![]() ![]() We also devised a contingency plan that would allow control to be temporarily switched back to the legacy PLC, if needed, any time during the process. This provided the structure for converting sections of logic in phases. ![]() Programming added to the original PLC allowed control for each device to be quickly switched between PLCs. We employed a customer-specific technique to maintain connection between the two PLCs, including diagnostics to help place all equipment into a safe state in the event that communication was lost. The team kept field wiring connected to the Modicon I/O modules, with the original PLC remaining online until all programming was transferred to the new PLC. We approached the conversion in phases, with all I/O modules in place and operational. Several Wonderware InTouch HMIs provided the operator interface to the system with a Wonderware Historian providing the required data logging and reporting. The controller communicated with several other Modicon and Rockwell PLCs via Ethernet, Data Highway Plus (DH+) and Modbus Plus networks to provide interlocking with other process systems. The existing system consisted of a Modicon Quantum PLC with more than 1000 I/O points distributed across six Quantum and 800 series I/O racks. Each phase would entail transferring a section of the control system logic to the ControlLogix PLC, while the original control stayed intact. To accommodate their budget and aggressive production schedules, we would need to complete the project in phases, with no downtime. This client, a global manufacturer of household products, asked MidStates to upgrade a large process control system from a legacy Modicon system to a Rockwell ControlLogix platform.Ī key objective was to retain their large network of existing I/O modules, avoiding the considerable engineering time, expense and downtime of replacement, while realizing the benefits of a modern control platform. ![]() ![]() Many clients are facing the challenge of migrating legacy systems to new technologies-to take advantage of increased functionality and performance plus decreased maintenance cost and downtime. In our experience, PKTX cards are the most popular.Convert a Legacy Modicon Process Control System to a Rockwell ControlLogix Platform To connect a PC using a connection that a PC doesn’t natively support, such as RS485 or blue hose, one can either use an external converter, or an internal card to make the connection. Support for custom, user defined structuresīecause of Allen Bradley PLCs’ immense popularity, many different media and protocol converters exist.Support for device or connection redundancy. ![]()
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