A-B Upgrades/Software : PLC Upgrades/Migrations

Note: Detailed conversion information for each A-B model can be found in the specific model's tab.

The most popular 2 SoftPLC controller models that can replace an Allen-Bradley PLC CPU are NeoPAC SoftPLC's and Smart SoftPLC's.

A NeoPAC SoftPLC can be factory equipped with (1) A-B interface, which can be for RIO (Remote I/O), either Master (controller) or Slave (adapter), or DH+ (Data Highway Plus). If you need more than (1) bluehose interface, select a Smart SoftPLC.
A Smart SoftPLC can be factory equipped with up to (2) A-B interfaces. Interfaces can be RIO (Remote I/O) channels, either Master (controller) or Slave (adapter), or DH+ (Data Highway Plus).

If you need more than (2) interfaces, or the old A-B PLC connected to other I/O systems (eg: DeviceNet), we offer SoftPLC Gateways and Hardbook SoftPLC options.

Any HMI/SCADA/DCS system can be used, normally without change, as the SoftPLC will appear as an A-B PLC to the operator interface - either as a PLC-5/SLC-500 or using PLC-2 compatibility mode on serial DF1, DH+ or A-B Ethernet networks. Or, you can upgrade the operator interface as well - either with one of our migration solutions, or with any product of your choice - all are compatible with SoftPLC.

Most special modules are supported as part of the migration process, or many times the modules can be eliminated with functions that are standard in the SoftPLC (eg: Modbus communication).

Application/Documentation Conversion

Note: Detailed conversion information for each A-B model can be found in the specific model's tab.

SoftPLC Corporation has developed sophisticated utilities that automatically convert A-B ladder logic and documentation to our file format. In most cases, the automatic conversion is 98% or better. These tools provide a report that lists not only what may need manual review, but also details about the conversion process such as a cross-reference from old address to new, rung number equivalences, and more.

We offer the conversion services as a low flat-rate fee*, with an optional hourly fee for an engineering review of the results and/or manual conversion of any flagged logic, or to enter documentation from the original machine program printout (when files are not available).

We provide a no-charge engineering pre-review of each application prior to issuing a formal hardware quotation, to help ensure your new SoftPLC based system start-up will be as easy as possible. This review includes an existing system equipment analysis and a review of the program logic, resulting in a list of any potential issues found with recommended solutions.

As part of our migration service, we can even ship your new SoftPLC with the converted application pre-loaded.

Application conversion is included in our Migration Kits.

* For most A-B models, some models are quoted by project.

PLC-5 Migrations

PLC-5 migrations to SoftPLC are unbelievably smooth! Minimal hardware changes are required in most cases. But, even more significantly, the ladder logic is not converted - it is imported! Rarely does any logic need to be changed, since SoftPLC was initially modeled after the PLC-5.

This means no re-training of personnel, no re-programming of HMI/SCADA systems, and minimal documentation/drawings re-work.

Application Conversion Steps:

1. Email us your RSLogix5 .RSP file if available, or
   if the files are in 6200 format, export the logic to "pc5" format (using "Save as pc5" or "Save as text"), and export the documentation to text format.
2. We will convert them to a single SoftPLC application file that will load into TOPDOC NexGen
3. Download the application to your new SoftPLC controller using TOPDOC NexGen

Hardware Migration:

1. Replace the PLC-5 processor with a 1771-ASB remote adapter module or reconfigure it as a remote I/O adapter (If the PLC-5 had extended local I/O, replace all local adapters with remote adapters.)
2. Install the SoftPLC CPU and connect it via "blue hose" to the first I/O adapter
3. Connect any other hardware to the SoftPLC as needed (eg: HMI/SCADA, serial devices, other networks)

If your original system was redundant, had multiple RIO or DH+ networks, or other specialty functions, contact us to for an engineering review and quote.

SLC-500/MicroLogix Conversions

SLC-500 migrations to SoftPLC are almost unbelievably easy! Minimal hardware changes are required in most cases. Rarely does any logic need to be changed, since SoftPLC is a superset of the SLC-500 and PLC-5. The primary differences are in the addressing of digital I/O (which the automated conversion utility handles) and the support of third party I/O modules.

Since the MicroLogix has built-in I/O, conversions are normally done for the logic/documentation only, with the hardware being replaced either by a Smart SoftPLC with either Tealware or another type of I/O or with a NeoPAC SoftPLC.

After conversion, there is little re-training of personnel, minimal (if any) re-programming of HMI/SCADA systems and minimal documentation/drawings re-work required.

