FactoryTalk LogixEcho v2

Version 1.0 & 2.
PUBLIC
Digital Engineering Use Cases
Machine Prototyping Virtual Throughput Analysis Operator Training

Easily design and build the Commissioning Optimize throughput with Simulators
next generation of machines Design, test, validate, & real-time 3D simulation of Reduce risk by training your
with confidence commission machines dynamic processes workforce in a safe, virtual
before they go into service environment
Digital Twin Workflow
Mitigates risks and adds flexibility in your projects
TRADITIONAL SCHEDULE
Improve project System Mechanical Control Sys. Fabrication / Physical Physical

Rework
Design Design Design Integration Testing Testing
delivery timeline
DIGITAL TWIN SCHEDULE

Improve quality of
design
System
Design
Virtual SAVINGS
Reduce hardware Testing
dependencies Mechanical
Design
Reduce Control Sys. Fabrication / Physical

Design Integration Testing
commissioning risks
PUBLIC
V1.0
Emulate ControlLogix®
5580 Controllers Ethernet Connectivity SDK (Public Interface)
• Fully test your control code in a • Front port of controller • Interface with high fidelity
safe, virtual environment emulated process simulators and
Operator Training Simulators
• The emulated chassis supports • Produce/Consume and MSGs
(OTS)
up to 17 controllers between emulated controllers
• High-speed data exchange
• Execute controller project as • Connect to HMI or other
designed without modifications software with Class 3 MSGs • Virtual time-scaling
• Snapshots
PUBLIC
V1.0
Access is Similar to a Physical Controller
Configuring an emulated controller is fast

• Get the corresponding emulator firmware kit from the PCDC
• Create emulated controller instance with appropriate
firmware revision and IP address
• Configured controllers appear in FactoryTalk® Linx software
• Create up 17 emulated controllers in one emulated chassis
PUBLIC
V1.0
Apply Same Project to Physical or Emulated Controller
Same Project File Studio 5000

No changes to the project file required. The same Logix
project file developed for the physical controller Designer®
will download to the emulator. The I/O tree will be Project File
maintained, all languages and instructions Co-located
supported.
Remote
PUBLIC
V1.0
Supported Controllers
ControlLogix® 5580 Controllers

All -E, -XT, -NSE and –P controllers
Firmware version 33 or later
Catalogs
1756-L81E 1756-L82E 1756-L83E 1756-L84E 1756-L85E
1756-L81EK 1756-L82EK 1756-L83EK 1756-L84EK 1756-L85EK
1756-L81E-NSE 1756-L82E-NSE 1756-L83E-NSE 1756-L84E-NSE 1756-L85E-NSE
1756-L81EXT 1756-L82EXT 1756-L83EXT 1756-L84EXT 1756-L85EXT
1756-L81EP 1756-L83EP 1756-L85EP
Future Releases: GuardLogix® 5580, CompactLogix™ 5380 and Compact GuardLogix® 5380 Controllers
PUBLIC
V1.0
Simulate Control Code and HMI Interaction All from a Single Workstation or Distributed
Step 1: create Logix application and run in Studio 5000®

Logix Emulate™
Step 2: Existing HMI shortcut(s) will work provided the

emulated controller is at same IP as physical controller
PUBLIC
V1.0
Virtual SD Card Support
Support for SD Cards

• By default, a virtual SD card is attached to a
controller (as a folder on your Windows directory)
• You can backup/restore projects, read/write
data from the controller applications, log, just as
you would with a physical SD card in the
controller.
• Unlike the physical controller:
• Firmware is not stored to the virtual SD
• The content is stored unencrypted
PUBLIC
V1.0
Studio 5000 Logix Designer® to Emulator Instance
Studio 5000 Logix Designer® can

download over Ethernet. It can also bridge
through one emulator instance connected
over Ethernet to another emulator
instance through the emulated
backplane.
Backplane
Studio 5000 Logix

