Migration / Conversion

Rockwell and Non

Rockwell Equipment
How to Step Forward

Richard Lindbro

Customer Support & Maintenance

Rockwell Automation

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Migration / Conversion - Agenda

1.1.Objectives
Objectives

2.2.Migration
Migration/ /Conversion
ConversionSolutions
Solutions

3.3. Migration
MigrationofofRockwell
Rockwellsystems
systems

4.4.Conversion
ConversionofofSiemens
Siemens

5.5.Conversion
ConversionofofSattCon
SattCon

6.6.Summary
Summary––Step
StepForward
Forward

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Migration / Conversion - Agenda

1.1.Objectives
Objectives

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 Objectives

• To show how to migrate Rockwell to Rockwell Equipment

– Migration of PLC-2
– Migration of PLC-3
– Migration of PLC-5
–

• To show how to convert Non-Rockwell to Rockwell Equipment

– Conversion of Siemens S5
– Conversion of Siemens S7
– Conversion of SattCon
–

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Migration / Conversion - Agenda

2.2.Migration
Migration/ /Conversion
ConversionSolutions
Solutions

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 Migration / Conversion Solutions

WE CAN GET YOU FROM HERE...

• Uncertain parts sourcing
• Limited network options
• Higher repair costs
• High unscheduled downtime risks
• Questionable reliability of older electronics
• No warranty coverage
• Old equipment that lacks production
efficiency

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 Migration / Conversion Solutions

...TO HERE
• Product backed by the outstanding support of
Rockwell Automation
• Open, integrated architecture for increased
flexibility
• Re-use of engineering practices to reduce
development time and costs
• Maximizing returns from existing assets through
greatly improved control and monitoring
• Quickest response to customer or market demands
• Easy access to plant and production data from
business systems for better management decision
making
• Single environment for integrated motion, process
and safety for total plant control

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 All at once or step by step

STEP 1. OPERATOR INTERFACE REPLACEMENTS

• Graphic Conversion Utilities not only make

operatorinterface 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.

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 All at once or step by step

STEP 2. REPLACE LEGACY CONTROLLERS

• Utilizing our network interface approach, you can

replace your PLC-3 product without replacing
your existing I/O.
• Our logic and Tag Database conversion utilities
will help you quickly upgrade your programming
logic allowing you to take full advantage of a new
Rockwell Automation Logix™ controller.
• This means you not only save money, but will be
better positioned for both your current and future
production demands.

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 All at once or step by step

STEP 3. I/O REPLACEMENT (DO IT ALL OR ONE RACK AT A TIME)

• I/O cross reference documentation

assures correctness and provides
historical back-up for future
troubleshooting or diagnostics.
• I/O replacement represents a large
investment, but our approach lets you
replace by individual section or all at
once.
• In either case, you can run both new and
old I/O networks simultaneously.
• Whatever’s right for you and your budget

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Migration / Conversion - Agenda

3.3. Migration
MigrationofofRockwell
Rockwellsystems
systems

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 Migration

Systems to migrate
• PLC-2 to ControlLogix or PLC-5 or SLC500/MicroLogix.
• PLC-3 to ControlLogix, PLC-5.
• PLC-5/250 to ControlLogix.

Legacy code Conversion to RSLogix 5000

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 Migration

• Migration of PLC-5 or SLC 500 Logic to

Logix-Based Logic.
• This is done with an integrated tool in
Logix 5000.
• The procedure is described in manual
1756-rm085 in Litrature Library on
AB.com

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Migration / Conversion - Agenda

4.4.Conversion
ConversionofofSiemens
Siemens

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 Conversion from Siemens: S5 or S7 PLC
Phase 1
HMI / EOI Factory Talk View Phase 3
Use Encompass Partner
Use utility / and ControlLogix Profibus
Engineering Services DP Master Module to
control S5 I/O Profibus DP/
to convert Siemens
EtherNet IP
Logic to Logix

Phase 2
S5 Controller Replace legacy HMI/EOI w/
Replace the controller Engineering
w/o replacing the Services…graphic utilities
legacy I/O to assist conversion of
PanelMate, TCP,
Profibus DP WonderWare, and Intellution

Siemens ET100U/200U
with IM318-B/C

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Technical Tools: Logic Code Conversion.
Siemens S5 to Logix Original Code.

All STL Code gets translated into the Ladder Logic

All STL
documentation
brought into the
converted Logix code

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Technical Tools: Logic Code Conversion.
Siemens S5 to Logix Converted Code.