Application Conversion Steps:

1. Email the .RSP file from the RSLogix500 software to us
2. We will convert the program and documentation to a SoftPLC application file that will load into TOPDOC NexGen
3. Download the application to your SoftPLC controller using TOPDOC NexGen

Hardware Migration:

1. Replace the SLC-500 processor with a remote I/O adapter (1747-ASB) module (If the SLC-500 had extended local I/O, replace any local adapters with remote adapters as well)
2. Install the SoftPLC controller and connect it via "blue hose" to the first I/O adapter
3. Connect any other hardware to the SoftPLC as needed (eg: HMI/SCADA, serial devices, other networks)

If your system uses third party modules or specialty functions, contact us to for an engineering review and quote.

PLC-2 Migrations

PLC-2 migrations to SoftPLC are almost unbelievably easy! Minimal hardware changes are required in most cases. Logic conversions are normally 98% or better.

The converted logic resembles PLC-5/SLC-500/MicroLogix logic, so if personnel are familiar with those models, minimal re-training is required. Existing HMI/SCADA products can communicate to SoftPLC using a PLC-2 compatibility mode, so these often do not require re-programming.

Application Conversion Steps:

1. Upload the existing PLC-2 program using TOPDOC for PLC-2. As part of our conversion service, we can either provide the loan of TOPDOC PLC-2 and an Attached Mode Cable, or program entry services when only a hard copy print of the logic is available.
2. Export the documentation from your PLC-2 programming software to text format.

(Note: If you do not have existing PLC-2 software files or cannot provide the text formatted files, we offer an optional low cost service to enter the documentation into TOPDOC PLC-2 from a hard-copy printout, so that it can be converted with the logic.)

3. Email these files (or reports) to us. With our automated PLC-2 to SoftPLC conversion utility, we convert the logic and documentation to a single SoftPLC application file that will load into TOPDOC NexGen. If there is logic that doesn't convert, or needs to be modified, our application engineers will discuss options with you.
4. Download the application to SoftPLC using TOPDOC NexGen

Mini PLC-2 Hardware Migration:

1. Replace the Mini-PLC-2 processor with a 1771-ASB remote adapter module.
2. Install the new SoftPLC and connect it via "blue hose" to the first I/O adapter
3. Connect any other hardware to the SoftPLC as needed (eg: HMI/SCADA, serial devices, other networks)

PLC-2/30 or PLC-2/20 Hardware Migration:

1. If remote I/O, replace the PLC-2 processor with the SoftPLC controller
2. If local I/O, replace each local adapter (1771-AL) with a remote adapter (1771-ASB). Install the SoftPLC and connect it via "blue hose" to the first I/O adapter
3. Connect any other hardware to the SoftPLC as needed (eg: HMI/SCADA, serial devices, other networks)

If your system had multiple RIO or DH+ networks, or other specialty functions, contact us to for an engineering review and quote.

PLC-3 Migrations

SoftPLC is an extremely powerful controller. Even though the PLC-3 was used in large, complicated applications, a SoftPLC can handle the challenge! Minimal hardware changes are required in most cases. Logic conversions are normally 95% or better.

The converted logic resembles PLC-5/SLC-500 logic, so if personnel are familiar with those models, minimal re-training is required. Many PLC-3's communicated to HMI/SCADA using PLC-2 compatibility mode which is supported by SoftPLC, so these often do not require re-programming.

Application Conversion:

PLC-3 programs often require manual intervention after the bulk of the program has been automatically converted. We will provide a quote for the conversion after we receive the files and an application engineer has reviewed them.

1. Using your PLC-3 programming software, export the logic to .ACH format (text). If you are using TOPDOC PLC-3 or 6200 software, the .LOB or .PLC formats are also acceptable. If you do not have PLC-3 software, we can include the cost of "renting" TOPDOC PLC-3 as part of your conversion process.
2. Export any documentation from your PLC-3 programming software to text format. If you are using TOPDOC PLC-3 or 6200 software, the .DBF and .CMT formats can be used directly.
3. Email these files to us. With our automated PLC-3 to SoftPLC conversion utility, we will run a test and report the automatic conversion success rate, as well as the quote for the conversion services.
4. After your approval, we will convert the logic and documentation to a single SoftPLC application file that will load into TOPDOC NexGen.
5. Download the application to the SoftPLC controller using TOPDOC NexGen.

Hardware Migration:

1. Replace the PLC-3 processor with the SoftPLC controller, and connect it via "blue hose" to the first I/O adapter
2. Connect any other hardware to the SoftPLC as needed (eg: HMI/SCADA, serial devices, other networks)

Other Conversions

Other A-B PLC and other vendor's PLC systems can also be converted. We are happy to discuss these with you to explore options, feasibility, and costs.

• A-B Pyramid Integrator (PLC-5/250)
• A-B SoftLogix5
• GE Fanuc 90/70, 90/30
• Schneider/Modicon
• Siemens S5, S7