PLC Modernization Solutions for Automation Managers - How to Choose the Right One for Your Plant?

Back in July 1985, the number one song in the pop music world was "Everybody Wants to Rule the World" by Tears for Fears. In the automation world, the popular Allen-Bradley PLC-2 was being replaced with an updated new processor and large-format, high-density IO cards that would go on to rule the small-system market for quite some time. This was the PLC-5 platform and the 1771 family of cards.

And like many battle-hardened industry veterans, we have aged considerably since the 80’s and so has the PLC-5! It’s CPU is officially “End of Life” meaning there will be no further support from the factory. As an Automation Manager responsible for reliable process control and continuous data streams, this means it’s time to consider your options, here’s why:

• No factory support on PLC-5 CPUs
• 1771 I/O cards are “Active/Mature”; migration recommended
• 30-year old 1771 cards failing
• Repair and/or spare parts may not be available
• Rely on eBay or used equipment resellers? Not a solid business plan.
• 2 databases to maintain (DCS & PLC)
• 2 skill sets required (DCS & PLC)
• 2 spare inventories to maintain (DCS & PLC)
• Need to replace QUICKLY and inexpensively
• Limit/eliminate re-termination of aging field wiring
• Limit/eliminate need for additional footprint for new I/O

Luckily Emerson offers a range of migration tools and solutions for many legacy control systems including Siemens, Honeywell, ABB, Schneider, and yes, the Allen-Bradley PLC-5.

Modernization Toolkit Highlights:

• Tool assisted services minimize risks associated with manual configuration conversion, and accelerate new system implementation
• PLC5 Logic Conversion and automated documentation
• Establish plant configuration standards for ease of maintenance and replicating applications at different sites
• Migrate from PLC-5 to DeltaV without lifting a wire with the Signal Conditioning Card swingarm solution.

Ideal for cold cutover on a compressed schedule, there are FlexConnect™ mass termination boards and wiring harnesses available for Provox, Baily INFI90, Rockwell PLC-5 and SLC series, Honeywell TDC, Foxboro IA, Modicon, Siemens-Moore APACS and QUADLOG:

• Quick cutover
• Saves time and money
• HART ® Pass through
• Don’t have to lift the field wires
• Most cabinet documentation doesn’t have to change

Start your modernization journey with the most visible part of the control system, the consoles and graphics. Alleviate most Operations pain-points by taking advantage of today’s performance enhancing technologies and human centered design of a modern HMI, while taking a staged approach to modernize the controllers and IO as time and budgets allow.