Designer®
Ethernet
PUBLIC
V1.0
Emulator-2-Emulator Communications
Class 1 (Produce/Consume) or Class 3 (Messages)

communication between emulator instances can
be established across:
• the emulated backplane
• Ethernet using the EtherNet/IP protocol.
Backplane
Ethernet
PUBLIC
V1.0
Emulator-2-HMI/Other CIP-based software
Class 3 (Messages) communication between

emulator instance and HMI/other CIP-based
software:
• Over EtherNet/IP
• Bridged over backplane to EtherNet/IP
HMI
Backplane HMI/EOI (CIP Class 3)
Ethernet
PUBLIC
V1.0
Remote connections to Emulators

Remote instances of Studio 5000® Logix Emulate™ and HMI software can communicate with the emulator instances over
Ethernet.
• When Studio 5000 Logix Designer® is not installed on the same OS as FactoryTalk® Logix Echo certain workflows are
disabled that depend on Logix Designer application services (that is Creating an emulator from ACD, program Download
through FactoryTalk® Logix Echo dashboard or API)
Workstation or Virtual Machine #1 Workstation or Virtual Machine #2
Studio 5000 Logix

Designer®
HMI
Backplane HMI/EOI (CIP Class 3)
Ethernet
PUBLIC
V1.0
IP address Considerations
IP address Considerations
• Only one controller needs an IP address assigned (the rest of the controllers can be bridged to
through the Ethernet connected controller, over the backplane
• The dashboard will only present IP addresses that are configured on the workstation including
the loopback address, reserved in Windows for testing, 127.0.0.1.
• After assigning 127.0.0.1 to an emulator, you can reassign the IP address to any loopback address
(127.x.x.x) on the general properties pane of the controller.
• Alternatively, if you have administrative privileges, additional IP addresses can be assigned to
your network adapters to support additional controllers on Ethernet.
Important
• Studio 5000 Logix Designer® will not allow you to use loopback addresses for the controller in the
I/O tree, helping help prevent you from using loopback addresses for Produce/Consume
messages between emulators over Ethernet.
PUBLIC
V1.0
Performance - Communications
Maximum Achievable Specifications

• Class 1 Produced/Consumed messages between emulators: 20,000 pps
• Class 1 chassis total: 160,000 pps
• Class 3: 700 messages/second
• Class 3 chassis total: 3,700 messages/second
• Minimum RPI: 15ms
Important
• As the software runs as a normal user program, it can and will be interrupted by other Windows
services and processes adversely impacting performance
• Despite 99.9% of messages getting successfully transmitted/received, CIP connections will
occasionally time out due to interrupts from other Windows services
PUBLIC
V1.0
Performance – Installation Hardware Requirements
CPU – 2.2 GHz Intel Core i3 or faster processor:

• At least one logical core for the OS
• At least two logical cores for the core FactoryTalk® Logix Echo
application
• At least one logical core per emulated controller instance
• Additional logical cores dependent on additional software installed
on workstation
Memory – at least 8GB:
• 2GB for the base FactoryTalk® Logix Echo application
• 256MB per emulated controller instance (4.52GB for full 17 controller
emulated chassis
• Additional memory for OS and other software applications
Virtual Machine Consideration
• Use Intel Virtualization Technology
PUBLIC
V1.0
Performance - Download
Note on Building the Project

• Studio 5000 Logix Designer® will build for the physical controller by default
First Download
• If you build before connecting to the emulator, the build process will be repeated when
connecting to the emulated controller for the first time
• Subsequent downloads are typically 2x faster than on physical controllers
PUBLIC
V1.0
Simulation Connectivity Capabilities
Emulated Controllers HMI HMI/EOI (CIP Class 3)
Ethernet
Other Emulated Controllers
Public Interface Other Software (CIP Class 3, OPC)
External Simulations: User Application Dynamic Digital Twin Operator Training Studio 5000® Co-Simulation
• Device Simulators Simulation Models
• Machine Interface™
• Process
• Plant (C#/.NET)
PUBLIC
User Application V1.0
FactoryTalk® Logix Echo SDK
Integrate FactoryTalk® Logix Echo into your own Software Applications
(C#/.NET)
Integrate all FactoryTalk® Logix Echo functionality into your
own software application. Use the SDK and API locally to build
applications to connect directly to controllers for simulation
and data analysis
The SDK documentation kit contains:

