Rockwell PLC-5 Migration To ControlLogix

Several years ago, Rockwell Automation announced that after more than 25 years of production, the PLC5 will be moving into the Silver Series Program.

The Rockwell Silver Series is a phasing out period, usually lasting around 2 years, allowing users to complete a migration upgrade before support and product availability run out.

In fact there are many PLC5 products that have already been phased out and are no longer available.

Since the Silver Series announcement for the PLC5 system, many users have taken up the opportunity to migrate their old systems to the latest ControlLogix platform before the PLC5 support ends. To assist in this required migration, Rockwell Automation have developed some very sleek and easy to install modular adapter units along with some very useful migration tools, together these provide a very quick and efficient migration path for all PLC5 systems.

Now is the time to plan your migration
before the PLC5 is discontinued in June 2017.

Quite often the migration of any system is a great way of tidying up loose ends and implementing system changes that plant managers have been putting off for whatever reason. As time goes on things like programs, drawings and manuals tend to get misplaced or lost and system changes don’t always get documented leaving drawings incomplete and inaccurate. The lack of accurate documentation or services makes it very hard to manage any system.

You can take advantage of the migration process by getting those program alterations and system improvements completed at the same time. That way, by the end of the migration process, you will have a fresh, up-to-date system with complete and accurate documentation.

PLC Series History

PLC1 - 1970
PLC2 - 1978
PLC3 - 1981
PLC5 - 1986

Logix Conversion Kit Example

Migration Myths

Difficult
Too Risky
Extensive Downtime

PLC5 Migration Options To Choose From

Logix Conversion Kit

The Logix Conversion Kit migration option is a very cost effective solution because it allows you to keep your existing field device installation without the need for rewiring or rebuilding panels. The PLC5 adapter modules connect into the existing wiring terminals which then convert directly into the new ControlLogix system.

This method will greatly reduce the migration cost and amount of plant downtime required for the migration because it is based on a very efficient plug-and-play installation method.

Panel Replacement

There are occasions where a complete control panel or switchboard replacement is the better option. Maybe the old panel is beyond repair, too small for the new system, or future expansion is required that the old panel cannot handle. In this situation a brand new panel is designed and built off-site and fitted with the new control system. The old panel is then disconnected and removed, the new panel is installed in its place and the field wiring is connected into the new control system.

This method will increase the amount of downtime required for the migration, but you have the advantage that everything is brand new which makes maintenance a lot easier and the panel is purpose built and ready to meet the future needs of your plant.

Easy PLC5 Migration

Step 1 - On-Site Assessment

Our staff will attend site to gain a better understanding of your requirements. We will evaluate your existing plant to identify what products and services are going to give you the easiest migration with minimal disruption.

Step 2 - Migration Plan Development

After our site assessment, we will have all the information needed to develop a tailored migration solution that best fits your requirements. We will present you with all your available options and discuss the differences between each one.

Step 3 - Engineering and Program Conversion

Our engineering staff will convert your existing programs into the new Logix platform using specially developed migration software. Once your existing PLC and HMI programs have been converted, we will review the code and then download it into your new ControlLogix processor or PanelView for thorough workshop testing.

Step 4 - On-Site System Upgrade

Once the engineering and software conversion has been completed and tested, we will start your site upgrade. The Automated Electrics team will remove the old PLC5 system and the new ControlLogix system will be installed. We will complete our pre-operational checklists and Inspection & Test Plans (ITP’s) to ensure everything is installed and operating correctly.

Step 5 - Plant Start-Up

After the on-site system upgrade is finalised, the plant will then be ready for an operational test performed by the customer and assisted by our engineers. Once the operation has been validated, all the necessary documentation and software files will be finalised for customer acceptance.

Automated Electrics can help you develop a proactive migration plan that fits your needs. We have plenty of resources available to complete your migration with minimal disruption. To put it simply, migrations have never been easier!

Get the right advice with a team you can trust, Automated Electrics.
We take the worry out of any PLC5 migration.

Your PLC-5 Migration Solution Starts Here

A Well Planned Migration Offers

Reasons To Migrate

Reduced plant downtime during migration.
Controlled costs and expenditure.
Staged timing with minimal disruptions to operations.
Creation of spare parts for older systems not yet migrated.

Better technology and features available in the Logix PLC’s.
The Logix PLC is faster and easier to program.
Cost effective maintenance.
Improved productivity and system performance.
Increased security and plant data availability, leading to more informed business decisions.