1. PLC-5® and 1771 I/O Migration to ControlLogix®

2. Agenda 1. The Solution 2. Time Study 3. Product Lifecycle
4. Phased Migration
5. Migration Tools Detail
6. Summary
7. For More Information

3. The Solution: PLC-5 and 1771 I/O Migrations Made Easy
DH+ Network
EtherNet/IP Network
Remote I/O Network
EtherNet/IP Network
Rockwell Automation has developed a unique phased migration strategy for PLC-5 and 1771 I/O that will allow you to quickly and easily migrate to Integrated Architecture while maintaining the existing field wiring and physical footprint in your control cabinet. This approach will:
• Lower conversion time
• Reduce risk by preserving existing field wiring connections
• Lower engineering and labor costs
• Minimizing production downtime
Additionally, you will gain the benefits (to name a few) of the Integrated Architecture:
Architecture Simplification
Using one control platform across any discipline helps eliminate the need for separate controllers and systems.
Greater Information Access
Converging multiple manufacturing disciplines into a single platform gives you greater access to real-time information on the plant floor, remotely, or throughout the enterprise.
Faster Startups
The commonality between disciplines provides faster startups due to ease of integration between them. Reuse engineering designs as well as a common, tag-based system database to reduce your development and commissioning time.
Lower Maintenance
A common Logix control engine and development environment help reduce maintenance, spare parts and training costs.
Optimized Productivity
Reuse program segments or tags for new applications to help you react quickly to market and business changes.

4. Unmatched Value: Time Savings and Risk Reduction!
I/O Wiring Conversion system:
Typically saves 10 hours per rack of ten, 40-point I/O modules
Lowers engineering and labor costs
Reduces production downtime
Reduces risk by eliminating potential wiring errors
Preserves existing field wiring connections by using existing 1771 swing-arms
No need to drill new holes in the control panel
How much time are we talking about saving you? Let’s take a look at this quick time study (click on green “Launch Time Study Video” button)…..
After time study video:
As you can see, Rockwell Automation is providing tools for this migration that not only make it quick and easy to migrate to newer technology, but also allows you to continue to realize a return on your hardware investment in 1771 I/O. By keeping this hardware and wiring intact, your production downtime, as well as engineering and labor costs, will be minimized.
When we develop new products like PLC-5 and 1771 I/O, we use clear product development standards and procedures, and we design with a migration path in mind, taking into account both backward compatibility and future technology. Our commitment to helping customers get the most out of their equipment until the time comes for them to migrate to newer technologies is coupled with our ability to help them navigate the eventual transition with options suited to their unique requirements. Let’s take a few minutes to discuss this further by talking about the different phases of the product lifecycle as well as some tools that help you manage your inventory and the inevitable transition to newer technology….

5. Understanding the Product Lifecycle
Product Launch
A Newer Product in that Category is Launched
Announcement that Product will be Discontinued
Discontinued Date
We understand the critical need for customers to be able to leverage their investments in knowledge and equipment, so when it does come time to retire a product, we communicate that change as early as possible to help them plan the transition (often up to two years in advance). This commitment to supporting our customers' automation investments is founded on:
Superior product longevity and communication throughout the lifecycle
A phased migration strategy with an extensive toolkit to support it
Global solutions and services

6. Product Lifecycle Status Webpage
Rockwell Automation has distinguished itself among suppliers by shipping many solutions for more than 30 years and supporting products for as long as 7 years after their discontinuation
In some situations, the End of Life timeframe is much smaller due to circumstances beyond Rockwell Automation’s control (e.g., when a third-party supplier stops making an essential element for a Rockwell Automation product).

7. Phased Migration: Existing Control System
DH+ Network
Remote I/O Network
Enabling Migration Tools:
Installed Base Evaluation
Integrated Architecture Builder
With Rockwell Automation, you can feel confident about embarking on a Phased Migration.
Use Integrated Architecture Builder and ProposalWorks Selection software during the planning phase of your project.

