Parse, simulate I/O, and safety-analyze Allen-Bradley ControlLogix programs with AI-powered diagnostics mapped to ISO 13849 and IEC 62061.
Load any Studio 5000 L5X export and get instant I/O simulation, ladder logic visualization, and automated safety analysis — no Rockwell license required.
git clone https://github.com/YOUR_ORG/s5k-sim.git
cd s5k-sim
npm install
npm run devOpens at http://localhost:3000. The app loads with a built-in demo project (conveyor safety system). To load your own program, click LOAD L5X and select an export from Studio 5000.
- Open your project in Studio 5000 Logix Designer
- File → Export (or right-click the Controller in the Controller Organizer)
- Select L5X File (*.L5X)
- Save and load into S5K-SIM
A sample L5X file is included at samples/S5K_Demo_Conveyor.L5X.
Full tag database with type, usage, and description. Filter by BOOL, analog, safety-pattern, or AI-pattern tags. Click BOOLs to toggle live values.
Ladder diagram rendered from L5X rung text with real-time energization state. See rung continuity change as you toggle inputs during simulation.
Split input/output panel with toggle switches for discrete I/O, sliders for analog values, and Force/Unforce capability that mirrors Studio 5000 behavior.
Scans program structure and detects:
- Actuator outputs without safety interlocks (flagged against IEC 62061 SIL requirements)
- Latched outputs (OTL) without corresponding unlatch (OTU)
- Inhibited modules with silently zeroed I/O
- Major fault configurations and comm loss behavior
- Fast RPI concerns and network loading
- Safety tag pattern detection (E-Stop, guard, interlock, light curtain)
Every finding includes a recommendation referencing ISO 13849, IEC 62061, IEC 62443, or NFPA 79.
Auto-generates E-Stop, power-on sequence, and comm-loss test procedures from detected safety tags. Includes executable FORCE buttons and live PASS/FAIL evaluation against expected states. Each scenario maps to specific IEC/ISO clause references.
Estimates Diagnostic Coverage, Category, and Performance Level from tag naming conventions. Includes guidance on mapping AI/CV confidence outputs to safety architectures per ISO/IEC TR 5469:2024.
Module inventory with slot assignments, RPI rates, inhibit status, and fault configuration.
The scan engine executes ladder logic instructions in real time:
- Bit-level: XIC, XIO, OTE, OTL, OTU
- Math: MOV, ADD, SUB
- Compare: EQU, GRT, LES
Click RUN to start the scan cycle. Toggle inputs in the I/O Sim panel and watch outputs respond through the logic.
Extracts from Studio 5000's XML export format:
- Controller-scope and Program-scope Tags
- I/O Modules (catalog numbers, slots, ports, RPI, fault config)
- Programs and Routines (ladder rung text with comments)
- Tasks (continuous, periodic, event)
- User-Defined Types (UDTs)
- Add-On Instructions (AOIs)
s5k-sim/
├── index.html
├── package.json
├── vite.config.js
├── src/
│ ├── main.jsx
│ ├── index.css
│ └── App.jsx
├── samples/
│ └── S5K_Demo_Conveyor.L5X
├── public/
│ └── favicon.svg
├── LICENSE
└── README.md
| Standard | Coverage |
|---|---|
| ISO 13849-1 | Performance Level, Categories, Diagnostic Coverage |
| IEC 62061 | SIL assessment, safety function architecture |
| IEC 60204-1 | Stop categories (0, 1, 2), control circuit design |
| IEC 62443 | Industrial cybersecurity zone architecture |
| ISO/IEC TR 5469:2024 | AI trustworthiness in safety-related systems |
| NFPA 79 | Industrial machinery electrical standard |
Disclaimer: This tool provides estimated analysis based on naming conventions and program structure. It is not a substitute for formal SIL/PL verification using tools like SISTEMA, or for professional safety engineering review.
- Structured Text (ST) parsing and simulation
- Function Block Diagram (FBD) visualization
- Timer (TON/TOF/RTO) and Counter (CTU/CTD) simulation
- Tag trend charting with historical playback
- OPC-UA live connection for real PLC tag read/write
- SISTEMA XML export for formal PL verification
- Multi-user collaborative simulation
npm run build # Output to dist/
npm run preview # Preview production build locallyThe dist/ folder can be deployed to any static hosting (Netlify, Vercel, GitHub Pages, S3).