• Detailed explanations of all API functions and their uses
with sample code
• NuGet package, which includes .NET Standard 2.0
assemblies that allow access to API. (Installable in any .NET
application that supports .NET Standard 2.0)
Two Sets of APIs:

• Service API: Use to manage the system and to perform all
the functions that can be done from the dashboard
• Controller API: Use to control the execution, scale time, and
access tags in an emulated controller
PUBLIC
Dynamic Digital Twin V1.0
Emulate3D™ Integration
Introduction: A note about Free-Running vs. Co-Simulation Modes
Free-Running mode:
• By default the virtual timing model of the emulated controller tracks real-time (windows system
time) as closely as possible (to within a few milliseconds), we refer to this as ‘Free-Running mode’.
• In the event there are not enough computing resources to track the system time, the model will
begin skipping Continuous Task scans (and will set a fault once too many scan skips are necessary
to keep up)
FMI for Co-Simulation

• Through the API, the emulator can be switched into Co-Simulation mode using the FMI for Co-
Simulation Interface. This is an open standard interface for coupling simulation models in a co-
simulation environment. The data exchange between models (for example the controller model and
the plant/machine model in Emulate3D™) is restricted to discrete communication points. In the
time between, the models are solved independently from each other. A time master application (in
our case Emulate3D™) controls the data exchange between the models and the time
synchronization.
PUBLIC
Functional Mockup Interface for Co-Simulation
Available in Emulate3D™ 2020 minor release at launch of FactoryTalk® Logix Echo
Integration using Co-Simulation and Data Exchange API
• Enables E3D model and controller model to be synchronized
• Supports time-scaling (Change between Free-running
mode and Co-Simulation mode)
• Modifying Continuous Task Fidelity (skip task scans)
Integration over Class 1 or Class 3

• E3D can communicate over EtherNet/IP just like physical
controllers
PUBLIC
Example 1:
• E3D runs as fast as possible with
Controller in Co-Simulation mode
• Emulate3D™ reports the controller can
be scaled to ~3x
PUBLIC
Example 2:
• Emulate3D™ runs as fast as possible
with Controller in Co-Simulation mode
• User reduces the Continuous Task
Fidelity to 10%
• Emulate3D™ reports the controller can
be scaled to ~11x-12x
PUBLIC
Operator Training
V1.0
Operator Training Simulators Simulators
High-Speed Data Exchange and Co-Simulation Interface for Integration with OTS
Overview
• Use your own or third-party party simulation tools
to interact with emulated controllers to create and
simulate the plant responses
Emulated
Benefits controllers
• Provides dynamic, real-time responses like the

actual plant
• Train operators in specific scenarios in a safe, fully
functioning virtual system using the actual
displays from operations
Operator
• Develop and test new control strategies or plant Training
optimizations in a lab environment Simulator
PUBLIC
Operator Training
Simulators V1.0
Snapshot Capabilities
Snapshot Concept
Save one or more controller’s state at a specific point
in time that can latter be restored
• Includes controller time, application tag data and
execution context
Use Cases
• Operator Training Simulators: Restore training
scenarios that are difficult or time-consuming to
recreate
• Automated Testing: Continuously recall a known
scenario for testing
PUBLIC
Operator Training
Simulators V1.0
Snapshot – What happens
Saving a Snapshot Snapshot

