reference Manual, publication
ENET-RM002
Describes the following Ethernet concepts:
• Overview
• Network layout and components
• Network infrastructure devices
• Network infrastructure features
•Protocol
EtherNet/IP Socket Interface
Application Technique, publication
ENET-AT002
Describes the socket interface that you can use to program MSG
instructions to communicate between a Logix 5000™ controller and
Ethernet devices that do not support the EtherNet/IP application protocol.
EtherNet/IP Embedded Switch
Technology Application Guide,
publication ENET-AP005
Describes how to install, configure, and maintain linear and Device Level
Ring (DLR) networks by using Rockwell Automation® EtherNet/IP devices
that are equipped with embedded switch technology.
Integrated Architecture® and CIP Sync
Configuration ApplicationTechnique,
publication IA-AT003
Provides information on CIP Sync™ and the IEEE 1588-2008 Precision Time
Protocol.

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 11
Preface
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local Allen-
Bradley® distributor or Rockwell Automation sales representative.
Integrated Motion on the EtherNet/IP
Network Reference Manual,
publication MOTION-RM003
Reference descriptions of the AXIS_CIP_DRIVE attributes and the
Logix Designer application Control Modes and Methods
Electronic Keying in Logix5000
Control Systems Application
Technique, publication LOGIX-AT001
Describes how to use electronic keying in Logix5000™ control systems.
Logix5000 Controllers Design
Considerations Reference Manual,
publication 1756-RM094
Provides information to help design and plan Logix5000 control systems.
Logix5000 Controllers Instructions
Reference Manual, publication
1756-RM009
Describes the programming instructions available to use in Logix Designer
application projects.
Motion Coordinate System User
Manual, publication MOTION-UM002
Details how to create and configure a coordinated motion application
system.
Industrial AutomationWiring and
Grounding Guidelines, publication
1770-4.1
Provides general guidelines for installing a Rockwell Automation industrial
system.
Product Certifications website, http:/
/www.rockwellautomation.com/
global/certification/overview.page
Provides declarations of conformity, certificates, and other certification
details.
Table 1 - Additional Resources
Resource Description

12 Rockwell Automation Publication 5069-UM002A-EN-P - January 2019
Preface
Notes:

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 13
Chapter 1
CompactLogix 5480 System
This chapter describes a CompactLogix™ 5480 system.
Minimum Requirements The CompactLogix 5480 controller has minimum programming software and
firmware revision requirements. For example, you must use Studio 5000 Logix
Designer® application, version 32.00.00 or later with the controller.
The controller firmware revision must be compatible with the software version
that you use.
For more information on controller firmware revision and programming
software version compatibility, and other minimum software requirements, see
page 14.
Topic Page
Minimum Requirements 13
Real-time Control and Windows Environment in the Same
Controller
14
Controller Features 15
CompactLogix 5480 System 16
Design a CompactLogix 5480 System 18
Power the System 20
Secure Digital (SD) Card 34
Replaceable Fans 35

14 Rockwell Automation Publication 5069-UM002A-EN-P - January 2019
Chapter 1 CompactLogix 5480 System
Software Application Requirements
In addition to the Logix Designer application requirement, there are other
minimum software version requirements in a CompactLogix 5480 system. If a
CompactLogix 5480 system does not meet the minimum requirements, it does
not work.
For more information on the software application requirements, see:
•Table 3 - Components in a CompactLogix 5480 System on page 18
• Product Compatibility and Download Center (PCDC) available at:
http://compatibility.rockwellautomation.com/Pages/home.aspx
Controller Firmware and Logix Designer Application Compatibility
In Logix 5000™ control systems, the controller firmware and the
Logix Designer application must be compatible. To be compatible, the
firmware and software must be of the same major revision level.
For more information on controller firmware revisions and software
application minimum requirements, go to the PCDC.
• The Download section has the firmware for your controller.
• The Compare section has software compatibility information for
software applications that are used in a CompactLogix 5480 control
system.
Real-time Control and
Windows Environment in the
Same Controller
The CompactLogix 5480 controller uses a high-performance architecture to
support the functionality that is common to Logix 5000 controllers.
The controller goes beyond other Logix 5000 controllers, in that a COS runs
in parallel with the Logix control engine. The pre-installed, licensed COS lets
you perform tasks on the controller that must be performed on an external
workstation in other Logix 5000 control systems.
For more detailed information about the COS, see Chapter 10, Commercial
Operating System on page 211

