Legacy PLC-5 to ControlLogix Migration

Client challenge

Unsupported controllers and limited spare parts put the cell at risk. The original logic worked, but documentation was thin and a hard cutover was not acceptable.

Proposed solution

We mapped I/O and sequences, converted and validated logic in stages, and coordinated HMI updates plus Keyence inspection signals. Cutover was planned around a short production window with rollback checkpoints.

Implementation process

1. 01Legacy logic audit and I/O verification
2. 02ControlLogix architecture and network design
3. 03Offline logic conversion and simulation
4. 04Staged hardware replacement with rollback checkpoints
5. 05Cutover validation and maintenance handover