Command
A “Power Cycle Persistence Snapshot”: We take an entire
capture of the controller (static and dynamic data, like what Stop Controller at
Safe Spot
happens during a power down of a physical controller)
Sequence of Events
Power Down
• Snapshot Command: To help prevent data integrity of controller
issues that the controller is paused at the end of task
scanning (beginning or end of continuous task (or idle if
no continuous task)
Snapshot saved
• The controller powers down to save dynamic and static
data
• Power up of the controller (first scan and pre-scan
skipped)
The full state is captured as a snapshot
• PUBLIC
Operator Training
Simulators V1.0
Snapshot – What happens
Restoring a Snapshot Snapshot

Restore
Replaces over existing controllers
Turns off existing
Sequence of Events controller
• Snapshot Restore: Turns off existing controllers.

Controllers must be present in target slots of the snapshot
Replaces
restore. Inconsistencies presented to the user. Persistence Files
• The persistence files are replaced with the files from the
snapshot
Power-up (no pre/first scan)
• On power-up the controller restores and resumes user of controller
execution, skipping first scan or pre-scan operations
• While the IP address from the snapshot will be applied to the
controller, it will not bind to the IP address unless that IP is Snapshot Restored
present on the workstation
PUBLIC
Studio 5000® V1.0
Simulation
Interface™
Integration with Studio 5000® Simulation Interface™
Connect
Leverage Studio 5000® Simulation Interface™ to map
tags in your emulated controller to variables in your
mathematical model for precise simulation scenarios
Supported Interfaces
• Functional Mockup Interface: Open standard for
model data exchange. Import FMI 2.0 co- Studio 5000®
Simulation
simulation compliant models in Studio 5000® Interface™
Simulation Interface™
• MATLAB with Simulink. Exchange data with
Simulink models.
• New: Import and reduced order model digital twins
PUBLIC
V2
PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 29

V2
Emulate GuardLogix® 5580 Architecture & interfacing Axis Test Mode

Controllers enhancements • 5580 ControlLogix® &
• Fully test your standard and • Multiple chasses instances in GuardLogix® Standard task
safety control code in an one node motion logic and CIP Motion
isolated, virtual environment drive connection emulation
• Produce/Consume and MSGs
• Execute controller project between emulated controllers • Low Fidelity CIP Motion
configured as SIL2/Pld and in another chassis axis/drive simulation model for
SIL3/PLe as designed without Kinetix, PowerFlex® CIP Motion
• Echo API enhancements drives and 5730 iTRAK®
modifications

V2.0
Emulated GuardLogix® 5580
GuardLogix® 5580 Controller Emulation
• Fully test your safety control code in a safe, virtual

environment
• Execute controller project as designed without
modifications. The I/O tree will be maintained, all
languages, instructions and task types supported
• All functionalities introduced in FactoryTalk® Logix Echo V1
apply to GuardLogix® Emulator
• Virtual SD Card
• Emulator 2 Emulator Ethernet and Backplane
communication (Class 0/1 & 3)
• Snapshot – controller state save
• Service and Controller API

V2.0
GuardLogix® 5580 Safety Controllers

All -ES –ESK controllers and safety partners
Firmware version 35 or later
Catalogs
1756-L81ES 1756-L82ES 1756-L83ES 1756-L84ES 1756-L8SP
1756-L81ESK 1756-L82ESK 1756-L83ESK 1756-L84ESK 1756-L8SPK
Future Releases: CompactLogix™ 5380 and Compact GuardLogix® 5380 Controllers

V2.0
Safety task
• Emulation of both standard and safety tasks

• Safety instructions set execution within the safety task
• Safety Add-On instructions support
Main Task Periodic Task Event Task Safety Task

V2.0
Safety levels support
• Both SIL2/PLd and SIL3/PLe safety levels are supported

• Safety Partner mimicking in Echo Dashboard and API
• Chassis slot reservation
• Partner available configuration parameter
• No parallel emulation of Safety Partner module
SIL2/PLd
SIL3/PLe