8. Phase 1: Logic Code Conversion & Monitor Mode
Making the decision to keep or replace HMI before performing controller code conversion will save time and money
DH+ Network
Using the 1756-RIO Module in “Monitor Mode” allows you check your logix before going live. The module reads the inputs but outputs are disabled.
Remote I/O Network
Enabling Migration Tools:
Logic Code Conversion Services or embedded software translation tools
1756-RIO Module
Phase 1 Tools: Logic Code Conversion Services (or embedded software conversion utilities) and 1756-RIO Module
Phase 1 often begins by converting PLC-5 processor code to Logix code. Our logic and tag database conversion utilities will
help you quickly upgrade your processor code allowing you to take full advantage of the Rockwell Automation Logix family
of Programmable Automation Controllers (PAC). Once the converted code has been downloaded to the Logix PAC, the
new 1756-RIO Remote I/O module can be used as the network interface to the 1771 I/O over the existing Remote I/O network.

9. Phase 2: Controller Replacement
Making the decision to keep or replace HMI before performing controller code conversion will save time and money
DH+ Network
The I/O wiring conversion system allows replacement using existing wiring and mounting holes.
1756-RIO module configured as a scanner allows ControlLogix communications to RIO Adaptors located in remote racks.
1756-DHRIO allows communication over the existing DH+ network
Remote I/O Network
Enabling Migration Tools:
I/O Wiring Conversion System
1756-RIO Module
Phase 2 Tools: I/O Wiring Conversion system (if you have I/O local to PLC-5) and 1756-RIO Module
Phase II involves replacing the existing PLC-5 controller(s), while continuing to use the 1771 Remote I/O. Replace the PLC-5 controller with the Logix PAC and the 1756-RIO Module. The same 1756-RIO Module used in Phase I is now configured to perform as the master instead of the monitor. The Logix PAC can now control any I/O that resides on an 1771 network.

10. Phase 3: HMI/EOI Migration
DH+ Network
EtherNet/IP Network
Remote I/O Network
Enabling Migration Tools:
HMI Application Code Conversion Services or embedded software conversion utilities
Phase 3 Tools: HMI Conversion Services or embedded software conversion utilities
During this phase of the migration, existing HMIs or EOIs can be replaced with FactoryTalk View products using Application
Conversion Utilities (ACU). ACUs not only make operator interface conversion much more cost effective, but give you
greater flexibility regarding the final product. This means that you can account for how operators use your equipment and
design interfaces that help maximize their productivity. In the end, this will allow you to give your operators the tools they
need to get quality product to your customers. Rockwell Automation currently offers conversion from
WonderWare and Intellution iFIX HMI interfaces.

11. Phase 4: Remote I/O Replacement
EtherNet/IP Network
With the I/O wiring conversion system, 1771 I/O racks can quickly be replaced with 1756 I/O without disturbing the field wiring…one rack at a time if necessary.
1756-RIO modules configured as adaptors in the remote racks.
Remote I/O Network
Enabling Migration Tools:
I/O Wiring Conversion System
1756-RIO
Phase 4 Tools: I/O Wiring Conversion system
In the final phase of the migration process, the I/O Wiring Conversion System is used to replace the 1771 I/O with the ControlLogix I/O. Because I/O replacement represents a large investment, we provide an approach that’s right for your schedule and budget. The I/O Wiring Conversion System provides a method to connect the existing 1771 I/O wiring to the 1756 I/O modules without disturbing the field wiring connections, dramatically reducing labor time and eliminating the potential for downtime that could result from wiring mistakes during the migration. Planning your migration is more manageable as I/O can be swapped one rack at a time or all at once based on your schedule and budget. In either case, you can run both new and old I/O networks simultaneously. Additionally, I/O cross reference documentation assures correctness and provides historical back-up for future troubleshooting or diagnostics.

12. Phase 4: Remote I/O Replacement & Network Upgrade
EtherNet/IP Network
EtherNet/IP Network
Remote I/O Network
Enabling Migration Tools:
I/O Wiring Conversion System
Phase 4 Tools: I/O Wiring Conversion system

13. Enabling Migration Tools
Installed Base Evaluation with Lifecycle Reporting
Integrated Architecture Builder
ProposalWorks™
1756-RIO Module
Logic Code Conversion Services and Utilities
HMI Application Conversion Services and Utilities
I/O Wiring Conversion System

14. Migration Tools: Installed Base Evaluation
Document the current system and Define the Final System Architecture
Determine scope of project
Identify reliability and longevity issues
Identify technical issues before they become major concerns
Perform an Installed Base Evaluation with Lifecycle Reporting:
Lifecycle Site Report
Lifecycle Location/Line Report
Lifecycle Machine Report
Lifecycle Panel Report
Plant Bill of Materials
Product by Location
Inventory Analysis
Red-Yellow-Green lifecycle coding identifies production status associated service risk
Performing an IBE will provide critical information necessary to develop support planning and migration prioritization
Documenting the Existing System and Defining the Final System
Creates a Migration Roadmap.