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 15
CompactLogix 5480 System Chapter 1
Controller Features Table 2 describes features available on CompactLogix 5480 controllers.
Table 2 - CompactLogix 5480 Controller Features
Feature Description
Onboard memory Logix control engine: 20 MB
Windows 10 (commercial operating system on controller):
• RAM - 6 GB
• SSD - 64 GB
Controller tasks • 32 tasks
• 1000 programs/task
• Event tasks; all event triggers
Communication ports • Three USB ports
– One device port for Logix control engine
– Two host ports for COS
• Four Ethernet ports
– Three for Logix control engine
– One for COS
For more information on the ports, see Table 3 on page 18.
EtherNet/IP™ network topologies supported • Device Level Ring (DLR)
• Star
• Linear
EtherNet/IP nodes supported, max 250
EtherNet/IP modes • Linear/DLR mode
• Dual-IP mode
For more information on EtherNet/IP modes, see Chapter 6, Connect
to Different EtherNet/IP Network Levels on page 127.
Integrated motion axes supported 512 - Can be any combination of physical, virtual, or consumed.
IMPORTANT: Of the physical axes, you can only configure 150 axes
for Position Loop control. Axes/ms, max is 100.
Local I/O modules, max 31
Programming languages • Ladder Diagram (LD)
• Structured Text (ST)
• Function Block Diagram (FBD)
• Sequential Function Chart (SFC)

16 Rockwell Automation Publication 5069-UM002A-EN-P - January 2019
Chapter 1 CompactLogix 5480 System
CompactLogix 5480 System The CompactLogix 5480 system is a DIN rail-mounted system that is part of
the Logix 5000 family of controllers.
The controllers can operate in various applications, for example, standalone
systems that include local Compact 5000™ I/O modules, as shown in Figure 1.
Figure 1 - CompactLogix 5480 Controller in a Standalone System
™
NET B1
LINK B1
NET A1
LINK A1
NET A2
LINK A2
SPEED X1
LINK X1
OK
RUN
FORCE
FAN 1
SD
FAN 2
CompactLogix 5480
B1
A1
1
2
A2
5069-L46ERMW
CONTROLLER
UPS
MP
SA
R
B
F
R
B
F
DC INPUT
5069-IB16
DC OUTPUT
5069-OB16
ANALOG INPUT
5069-IY4
ANALOG OUTPUT
5069-OF8
DC INPUT
5069-IB16

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 17
CompactLogix 5480 System Chapter 1
The controller can also operate in more complex systems with devices that are
connected to the controller via an EtherNet/IP network, as shown in Figure 2.
Figure 2 - CompactLogix 5480 Controller in a More Complex System
This example shows a CompactLogix 5480 controller in a EtherNet/IP
network star topology. For more information on other topologies and network
designs within which the controller fits, see the following:
• Chapter 5, EtherNet/IP Network on page 115
• Chapter 6, Connect to Different EtherNet/IP Network Levels on
page 127
527
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
DCINPUT
5069-IB16
DCOUTPUT
5069-OB16
ANALOGINPUT
5069-IY4
ANALOGOUTPUT
5069-OF8
COUNTER
5069-HSC2xOB4
Compact 5000™ I/O
2
1
Compact 5000™ I/O
DCOUTPUT
5069-OB16
ANALOGINPUT
5069-IY4
ANALOGOUTPUT
5069-OF8
COUNTER
5069-HSC2xOB4
Compact 5000™ I/O
Compact 5000™ I/O
SA Power MOD Power
SA Power MOD Power
™
NETB1
LINKB1
NETA1
LINKA1
NETA2
LINKA2
SPEEDX1
LINKX1
OK
RUN
FORCE
FAN 1
SD
FAN 2
CompactLogix 5480
B1
A1
1
2
A2
5069-L46ERMW
CONTROLLER
UPS
MP
SA
R
B
F
R
B
F
DCINPUT
5069-IB16
DCOUTPUT
5069-OB16
ANALOGINPUT
5069-IY4
DCINPUT
5069-IB16
CompactLogix 5480 Controller
Compact 5000™ I/O Standard Modules Compact 5000 I/O EtherNet/IP™ Adapter
Compact 5000 I/O Standard Modules
PanelView™ Plus 7 Terminal
Stratix® 5400 Switch
PowerFlex® 527 Drive Kinetix® 5500 Drive
Compact 5000 I/O EtherNet/IP Adapter
Compact 5000 I/O Standard Modules