V2.0
Safety signature
• Project with a safety signature can be downloaded without

any modification (signature remains unchanged)
• Generation of imitated signature for training purposes
(valid only for Echo controller)
SIL2/PLd, SIL3/PLe
IMITATED
SAFETY SIGNATURE

V2.0
Emulated GuardLogix 5580
Safety IO Module-related tags Safe State
• When inhibited or faulted, the safety I/O module tag data

will not be put in the Safe State so the safety I/O-related
tags can be overwritten
• You can use either Studio 5000 Logix Designer tag editor
or FactoryTalk Echo SDK to edit the values of safety I/O
module-related tags to simulate inputs and outputs
C# user’s script
Safety IO-related
tags read/write
Echo
API

V2.0
Other safety feature supported
• Tags mapping between safety and standard tasks

• Project Online Editing
• Safety Produce/Consume communication between
emulated GuardLogix® controller instances
• Safety Virtual SD Card handling
• Safety Lock/Unlock

V2.0
Multi-Chassis Architecture …
Multi-Chassis in a Single Node (PC/VM)
• Create Multiple chassis within one FactoryTalk® Logix Echo

installation
• Emulate more complex distributed control systems
• Exceed the limit of 17 emulated controller instances
• Manage the emulated control system architecture via Echo
Dashboard and Service API
• Create, restore and manage the complex control systems
snapshots

Cross-Chassis controller connectivity scenario
Class 1 (Produce/Consume) or Class 3 (Messages) communication between emulator instances in
multiple, different chassis within the single Node
Single Workstation or Virtual Machine Chassis A
Backplane
…
Chassis Z
Ethernet
Backplane

V2.0
Echo API enhancements
64-bit applications support
• The Client Library is modified to support the „Any CPU”

platform – both 32-bit and 64-bit applications
• Significant improvement for simulation packages users
Echo API
- Co-Simulation
- Data Exchange
32-bit client
application
64-bit client
Echo API
application

V2.0
Echo API enhancements
Client Library update
• New Client Library function for returning all user

application tags (controller and program scope tags)
• Individual bits access for integer tags (DINT, SINT, INT,...)

V2.0
Motion Test Mode
CIP Motion Axis simulation
• Build the digital twin of your assets by integrating an

emulated control system with a model
• Validate and commission your motion application without
connection to hardware
Motion Test
• Cross-controller platform feature, available for physical Mode
and emulated controllers (ControlLogix® and GuardLogix®
5580)
• Standard task motion logic, CIP Motion drive
connection
• Low Fidelity CIP Motion axis/drive simulation model
• Kinetix® & PowerFlex® CIP Motion drives , 5730 iTRAK®
• For the emulated controller, the Motion Test Mode is enabled
by default

The emulator is a virtual controller, used in the development, testing and simulation environments
With an emulator, you can: With an emulator, you cannot:
• Download and run logic written in any Logix language • Connect to physical I/O devices
• Be online with Logix Designer application, and all that • Connect motion axes to real drives
entails
• Produce/consume tags with other physical controllers
• Connect from an HMI [except for HMI Button Control • Use licensed-based source protection (precompile &
(HMIBC)] encrypt)
• Produce/Consume tags with other emulators
• Emulate a true redundancy primary/secondary pair
• Use MESSAGE instructions (duplex mode)
• Use virtual axes or/and Motion Test Mode to validate and
commission your motion applications without connection
to hardware
• Download a project configured for redundancy, although
it will always behave as a “Primary with no Partner”
(simplex mode)
PUBLIC
Differences between emulated controllers and physical controllers
Functionality Emulated Controller Behavior

Communication to physical devices The emulated controller is restricted from establishing
connections to physical devices. However, the API can be
used to simulate input and output values
License-based source protection Not supported, must be removed before downloading the
project
SD card encryption Content on virtual SD card is not encrypted or digitally
signed
Automatic Diagnostics Only controller instance diagnostics are collected. No I/O
device diagnostics supported.
Email Email functionality is not supported
USB port Not supported
Serial Number matching Ignores serial number matching
PUBLIC
Differences between emulated controllers and physical controllers – Con’t.