15. Migration Tools: Integrated Architecture Builder (IAB)
IAB includes a Migration Wizard specifically created for PLC-5 to ControlLogix migrations
helps you accurately convert an existing chassis to the equivalent 1756 counterpart
helps you determine any critical application considerations
picks out the necessary 1771 wiring conversion system components to greatly reduce your conversion time
selection of a mounting base
conversion modules for each I/O module
appropriate cabling
allows you to convert multiple chasses through a series of dialogs
Integrated Architecture Builder (IAB) is a Configurator tool that:
Enables you to create a quick system configuration
Enables you to efficiently generate accurate and comprehensive bills-of-material, graphics, and customized reports for Integrated Architecture solutions
Supplements other sales tools (e.g., Selection Guides, Catalogs)
Performs rule-based system/network checking

16. Migration Tools: Integrated Architecture Builder (continued)
IAB includes a Migration Wizard specifically created for PLC-5 to ControlLogix migrations
creates Bill of Material including:
fully configured 1756 chassis and modules
1771 Wiring Conversion System accessories
1756 swing arms (if Conversion Kit was not selected)
creates a Project Report detailing specification differences by module for Engineering to verify application concerns (see next slide for more details)
Full Bill of Material
Graphic representation of populated chassis
Cross reference table including 1771 module to equivalent (and any 1771 Wiring Conversion System accessories)
Application Considerations for each 1756 module included in Appendix at the end of the report
Integrated Architecture Builder (IAB) is a Configurator tool that:
Enables you to create a quick system configuration
Enables you to efficiently generate accurate and comprehensive bills-of-material, graphics, and customized reports for Integrated Architecture solutions
Supplements other sales tools (e.g., Selection Guides, Catalogs)
Performs rule-based system/network checking

17. Migration Tools: 1756-RIO (Remote I/O) Module
Communication performance equal to the existing PLC-5 system that it replaces
Ideal solution for phased migrations
Allows the reuse of the Remote I/O network when multiple racks of PLC-5 and ControlLogix products will be communicating to one another
Can be configured as:
Scanner which allows migration of master PLC-5 rack first
Adapter which allows migration of remote 1771 I/O racks first (note that a processor is still required in the ControlLogix rack)
1756-RIO configured as an Scanner
PLC RIO Ports configured as scanner
1756-RIO configured as an Adapter

18. 1756-RIO Performance
1756-RIO communication speed is equal to the PLC-5

19. 1756-RIO Module (more detail)
The 1756-RIO provides a Logix solution for communications over RIO
Transfer all data to/from module as normal I/O
Eliminates the MSG instructions and the confusion over tag names
Improved performance for data exchange with controller
Create a thin RSLogix 5000 I/O profile for the module
Allows you to configure how the controller talks to the module
Simplifies a portion of the configuration process (instance IDs and Sizes)
Provides a direct link to the module’s configuration tool
Communicate all chassis and module data in native INT (16 bit) format
Reduces data conversion processing by module which increases the performance of the module
Avoids conversion issues resulting from Boolean data
Embed Block Transfer Control and Status information into the data
Provides better visibility and control
Allows communications with all modules requiring Block Transfers

20. Migration Tools: Logic Code Translation Tool in RSLogix 5000
“Wizard-style” step-by-step dialogs guide the user through the translation process
You can use the embedded translation tools in RSLogix 5000 to convert your PLC-5 application code to Logix-based code. There are step by step video-based instructions that walk you through the process.
This tool successfully translates approximately 80% of the application code.
Updated and updateable controller list
Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

