ProSoft Technology: Migrate Your Legacy Remote I/O Systems Over Multiple Phases

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Migrate Your Legacy Remote I/O Systems Over Multiple Phases ProSoft Technology

Bobby Maxwell Product Manager

Upgrading and Migrating to EtherNet/IP™

ProSoft Technology®

Copyright ©2013 ProSoft Technology, Inc. All rights Reserved.

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Presentation Notes

ProSoft Technology is an industrial automation communications company and we’ve been an Encompass Partner for more than 20 years. We Specialize in Rockwell Automation In-Chassis communication products, but we also have an array of stand-alone gateways, industrial wireless and cellular solutions.

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What We’ll Cover

Why upgrading is important Migration options Challenges ProSoft Technology® Remote I/O™ Solutions Configuration examples Phased migration examples Other network migration solutions


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Upgrading to EtherNet/IP

Why upgrade?

Preventative maintenance Increased productivity Replacement equipment is harder to find


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There are lots of reasons to upgrade both your equipment and network. The I/O data hasn’t changed in smarter and more intelligent devices. What has changed is the amount of diagnostic information in them. This additional diagnostic data will allow you, the user, to monitor the device for network issues and circumvent any unnecessary downtime. The ability to access this additional data will allow you to put a predictive maintenance plan together maximizing uptime, optimizing productivity and plant operations. Number of devices on a network is increasing, not limited to 32 nodes anymore. The need to produce more product in a give amount of time to increase productivity is always being tracked and looking for ways to increase.

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Upgrading Options

Do nothing High risk!

Rip and replace

Some risk

Phased migration Low risk


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Do Nothing Not migrating/upgrading is not an option. You’ll need to put together a plan for upgrading High Risk Unscheduled downtime If a line goes down how long will it take to get back up? Components and equipment are getting harder to find Rip and Replace Scheduling downtime High cost for all of the equipment and loss of production Pulling all new cables Installing new wiring and components Projects get delayed, can you afford it? Phased Migration I’m sure all of you have heard the term phased migration before in some form or another. Today, I’m going to explain what a phased migration is and why it can save time and money. Allows users to upgrade equipment as they see fit Upgrades can occur during scheduled downtime Re use existing wiring

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Questions About Upgrading

Where do I start? What can I do? When can I do it?


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There are problems with upgrading. Where do I start? Do I start with the PLC or the components? What should I do? Should we upgrade a piece at a time or the whole thing at once? What are my options? Who’s going to do it? Do we have hire someone or do it in house? When can we do it? Can we afford the downtime associated with upgrading? What decisions need to be made before determining that it’s time to upgrade?

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Remote I/O™ Networks

Remote I/O™ was introduced 30+ years ago


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A factor in your decision making process should include any of the equipment pictured above. I’m sure you recognize a lot of this equipment as being currently installed in your plant. The Allen Bradley Remote I/O protocol was introduced more than 30 years ago and was the primary choice for I/O control for Allen Bradley systems the better part of 20 years. Rockwell has done a great job with keeping Remote I/O alive and well for as long as they have, but with more and more products entering the Silver Series or Discontinued stages of their lifecycle, it’s apparent that the time to upgrade is now.

Challenges with Phased Migrations

Remote I/O Communication cards are available for PowerFlex® 755/753 drives*

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PanelView™ Plus 6s – No Remote I/O solution

PowerFlex® 525 Drives – No Remote I/O solution


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There are challenges with phased migrations and upgrading a component at a time. Remote I/O support for newer products is not always readily available. And when it is available it’s not just a drop in replacement like it was before. It takes a decent amount of PLC work to get it up and running. Everyone knows that anytime you meddle with PLC code something that was working before doesn’t anymore, and it’s your fault.

Drive and PanelView Migrations

EtherNet/IP™ to Remote I/O Gateway

AN-X2-AB-DHRIO

Supports SLC™ and PLC-5®

processors

Does not require users to modify their PLC code

10 Copyright ©2013 ProSoft Technology, Inc. All rights Reserved.

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Template files help reduce configuration errors Multiple operating modes ODVA Compliant The gateway has a microSD card to store all the configuration files and can be inserted in to another gateway supporting your disaster recovery plan.

PanelView Migration

Upgrade up to eight Remote I/O PanelView terminals to EtherNet/IP PanelView Plus 6 terminals

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Remote I/O

PLC5

AN-X2-AB-DHRIO EtherNet/IP

PanelView Plus 6


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Whether it’s a single terminal or up to 8 terminals, only one gateway is required.

