Do any of you have experience with upgrading ControlLogix CPUs? I currently have a ControlLogix 1756-L61 CPU with V18 firmware from 2006 running critical processes for two large glass melt electric furnaces. The local rack includes the CPU, 2 ENBT adapters for redundancy with 2 HMIs, and some I/O modules. The remote rack has ENBT and I/O as well. One HMI communicates with the first ENBT in the local rack, while the other HMI communicates with the second ENBT. I am planning to upgrade to a 1756-L83E CPU, possibly with V33 firmware after a compatibility audit. I may need to update the ENBT adapters and modify the HMI application to work with the onboard CPU Ethernet port. Have you encountered any challenges during similar hardware upgrades that I should be aware of?
If you are unable to utilize the serial port, ensure it remains idle. The time synchronization for motion has been altered; however, no complications will arise if you do not have a designated time master.
It is crucial to analyze the PID or other time-based control code within the controller, gathering data on performance and execution times for each task, routine, and program. If a time-based instruction is improperly configured and tuned for a specific execution speed, the more advanced 5580 controller may not operate in the same manner. It seems like motion control, SERCOS, and Redundancy are not being utilized, so any potential compatibility issues from those sources are irrelevant. If your HMI application involves IP path or OPC Topic switching for fault tolerance, it is important to understand the functionality. Consider keeping the 1756-ENBT's in place and utilizing the L83E's onboard port for I/O or engineering purposes.
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EICS asked for advice on upgrading their ControlLogix 1756-L61 CPU with V18 firmware to a 1756-L83E CPU with possibly V33 firmware. The existing setup includes two Large Glass Melt Electric Furnaces and HMI communication through ENBT adapters. The upgrade may require flashing the ENBTs and modifying the HMI application for the new CPU Ethernet port. If any HMI communication goes through the ENBTs, the HMI configurations should remain unchanged. Have you encountered this type of hardware upgrade before? What pitfalls should be considered?
EICS inquired about upgrading their existing ControlLogix 1756-L61 CPU with V18 firmware to a 1756-L83E CPU with possibly V33 firmware. This upgrade is crucial for their 2 Large Glass Melt Electric Furnaces process. The current setup includes a local rack with the CPU, 2 ENBT adapters for redundancy, and some I/O modules. The remote rack houses an ENBT and more I/O modules. Two HMIs are connected to the ENBT adapters in the local rack, both running the same application. To successfully upgrade, EICS may need to update the firmware of the ENBT adapters and modify the HMI application to accommodate the new CPU's Ethernet port. EICS is seeking advice on potential pitfalls from others who have undertaken similar hardware upgrades. They also mentioned the importance of having at least a series B 1756 chassis (series C being ideal) for this upgrade.
I recently went through a similar upgrade from a 1756-L62 to a L85E, and there were definitely some bumps along the way. One thing I would definitely recommend is thoroughly documenting your current setup, especially your I/O configurations and HMI communications, to compare post-upgrade. The firmware and software versioning can sometimes cause unexpected hiccups, especially if the HMI software isn't fully compatible with the new protocols or features of the newer CPU. Additionally, ensure you have a solid rollback plan in case any critical functionalities or communications don't behave as expected during the transition. It might also be wise to test everything in a controlled environment before fully going live. Good luck with your upgrade!
Upgrading to the 1756-L83E should provide you with some nice performance enhancements and features, but definitely keep an eye on firmware compatibility, especially with your existing I/O modules and ENBTs. I did a similar upgrade recently, and the biggest challenge was ensuring all the tags and addressing remained consistent, which required a lot of cross-referencing between the old and new setups. Also, if you're modifying the HMI applications, be sure to thoroughly test communication since integrating the onboard Ethernet can sometimes lead to unexpected hiccups in how data is passed compared to the older setup. Do a full backup of your current configuration, and perhaps run a parallel test with the new CPU before going live if possible!
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Answer: 1. What are the potential challenges to watch out for when upgrading a ControlLogix 1756-L61 CPU to a 1756-L83E V33? - The potential challenges to watch out for during the upgrade process include compatibility issues with existing hardware components such as ENBT adapters, I/O modules, and HMIs. Updating firmware and modifying HMI applications to work with the new CPU configuration may also pose challenges.
Answer: - To prepare for the upgrade, it is recommended to conduct a compatibility audit to ensure that the new CPU, firmware version, and any necessary hardware updates will work seamlessly with the existing system. Additionally, creating a detailed plan for updating ENBT adapters and modifying HMI applications is crucial to minimize disruptions during the upgrade process.
Answer: - When upgrading ControlLogix CPUs for critical processes, it is important to carefully assess the impact of the upgrade on system reliability, downtime, and performance. Planning for potential challenges, testing the new configuration in a controlled environment, and having contingency measures in place are essential to mitigate risks associated with the upgrade.
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