21. Migration Tools: I/O Wiring Conversion System

22. I/O Wiring Conversion System Components
Base Plate to house
Conversion Modules
D-shell Connector for
1492 Cable
Cover Plate to attach
1756 Chassis
1756 Chassis and I/O
Pre-drilled & tapped holes for mounting 1756 Chassis
What is an I/O Wiring Conversion System?
A set of Bulletin 1492 products that reduces rewiring time and ELIMINATES RISK when replacing 1771 I/O with ControlLogix 1756 I/O
The Bulletin 1492 I/O Wiring Conversion System consists of 3 components:
Bulletin 1492 Conversion Modules
Convert 1771 I/O field wiring to 1756 I/O compatible wiring
Uses the existing 1771 I/O swing-arm - field wires remain attached and undisturbed
Provide fusing if previously available on a 1771 output, but not on 1756 output
Bulletin 1492 Conversion Mounting Assembly
Consists of a Base Plate and a Cover Plate
Base Plate mounts in existing 1771 mounting holes
Cover Plate provides for installation of the new 1756 chassis
Bulletin 1492 Cable
Converts the field terminations to match a compatible 1756 I/O modules
D Shell on one end for connection to Conversion Module
1756 RTB (removable terminal base) on the other end for Connection to 1756 I/O module
Let’s see how these components work together to offer this migration solution (click on the green “Launch Wiring System Demo” button)….

23. I/O Wiring Conversion System Components
Mounting Assembly
Base Plate
Cover Plate
Conversion Modules
Cables

24. Migration Tools: EXPANDED I/O Conversion Cable Assemblies
Extension set of conversion cables for digital and analog modules
Converts field terminations to match the compatible 1756 I/O module
More information available in the I/O Wiring Conversion System Selection Guide
Digital Inputs and Outputs
Analog Inputs & Outputs

25. We give you notice, we give you options!
Rockwell Automation offers:
Superior product longevity and communication throughout the lifecycle
Phased Migration Strategy and Extensive Migrations Toolkit
Global Solutions and Services
PLC-5 and 1771 I/O Migration Strategy from Rockwell Automation offers unmatched value:
Typically saves 10 hours per rack of ten, 40-point I/O modules
Lowers engineering and labor costs
Reduces production downtime
Reduces risk by eliminating potential wiring errors (preservation of existing field wiring)
As you can see, Rockwell Automation is providing tools for this migration that not only make it quick and easy to migrate to newer technology, but also allows you to continue to realize a return on your hardware investment in 1771 I/O. By keeping this hardware and wiring intact, your production downtime, as well as engineering and labor costs, will be minimized.
Superior Product Longevity and Communication Throughout the Lifecycle Rockwell Automation has a strong track record of keeping products viable, resulting in long product lifecycles relative to our competition. As our products age, we provide options to help customers extend product life as long as possible, and enough advance notification to allow them to transition as seamlessly as possible to the next generation of products.
Phased Migration Strategy and Extensive Migrations Toolkit Rockwell Automation provides the broadest portfolio of upgrade and replacement options, along with a phased migration approach that minimizes risk and protects customers’ investments as they move to new technology; we can help you to get there all at once or in stages at a pace that is comfortable for you and your budget
Global Solutions and Services Rockwell Automation provides project management, domain expertise, and global execution to help optimize our customers’ experience during every phase of the automation lifecycle. Beyond our solution delivery capabilities, our full suite of services can help our customers optimize plant assets, increase productivity, and improve their overall financial performance. Migrations require a high level of trust. We have the technical, industry, and project management expertise to get the job done
Customer Value (some key advantages of Integrated Architecture):
Improve equipment utilization and manufacturing performance Better asset management, simplified architectures, greater information access, and lower maintenance costs all add up to increased productivity.
Increase data availability and security Integrated production and enterprise systems allow for a better flow of information from the plant floor to the top floor. This makes for faster, more informed business decisions.
Increase production flexibility and quality Less time spent in development means more time spent on creating new intellectual property. In addition, quicker production modifications allow for quicker response to changing market demands.
Use leading-edge technologies to gain competitive advantage and/or global presence Updated technology using intelligent devices often helps to improve uptime, increase speed, and simplify integration. In addition, information that is easily extracted and shared can be used across the customer’s enterprise or around the world.
Reduce operation and maintenance costs, as well as downtime New equipment and integrated control systems require fewer spare parts, minimize downtime needed for repairs, and lessen operator training requirements, meaning appreciable cost reductions.
Achieve regulatory compliance Integrated systems allow for greater communication and standardization across multiple disciplines and locations.

26. For more information
Visit the Literature Library:
Rockwell Automation Migration Solutions Brochure MIGRAT-BR002A-EN-P (May)
PLC-5 > ControlLogix Phased Migration Solution Profile
1756-RIO Product Profile
1492 I/O Wiring Conversion System Selection Guide
Visit the E-tools Website:
Install Integrated Architecture Builder
Install ProposalWorks
Visit the Silver Series Website
Visit the Migration Solutions Website
Visit the IA Tools Website

27. Thank you