Drive Migration

Upgrade up to four remote I/O drives to PowerFlex drives on the EtherNet/IP network

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EtherNet/IP to AB Remote I/O Gateway (AN-X2-AB-DHRIO)

Blue Hose AB Remote I/O

EtherNet/IP

PLC5

PowerFlex Drive 1336 Drive


Example Configurations


Click the image below for product configuration

http://www.prosoft-technology.com/Products/Gateways/EtherNet-IP/EtherNet-IP-to-Allen-Bradley-Remote-I-O-or-DH-Gateway

AB Remote I/O



Media Migration Problems


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Now that we’ve discussed some component migration, let’s talk about media migration. Would you want to run new Ethernet cable through that? Are you ready to run conduit and pull Fiber?

EtherNet/IP over Blue Hose

Media migration Allows users to run Ethernet and Remote I/O data on the existing cable at the same time

No configuration required


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Each module has a built in 3 port Ethernet switch, and diagnostic LEDs for the trunk and drop ports. No configuration required, modules are 100% plug & play. These products allow you to run Ethernet as well as Remote I/O data over the existing cable enabling you to upgrade legacy components without pulling wire.

Functionality Overview


EIP

Repurposed Remote I/O Cable

RIO RIO

EIP Master Slave

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Our products combine the local Ethernet signal and Remote I/O signal at the Master device in to a complex waveform sending it each Slave device on the network. The Slave devices then break the Ethernet and Remote I/O signals back apart and send them to the appropriate devices

Sample Phased Migration

1500’ Remote I/O network


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Now that we’ve discussed how each of the products work independently, let’s put them to work in a hypothetical control system migration. �We’ll start with a basic Remote I/O network that has a little bit of everything. PLC, Drives, Terminal, and I/O. The first step in this migration plan we’re going to use the AN-X2 products we spoke about earlier to upgrade the drives and the PanelViews. Remember when we add the AN-X2 gateways, we do so without modifying the PLC code. Now we want to add the ControlLogix and the 1756-RIO card. The Remote I/O card has a mode that allows you to monitor the existing application to build and debug your code before taking control of the network. Next we’ll add the media converters. We’ll want to power down the PLC or put it in program mode whichever you prefer and install the media converters at each cabinet. Power the PLC back up or put it back in run mode to validate and make sure everything is running as it was before we go to the next step. If something isn’t right, you can always go back. The PLC5 can take control of the network again you can continue troubleshooting and debugging until you get all the bugs worked out. Now you can decommission the existing Remote I/O rack and you end up with a handful of spares! Next we’ll want to start upgrading the remaining I/O. Again, this can be done in scheduled downtime with the 1771 to 1756 Remote I/O swing arm adapters the old 1771 I/O can be removed and replaced without having to change all of the existing field wiring. Flex I/O adapters can be changed from ASB adapters to AENT adapters without disturbing the field wiring as well.

Remote I/O Migration Summary


Reasons for migrating Types of migration Migration solutions

Sample configuration/migration

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Allen Bradley DH+



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Migration replacement for the 1770-KF2 Troubleshoot from a remote location

EtherNet/IP to GE Genius I/O Gateway (AN-X2-GENI)

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GE Genius I/O

Genius I/O Field Control Bus Interface Unit with I/O

GE Genius Bus

Ethernet Global Data Network

MVI56-EGD

Genius I/O


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Supports migration from both GE 9030 or 9070 processors

Modicon S908 I/O

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Operator Station

EtherNet/IP to Modicon S908 I/O Gateway (AN-X-MOD)

Modbus Plus

MVI56-MBP


Simatic/TI 505 I/O

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TI 505 Remote I/O

EtherNet/IP to Texas Instruments Remote I/O

Gateway (AN-X-TI)

Siemens IE

EtherNet/IP

Balance of Plant MVI56E-SIE


DCS Migration

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Honeywell IPC-620

Honeywell IPC-620 Module (CLX-422-IPC)

Fisher PROVOX

Fisher PROVOX Module (CLX-PVX)


Questions?


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For more information visit: www.psft.com/eiprio

ProSoft Technology: Migrate Your Legacy Remote I/O Systems Over Multiple Phases

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Transcript of ProSoft Technology: Migrate Your Legacy Remote I/O Systems Over Multiple Phases