Allen-Bradley PLC-5 Upgrades and Migrations

Tritronix completes numerous Allen-Bradley PLC installations and PLC-5 system upgrades in a wide variety of industries each year. PLC-related work makes up approximately 60% of the 450+ projects Tritronix performs each year. Upgrading legacy systems or replacing obsolescent/unsupported hardware represents a large portion of this work.

We can consult on specific aspects of control systems, or we can provide complete turnkey solutions supported with our design, procurement, fabrication, installation and commissioning experience.

PLC System Integration Consulting

We can:

  • Evaluate your existing PLC control system.
  • Evaluate vendor bids for PLC solutions.
  • Procure PLC hardware.
  • Provide client representation at factory acceptance testing and final site acceptance testing.
  • Make PLC performance recommendations.
  • Provide detailed designs for PLC system additions.
  • Provide migration plans for PLC system obsolescence.
  • Design PLC industrial communication networks.
  • Provide full integration from primary PLC devices at the plant floor to information at management levels.
  • Provide drafting and CAD services.
  • Provide electrical and instrumentation design services.

PLC Commissioning

We provide start-up and commissioning services with full documentation including:

  • Electrical/instrument PLC system commissioning.
  • Factory and site PLC acceptance tests.
  • Operations/maintenance manuals.
  • Field PLC installation checks.
  • Loop/control logic checks.

Relevant Project Experience

Tritronix has extensive PLC-5 upgrade experience. Below are some recent sample projects where we operated as the Main Automation Contractor (MAC) for design, programming and commissioning. Performed for a variety of industries, the projects touched on Ethernet, ControlNet, DH/RIO and DeviceNet network topologies.

Industry PLC-5 Upgrade Path I/O Notes
Pipeline PLC-5 to ControlLogix 5000 DI/DO ~300, AI/AO ~50 90% of the 1771 I/O remains (via RIO) – remainder is 1756
Pipeline PLC-5 to ControlLogix 5000 DI/DO ~500, AI/AO ~100 90% of the 1771 I/O remains (via RIO) – remainder is 1756
Food and Beverage PLC-5 to ControlLogix 5000 DI/DO ~1,900, AI/AO ~425 15% of 1771 I/O remains (via RIO) – remainder is 1756
Pipeline PLC-5 to ControlLogix 5000 DI/DO ~500, AI/AO ~100 90% of the 1771 I/O remains (via RIO) – remainder is 1756
Food and Beverage PLC-5 to ControlLogix 5000 DI/DO ~850, AI/AO ~100 25% of 1771 I/O remains (via RIO) – remainder is 1756
Pipeline PLC-5 to ControlLogix 5000 DI/DO ~500, AI/AO ~100 90% of the 1771 I/O remains (via RIO) – remainder is 1756
Water Treatment PLC-5 to ControlLogix 5000 DI/DO ~350, AI/AO ~50 100% of the 1771 I/O remains (via RIO)
Pipeline PLC-5 to ControlLogix 5000 DI/DO ~500, AI/AO ~100 90% of the 1771 I/O remains (via RIO) – remainder is 1756