After researching, I've found that much of the equipment is considered outdated. However, our contractor is confident that it can still be used. Should we opt for a complete upgrade with newer equipment?
When transitioning from an old PLC to a new one, there are important considerations to keep in mind for a smooth process: A) Take note of the difference in time bases between SLC timers and Control Logix timers. Control Logix operates in milliseconds, so remember to adjust your .ACC and .PRE values accordingly. B) Ensure that all inputs are mapped at the beginning of a task and all outputs at the end to prevent asynchronous issues. This will avoid any changes in I/O while your code is executing. C) Prior to removing the old PLC, determine the scan time for your PIDs as this information will be essential when setting them up in a timed task on the new PLC. The L82, for example, operates much faster than its predecessor, so be sure to adjust accordingly to avoid issues like having incorrect PID values. D) Be aware that some commands may no longer exist or may be outdated. It's important to familiarize yourself with the new PLC's capabilities and functionalities. E) Remember to make your program user-friendly by using clear and descriptive tag names. Avoid cryptic tags like N12:0/2 and opt for names like Tank2_Agitator_Run instead. F) Lastly, be sure to thoroughly comment your code to make it easy to understand and maintain in the future. This will save time and effort down the line.
@RetiQlum2 has provided some valuable insights. In my experience, I avoid using conversion utilities for programs with complex structures. When I transitioned a system from a PLC-5 to ControlLogix, I started by printing out the existing code in a comprehensive binder and asked experienced engineers to identify redundant code. This process significantly streamlined the program, which had accumulated excess code over years of use in a 50-year-old manufacturing line that had undergone two previous upgrades. After marking up the printout, I manually transferred the old code to the new system, a tedious but ultimately beneficial task that allowed for optimization and consolidation of the code. In addition, I created easily identifiable tags and meaningful descriptions for each element, eliminating the need for a separate cross-reference document. This renaming process, along with restructuring the code into new subroutines when necessary, resulted in a more organized and user-friendly program. Despite the initial week of work required for this overhaul, the new program structure facilitated a smooth commissioning process with minimal debugging needed.
While it's possible to continue using older equipment, it's essential to weigh the potential risks associated with it. Outdated equipment can become less efficient, may not be supported by the manufacturer any longer, or may not be compatible with newer technologies on the market. However, replacing all at once can be costly as well. Perhaps, a phased approach to updating the equipment would be a balanced solution, ensuring your operations benefit from newer, efficient technologies without a significant immediate financial impact.
While it's important to trust your contractor's experience, I'd recommend considering the long-term implications of using outdated equipment. Yes, it might be functional now, but what about the maintenance costs and potential obsolescence down the line? Upgrading to newer equipment could be a significant upfront investment, but it might save you both time and money in the long run, considering improvements in efficiency, functionality, and support for newer technologies. Conduct a cost-benefit analysis to make a more informed decision.
I think one factor to consider is the life expectancy and efficiency of the current equipment. While the contractor may have experienced success with older models, updated equipment could offer improvements not only in performance, but also potentially in energy efficiency and long-term maintenance costs. It's a balance of upfront cost versus ongoing expenses. You might also want to consider the potential impact on your business operations if the existing equipment were to fail.
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Answer: 1. Should we upgrade our outdated equipment to newer models, even if our contractor believes the current equipment can still be used? - It is advisable to consider the long-term benefits of upgrading to newer equipment, as it can enhance performance, reliability, and compatibility with modern systems. Consult with your contractor to evaluate the feasibility and cost-effectiveness of an upgrade.
Answer: - Converting the software to ControlLogix platform can offer improved functionality, scalability, and support for advanced features. The Rockwell Conversion Utility streamlines the migration process, ensuring a smooth transition while preserving existing programming logic.
Answer: - To ensure a successful conversion, it is essential to thoroughly review the software compatibility, verify programming logic, address any potential issues or discrepancies, and conduct thorough testing post-conversion. Engaging with experienced professionals or Rockwell Automation support can also help with a seamless transition.
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