Upgrades

Obsolete Systems

When a PLC system becomes obsolete, it is very difficult, if not impossible, to replace failed hardware. This can result in significant loss in production. An obsolete PLC system needs to be upgraded by replacing the PLC hardware with new state of the art hardware.

Upgrading to a new PLC system requires more than just replacing the hardware. The PLC program used in the old PLC is not supported by new PLC's. Thus, the PLC program will have to be converted. This becomes more complicated if the manufacturer of new PLC system is different from that of the obsolete system.

Many PLC systems have an associated SCADA (Supervisory Control and Data Acquistion) terminal from which the operator controls and monitors the process through a series of graphic screens. These are usually Windows PC based systems. If the PC becomes obsolete and has to be replaced with a new PC, the SCADA software may not be compatible with the operating system of the new PC. In this case the SCADA software will have to be upgraded. For some systems, the current screens can be imported into the new software. For others the screens may have to be redrawn.

Upgrade Services

We can convert the current PLC program to one compatible with the new PLC system. In addition, we can specify the required PLC hardware and provide electrical drawings. With our partner contactor we can provide a turnkey system.

If the SCADA PC is obsolete we can determine the software upgrade required and load the software on the new PC. We can also redraw or modify the screens, if needed.

Upgrade Experience

We have pereformed many upgrades. Some have been simple, replacing a PLC with a newer version from the same manufacturer. Others have been more complicated, replacing a PC or DCS system with a PLC. Some representative examples are,

•Replace Allen-Bradley SLC 5/04 PLC with Allen-Bradley RSLogix PLC. Operator interface replaced with Wonderware™ SCADA.

•Replace Modicon 888 PLC with Allen-Bradley RSLogix PLC. Operator interface replaced with Allen-Bradley RSView™ SCADA.

•Replace a GE Series 6 PLC with a GE RX3i PLC.Operator interface replaced with Wonderware™ SCADA.

•Replace a Foxboro DCS system with a GE RX3i PLC.Operator interface replaced with Wonderware™ SCADA.

•Replace a PC controlled system (QBASIC) with Allen-Bradley RSLogix PLC.Operator interface replaced with Wonderware™ SCADA.

•Replace a Siemen's NC controlled system with Allen-Bradley RSLogix PLC.Operator interface replaced with Allen-Bradley's Panelview™ SCADA.

•Replace a G&L PLC with an Allen-Bradley RSLogix PLC. Operator interface replaced with Allen-Bradley's Panelview™ SCADA.