All STL
documentation
brought into the
converted Logix
code
All STL Code
gets translated
into the Ladder
Logic

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Migration / Conversion - Agenda

5.5.Conversion
ConversionofofSattCon
SattCon

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 Conversion of SattCon

• SattControl systems possible to convert:

– SattCon 35
– SattCon 15
– SattCon 31, 31-10, 31-50, 31-90

– Using 19” ALU-Rack

– SattCon 05

– SattCon 200
– Using Flex I/O

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 Hardware

Existing SattCon system Converted to ControlLogix

Using 19” ALU-Rack

CPU

Profibus
PBI-interface

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 Hardware

Existing SattCon200 system Converted to ControlLogix

Using Flex I/O
ControlNet

ControlNet

Update of ControlNet from version 1.3 to version 1.5

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 Hardware

• PBI-interface

– Customer driven development

– PBI-Interface card makes it possible to
access an 19” ALU-Rack as a Profibus
node and be controlled from a
ControlLogix CPU
– Each 19”ALU-Rack require a separate
PBI-Interface

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 Software

• Stepwise working sequence - executing the application program conversion

Step
Step11 Step
Step22 Step
Step33 Step
Step44

Get translated Program conversion

Configuration of Hands on adjustments
instruction lists and and importing of
Profibus PBI nodes of any generated
IDF listing from converted XML code in
and SATT rack I/O. errors.
SATT. RSLogix5000.

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 Software

”One To One” application program conversion concept.

DOX program
0090 :
0092 :
00 A -STARTCOND- S000.01
***************************************************
01 A ME-P.F.S. 0016 DUMMY MEMORY-START
MAIN SEQUENCE
CONDITIONS
***************************************************
02 = -STARTPHASE- S000.02
00 A RPM-STOPTIMER 1610 FLAG-RPM SYS.AL. FOR STOPPHASE TIMER
*
01 A T.RPM.STOPTIM T02 STOPPHASE TIMER WHEN RPM SYS.NOT USED
0093 :
02 ON RPM-STOPTIMER 1610 FLAG-RPM SYS.AL. FOR STOPPHASE TIMER
00 A SWITCH.Y-D 0121 DELTA CONTACTOR
03 A ME-RPM-0 0540 RPM=0/30SEC.
01 A -STARTPHASE- S000.02
04 A T.SENS-STPTIM T05
02 = -DELTA- S000.03
05 AN ME-AI110-AL 0642
*
06 RP
0094 :
07 A -STOP.DRY- S000.07
00 A -DELTA- S000.03
08 AN FIRST-SCAN 1675
01 A T.FROM-DELTA T49 TIME FROM DELTA TO TEST
09 = -STANDSTIL- S000.00
02 A TESTDIS-ON 1630
*
03 AN BY-PASS-TST.D 0035
0091 :
04 = -TESTWATER- S000.13
00 A -STANDSTIL- S000.00
*
01 O -STOP.DRY- S000.07
0095 :
02 A ME-P.F.S. 0016 DUMMY MEMORY-START CONDITIONS
00 AN TESTDIS-ON 1630
03 AN ME-VI.SHUTDWN 0611
01 O BY-PASS-TST.D 0035
04 RP
02 RP
05 A PB-START. 0300 ME
03 A -DELTA- S000.03
06 AN ME-TOTALALARM 0501
04 A T.FROM-DELTA T49 TIME FROM DELTA TO TEST
07 = -STARTCOND- S000.01
08 =S W.OFF-OK 0014 05 = -STANDBY- S000.05
*
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Software

”One To One” application program conversion concept.

CLX program

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Migration / Conversion - Agenda

6.6.Summary
Summary––Step
StepForward
Forward

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 Step Forward

• PLC-2 to ControlLogix or PLC-5 or SLC500/MicroLogix.

• PLC-3 to ControlLogix, PLC-5.
• PLC-5/250 to ControlLogix.
• Siemens – S-5, S-7 to ControlLogix.
• SattCon 35, 15, 31, 31-10, 31-50, 31-90 to ControlLogix.
• SattCon 05 to ControlLogix.
• SattCon 200to ControlLogix.

• Modicon – Quantum, 984, 584, 380, 381, 480, 485, 780, 785 to
ControlLogix.
• TI - 520, 520C, 525, 530, 530C, 535, 560, 560/565, 565, 560/560T,
560T, 545, 555, 575 to ControlLogix.
• GE Series 6 to ControlLogix.

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 27

 Step Forward

• This conversion concept has a lot of benefits:

– Converting application program using software, no typing error
– Reuse of the complete I/O installation
– No need for I/O test before start up
– Reuse of control cabinet documentation
– Reuse of I/O labeling
– Short time needed to verify and start up
– Always possible to reverse and reinstall the old system , fall back safety mode.
– Possible to ”split up” the start up commissions and use several occasions to test
before finally swapping to the new system.

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 28

 Step Forward

• Is this the way forward for your installed base?

• Any questions?
• Please contact your local Rockwell Automation Account Manager

Rockwell Automation is a leader in Migration Solutions

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 29
Copyright © 2009 Rockwell Automation, Inc. All rights reserved.