Rockwell PLC-5 to Modicon

M580 with Unity Pro

Upgrading your control system is easier than you think.

Challenges you may be facing:

• Unexpected downtime due to aging equipment
• Difficulty supporting multiple PLC platforms and programming
software packages
• Preserving the investment in your existing system during an upgrade
• Reduction in skills and/or staff at your plant From To
Rockwell PLC-5® ModiconTM M580
• Limited scheduled downtime during upgrades

Benefits of migrating to M580:

• Minimum downtime and risk to upgrade — do it during planned maintenance “I want to thank the Schneider Electric
• Retain prior investment in software and field wiring services team for our migration from
• Reduce unplanned downtime and enhance cybersecurity Rockwell to the Modicon system.
• Productivity benefits from a new, more transparent, future-proof solution Because our sodium hypochlorite
• Supported by Schneider Electric global service and execution capabilities system is our plant’s primary means
of disinfection, it was imperative that
Solutions and services for a smoother modernization a quick, seamless migration took
• Extensive experience with successful PLC-5 to M580 migrations place. Our project of migrating to an
• Automatic conversion of your PLC-5 application into UnityTM Pro improved PLC was done in a highly
• Stepwise upgrades in phases to meet your budget and schedule satisfactory manner. Thank you!”
• Retain your existing I/O and racks if required
Controls Engineer — Water/Wastewater plant
• Quick wiring solutions eliminate the time and risk of rewiring existing I/O

Switch to Modicon M580 with Unity Pro

Replace CPU with Unity M580 and retain application program with Automated efficiency Minimal downtime
a conversion service. Choose the preferred I/O rack and wiring Repeatable, reliable Typically 1 hour
solution — partial, stepwise, or full: processing with our migration time per
conversion software eight-slot rack

Partial: Stepwise:
Legacy CPU Retain Change Full: Full PLC application conversion
Targeted CPU
and I/O I/O racks I/O racks, replacement
and wiring retain wiring and software upgrade:

PLC-5 CPU Automatic conversion1

and of PLC-5 application
PLC-5 I/O to Unity Pro
Modicon M580

1
Some applications may require minor adjustments
Migration solutions for Rockwell PLC-5
Software upgrade to Unity Pro Benefits
Our proprietary software converter enables efficient conversion of your PLC-5 application
to the Unity Pro platform: For software
• Retention of prior
• Retain the look, feel, and function of your legacy applications investment in
• Build on them by adding programming sections using the latest programming PLC-5 programs
languages, functions, objects, and libraries of Unity Pro • Reduced risk
and errors due to
automatic conversion
of legacy programs
• Reduced time
to complete —
migrations can be
done in scheduled
maintenance
downtime windows
Before conversion After conversion
For hardware
Hardware upgrade • Retention of prior
investment in existing
Partial PLC upgrade to Modicon M580, retaining legacy I/O racks and wiring: racks and/or wiring
• Simplified
modernization
M580
with no rewiring
and reduced
Gateway commissioning time
M580 CPU • Flexibility to upgrade
in phases — address
operational or
budget constraints
Modicon M580 connects to PLC-5 I/O using Ethernet to Rockwell Remote I/O gateway

Total PLC upgrade to Modicon M580

and new X80 I/O while retaining field wiring
Time-saving solutions:
M580
Our quick wiring adapters let you change legacy
Rockwell PLC-5 I/O while retaining field wiring:

X80 I/O or Quantum I/O

PLC-5 I/O quick wiring adapters Wiring adapter

X80 I/O or Quantum IO mounted on an M580 PLC

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