18 Rockwell Automation Publication 5069-UM002A-EN-P - January 2019
Chapter 1 CompactLogix 5480 System
Design a CompactLogix 5480
System
Table 3 describes components that are used when you design a
CompactLogix 5480 control system.
Table 3 - Components in a CompactLogix 5480 System
Component Purpose Required For More Information
DIN rail Mounting system Yes CompactLogix 5480 Controllers Installation
Instructions, publication 5069-IN019
End cap (5069-ECR) Covers the exposed interconnections on the last
module in the system to help prevent equipment
damage or injury from electric shock when the
system is powered.
Ships with the controller.
Yes
Removable terminal blocks (RTBs) Connect the following to the controller:
• MOD power
• SA power
• UPS control signal
Yes
Replaceable fans Help maintain lower operating temperatures. Yes Replaceable Fans on page 20
External power supply(1) Provides Module (MOD) Power to the system Yes
Power the System on page 20
External power supply(1) Provides Sensor/Actuator (SA) Power to the
system
Yes - Only if the system
requires SA power.
If the system does not
require SA power, the
external power supply
is not needed.
Uninterruptible power supply (UPS) Provides control signals that let the controller
experience a controlled shutdown if the source of
MOD power is lost
No
IMPORTANT:
CompactLogix 5480
controller systems
typically use a UPS.
Logix Designer application Configures the project that defines Logix control
engine activity.
Yes Create a Logix Designer Application Project on
page 79.
Linx-based software Logix control engine
Used as follows:
• Perform configuration tasks, for example, to
assign IP addresses to the Ethernet ports or to
troubleshoot issues.
• Maintain communication over the EtherNet/IP
network in a real-time control system.
Yes Software online help
Throughout the publication
COS
Used to communicate information between the
COS and the Logix control engine.
Yes - If you use the COS. Software online help
Chapter 10, Commercial Operating System on
page 211
ControlFLASH™ software Update controller firmware. Yes Use ControlFLASH or ControlFLASH Plus
Software to Update Controller Firmware Only
on page 71.
Controller USB programming port Complete tasks that only require a temporary
connection to the controller, for example, when
you download a project or update firmware
— Connect a USB Cable on page 52
Two COS USB 3.0 ports Connect peripherals to be used with the COS —

Rockwell Automation Publication 5069-UM002A-EN-P - January 2019 19
CompactLogix 5480 System Chapter 1
Ethernet ports A1 and A2 Connect to device-level network — Chapter 6, Connect to Different EtherNet/IP
Network Levels on page 127
Ethernet port B1 Connects to the following networks:
• Enterprise-level network
• Device-level network
—
Ethernet port X1 Function as Windows 10 network interface, for
example, connect the COS to an enterprise-level
network
— • Chapter 6, Connect to Different EtherNet/IP
Network Levels on page 127
• Chapter 10, Commercial Operating System
on page 211
DisplayPort Connect to a monitor to use with the COS — Chapter 10, Commercial Operating System on
page 211
Secure Digital (SD) card
IMPORTANT: The 1784-SD2 card ships with
the controller.
Store data, such as the controller project and
diagnostics
No • Secure Digital (SD) Card on page 34
• Chapter 4, Use the Secure Digital Card on
page 101
Ethernet cables Used as follows:
• Access the Logix control engine from the
workstation over an EtherNet/IP network
• Connect the COS to an EtherNet/IP network
Yes Connect an Ethernet Cable on page 51.
USB cables Used as follows:
• Access the Logix control engine directly from
the workstation
• Connect peripherals to use with the COS
Yes • Connect a USB Cable on page 52
• Chapter 10, Commercial Operating System
on page 211
Compact 5000 I/O modules Used as follows:
• Local I/O modules that are installed in the
CompactLogix 5480 system
• Remote I/O modules accessible via the
EtherNet/IP network
• Yes - If your
application uses
local I/O modules.
• No - It is common
for CompactLogix
5480 controller
systems to use
remote Compact
5000 I/O modules.
But it is not
required. That is,
the system can use
other remote I/O
module types.
Chapter 7, Use I/O Modules on page 157.
Devices that are installed on an
EtherNet/IP network
Dependent upon device type. Examples include:
• Remote I/O modules
• Ethernet switches
• Motion control devices, such as drives
• HMI devices
No Varies by product type and catalog number
(1) We strongly recommend that you use separate external power supplies for MOD power and SA power, respectively.
Table 3 - Components in a CompactLogix 5480 System
Component Purpose Required For More Information

20 Rockwell Automation Publication 5069-UM002A-EN-P - January 2019
Chapter 1 CompactLogix 5480 System
Power the System The CompactLogix 5480 controller provides power to the system as follows:
• MOD Power - System-side power that powers the CompactLogix 5480
system and lets modules transfer data and execute logic.
System-side power is connected via the MOD power RTB.
• SA Power - Field-side power that powers some Compact 5000 I/O
modules and field-side devices that are connected to them.
Field-side power is connected via the SA power RTB.
• UPS Control Signals - Control signals that let the controller execute a
controlled shutdown and save the current state of the project, if the
source of MOD power is unexpectedly lost.
UPS control signals are connected via the UPS control RTB.
Figure 3 - CompactLogix 5480 Controller Power Connectors
™
NET B1
LINK B1
NET A1
LINK A1
NET A2
LINK A2
SPEED X1
LINK X1
OK
RUN
FORCE
FAN 1
SD
FAN 2
CompactLogix™ 5480
B1
A1
1
2
A2
5069-L46ERMW
CONTROLLER
UPS
MP
SA
R
B
F
R
B
F
I
I
UPS Control RTB
MOD Power RTB
SA Power RTB