Upgrading redundant PLC 5 CPU to Controllogix. Need advise and highlights

[flyers]

Hi guys,

We've a customer plant running about 10 sets of PLC 5 redundant, some of them has a few IO rack due to large quantity of IOs in the system. All PLC 5 are linked using DH+. These 10 machines are running independant. With the new budget approval they'd like to upgrade the PLC 5 CPU (mostly PLC5 40 and 60) to ControlLogix. While the IO will be still using PLC 5. We've not done any upgrade from PLC5 - CLX before.

Appreciate if anyone has done this can give me some advise what shall we check & clarify on the PLC 5 redundant system and shall we take good care?

We are thinking to propose to use redundant CLX running ControlNet + add an additional ControlNet module at the PLC-5 IO rack.

The PLC-5 ladder program should be rewrite manually in CLX style, right?

Thank you.

 

[Gerry]

You should definitely get the local Rockwell sales team to specify the hardware configuration for you. They should be very happy to help you out and buy lunch as well. Redundancy configurations require specific firmware versions.

The PLC-5 ladder program should be rewrite manually in CLX style, right?

Ideally, yes. The conversion utility won't take advantage of the tag naming capabilities or other enhancements.

 

[RSL]

I have never built one from the ground up myself, but the ONLY way to do it is with ControlNet. That is a requirement of Controllogix redundancy.

I am not sure about using PLC5 IO. That would be the main issue. The best way to use PLC5 IO with ControlLogix is with ControlNet by far. However I am not sure if you can use the PLC5 hardware in redundancy at all.

It would be wise to contact Rockwell as stated above. You need to find out for sure about being able to use that IO in a CLX redundant system.

Once you know the answer to that, ControlLogix redundancy is very easy to configure. I attached the links to some manuals below. They will likely answer most if not all your questions.

RSL



http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1756-um523_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/rn/1756-rn628_-en-e.pdf

 

[flyers]

Thank you, I'll further study and come back here again if I need any help from you guys.