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Controls and electrical in one company · WA electrical contractor IKONIAL745N4

PLC-5 migration

Most PLC-5 systems move to ControlLogix in phases. The processor goes first, inside one planned shutdown, and runs the I/O and field wiring you have. The I/O follows later, rack by rack.

A PLC-5/20 processor in a 1771 rack.

How a PLC-5 migration runs

Survey the system. A Line Evaluation records every rack, card, network and program, and gives you a phased plan with a budgetary price for each phase.
Convert the program before the shutdown. We convert it to run on ControlLogix, add comments other engineers can read, and test it against your I/O list.
Change the controller in a planned shutdown. The new controller runs the I/O and field wiring you have, so nothing in the field is disturbed.
Move the I/O rack by rack in later shutdowns, on current hardware, with the field wires kept in place where we can. At the end you will get as-built drawings and a program backup.

What we work on

PLC-5 processors and I/O, and the networks around them: Data Highway Plus, Remote I/O and ControlNet. Most plants move to ControlLogix, on Rockwell's standard migration path. If you would rather move to another platform, we will work to that.

Behind the engineer who comes

The engineers who upgrade your system will plan the work around your shutdowns. Behind them are the controls engineers, electricians and panel shop that rebuild and upgrade plants and vessels across the Pacific Northwest. If the job needs another trade, we will send them.

Licensed electrical contractor · UL 508A panel shop · Controls and electrical in one company

  1. Fix it now

    Urgent Support · Rapid Response · Drive Support

  2. Stop repeat faults

    Program and Drawing Recovery · Plant Electrical Service · Engineer Cover

  3. Plan the upgrade

    Line Evaluation · Pre‑Shipyard Survey

  4. Modernize in stages

    Modernization · Shipyard Support

Bottles with green caps on a conveyorField noteRestoring control on a high-attention bottling lineRead the field note

Questions

Does the line have to stop for the migration?Only inside shutdowns you have already planned. Each phase is sized to fit one.
Do we have to rewire the panels?Usually not. The field wiring stays where it is when the controller changes, and where we can when the I/O is replaced.
Our PLC-5 still runs. Why move now?Allen-Bradley stopped making the PLC-5 in 2017. When a part fails, the replacement has to come from used stock, and we do not fit used parts. A planned migration happens on your dates; a breakdown does not.

Book a Line Evaluation

We will reply by the next working day with dates and a quote.

Already broken down?

Or call 253-344-1523

Line or vessel down? Call 253-344-1523