Module discovery Not supported.
Motion support Motion support is limited to low fidelity CIP axes simulation
(Motion Test Mode) and virtual axes and consumed
axes. Produce-consume virtual axes supported.
Connections between controllers Produce/Consume messages work between emulated
controllers. Other I/O modules in the I/O Tree will show as
faulted.
Time-scaling Supported through the API.
SNMP Not supported
Redundancy Operates only as a primary controller. High availability
reports success, but the sync. with a second
controller/support of sync modules is not available. Scan
time does not reflect redundancy impacts.
Controller webpages Not supported
PUBLIC
Differences between emulated controllers and physical controllers – Con’t.

Fault dumps Fault dumps are always stored in the virtual SD card
directory, even if detached in emulated controller
properties.
Important: contents are not encrypted
HMIBC instructions HMI Button Control (HMIBC) instructions do not function (no
Class 1 connection to HMI)
GSV and SSV instructions Supports Get System Value (GSV) and Set System Value
(SSV) instructions for emulated controller instances only.
When GSV and SSV instructions target external objects, the
instructions return the result for an unconnected device.
PUBLIC
PUBLIC

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Version 1.0 & 2.

Machine Prototyping Virtual Throughput Analysis Operator Training

Improve project System Mechanical Control Sys. Fabrication / Physical Physical

DIGITAL TWIN SCHEDULE

Reduce Control Sys. Fabrication / Physical

Access is Similar to a Physical Controller

Configuring an emulated controller is fast

Apply Same Project to Physical or Emulated Controller

Same Project File Studio 5000

ControlLogix® 5580 Controllers

Firmware version 33 or later

Step 1: create Logix application and run in Studio 5000®

Step 2: Existing HMI shortcut(s) will work provided the

Virtual SD Card Support

Support for SD Cards

Studio 5000 Logix Designer® to Emulator Instance

Studio 5000 Logix Designer® can

Studio 5000 Logix

Class 1 (Produce/Consume) or Class 3 (Messages)

Emulator-2-HMI/Other CIP-based software

Class 3 (Messages) communication between

Backplane HMI/EOI (CIP Class 3)

Remote connections to Emulators

Studio 5000 Logix

Backplane HMI/EOI (CIP Class 3)

Maximum Achievable Specifications

Performance – Installation Hardware Requirements

CPU – 2.2 GHz Intel Core i3 or faster processor:

Note on Building the Project

Simulation Connectivity Capabilities

Emulated Controllers HMI HMI/EOI (CIP Class 3)

Public Interface Other Software (CIP Class 3, OPC)

The SDK documentation kit contains:

Two Sets of APIs:

FMI for Co-Simulation

Integration over Class 1 or Class 3

• Provides dynamic, real-time responses like the

Snapshot – What happens

Saving a Snapshot Snapshot

Snapshot – What happens

Restoring a Snapshot Snapshot

• Snapshot Restore: Turns off existing controllers.

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 29

Emulate GuardLogix® 5580 Architecture & interfacing Axis Test Mode

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 30

Emulated GuardLogix® 5580

GuardLogix® 5580 Controller Emulation

• Fully test your safety control code in a safe, virtual

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 31

Emulated GuardLogix® 5580

GuardLogix® 5580 Safety Controllers

Firmware version 35 or later

Future Releases: CompactLogix™ 5380 and Compact GuardLogix® 5380 Controllers

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 32

Emulated GuardLogix® 5580

• Emulation of both standard and safety tasks

Main Task Periodic Task Event Task Safety Task

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 33

Emulated GuardLogix® 5580