PLC-5 to ControlLogix Migration - Allen-Bradley

Are you currently using a PLC-5 controller in your setup?

The PLC-5 line was once a standard in automation, but it’s now nearing the end of its lifecycle. Rockwell Automation ceased hardware production in February 2022 and plans to discontinue software support by December 31, 2025. These days you will most likely find a cabinet like we encountered many time (see photos) which nobody dares to touch. As a result, it’s essential to start planning an upgrade—most often to ControlLogix controllers, which offer significantly improved functionality and performance.

What does this shift mean for your operations?

• Minimal Downtime Migration: The transition to ControlLogix can be conducted while your PLC-5 system remains operational. The ControlLogix can run in "shadow" mode, enabling thorough testing and validation, so you can switch over smoothly when your team is ready.

• Future-Focused Training: The ControlLogix platform uses a tag-based system, allowing technicians to program with familiar P&ID tags and creating user-defined data objects. This approach aligns closely with high-level programming languages, making training for new technicians more straightforward.

• Consolidation and Simplified Maintenance: With ControlLogix, it’s often possible to replace multiple PLC-5 units with a single controller that centralizes data reporting and simplifies integration with SCADA, DCS, MES, and ERP systems.

• Performance Boost: ControlLogix features a task-based processing engine, which offers greater flexibility than the PLC-5’s scan-based system. Tasks can be prioritized or scheduled for continuous or periodic execution, resulting in an estimated 10x speed improvement over PLC-5.

• Enhanced Safety: ControlLogix addresses several safety limitations of the PLC-5. It offers more precise safety control, supporting features like properly muting light curtains, monitoring device states, and allowing bypass conditions where needed.

• Reduced Long-Term Costs: PLC-5 parts are becoming harder and more expensive to find, with limited sources once spares are exhausted. Continuing with the PLC-5 may lead to unplanned downtime, as replacements often rely on third-party refurbishers whose standards can vary.

• Easier Expansion and Customization: ControlLogix’s modular options provide adaptability across nearly any application, allowing your system to grow with your needs. Furthermore, it’s designed to integrate seamlessly into your existing I/O and control cabinets, preserving the integrity of your wiring and reducing installation costs.

  
  

Choosing the Partner for Migration

At Dokoma, we understand that transitioning from a legacy system like the PLC-5 can feel overwhelming. To help ease this process, we work with you to develop a migration strategy that minimizes risk while maximizing the benefits of ControlLogix. Our team handles all necessary reprogramming and adjustments, including HMIs, setting up a robust, future-ready foundation for your technicians.

Our experience in large-scale migrations enables us to deliver a seamless process, with a focus on reducing errors, lowering engineering time, and keeping your operations running smoothly. With our proven record of successful transitions, Dokoma is the trusted partner you need to make the Allen-Bradley PLC-5 to ControlLogix Migration confidently and effectively.

In summary, the advantages of a planned upgrade to ControlLogix far exceed the costs and risks associated with waiting for a potential failure in your PLC-5. By making the move now, you’ll position your operations for improved performance and reliability, leaving legacy limitations behind.