Migration Solutions

Foxboro IA to PlantPAx Distributed Control System

We can get you from here . . .

Old equipment that lacks
production efficiency
Unscheduled downtime risks
High repair costs
Limited network options
Uncertain parts and
service sourcing
Weakening technical service
Questionable reliability of
older electronics
No warranty coverage
To here
Product backed by the outstanding
support of Rockwell Automation
Open, integrated architecture for
increased flexibility
Re-use of engineering practices to
reduce development time
and costs
Maximizing returns from existing
assets through greatly improved
control and monitoring
Quickest response to customer
or market demands
Easy access to plant and
production data from business
systems for better management
decision making
Single environment for integrated
motion, process and safety for total
plant-wide control

Philosophy
Your equipment is your livelihood - each day enabling you to
produce quality products on time, every time. As your equipment
ages, its inevitable that questions about part sourcing, service,
potential productivity gains from new technology, and increased
risks of downtime become stronger. You need to work with a supplier
that has the product, service, and industry knowledge to partner
with you on an upgrade strategy that will help you maximize your
competitive advantage thats Rockwell Automation.
Rockwell Automation and its partners will work with you to outline a
plan that fits your application needs and long-term goals. We can help
you migrate all at once or in phases, at a pace that is comfortable for
you and fits your budget, while leveraging the latest capabilities and
technologies of the PlantPAx Distributed Control System.

Philosophy of a Phased Migration

Learn how the technologies and expertise provided by Rockwell Automation enable the safest and most scalable
migration solutions. Whether you choose to upgrade all at once or in phases, we carefully outline alternatives
that provide flexibility while saving valuable production time.

Phase I: Replace operator consoles

with new HMI hardware and software

Op Station 1

Redundant Servers

Op Station 2

Although the first phase of the migration involves a lot of activity,

it requires no downtime and is very low risk. During this phase,
we deploy redundant HMI servers and Foxboro Gateway and
replace the existing operator workstations with new clients. Data
is converted to Logix native tags utilizing the database conversion
tool, making the data accessible throughout the new architecture.
At the same time, EtherNet/IP can be deployed redundantly in
self-sealing topologies. Additional steps are taken to mitigate risk
by deploying faceplates and graphics that look very similar to the
graphics your operators are already accustomed to, so that the new
HMI is adopted very rapidly - typically within a week.

EWS

Ethernet
AW51

Foxboro
Gateway

Nodebus

C
P
40

C C C
P P P
40 40 40

CP30/40/60

C
P
40

C C C
P P P
40 40 40

CP30/40/60

Fieldbus

C
P
40

Phase I Tools: Foxboro Faceplate Library, Database Conversion

Tool, Foxboro Gateway, PlantPAx Servers and Workstations,
Graphics Conversion Services

Phase II: Interoperate Logix controllers

in conjunction with your current system

C C C C C C C C C C C C C
P P P P P P P P P P P P P
40 40 40 40 40 40 40 40 40 40 40 40 40

Op Station 1

In this phase of the migration, you will leverage the new HMI
infrastructure and add the ControlLogix Programmable Automation
Controllers (PACs) and I/O while interoperating with the control
platform of the existing legacy system. With this approach you
can add production capacity and manufacturing flexibility while
incorporating new technology in your manufacturing environment.
This will allow you to quickly benefit from many aspects of PlantPAx
Distributed Control System including greater MES/ERP connectivity
and tighter IT integration.

C
P
40

Fieldbus
Module

C C C C C C C C C C C C C
P P P P P P P P P P P P P
40 40 40 40 40 40 40 40 40 40 40 40 40

Fieldbus
Module

EWS

Redundant Servers

Op Station 2

EWS

Ethernet
AW51
ControlLogix

Foxboro
Gateway

Nodebus

C
P
40

Phase II Tools: Foxboro Gateway

C C C
P P P
40 40 40

C
P
40

CP30/40/60

C C C C C C C C C C C C C
P P P P P P P P P P P P P
40 40 40 40 40 40 40 40 40 40 40 40 40

Fieldbus
Module

C
P
40

C C C
P P P
40 40 40

C
P
40

CP30/40/60

C C C C C C C C C C C C C
P P P P P P P P P P P P P
40 40 40 40 40 40 40 40 40 40 40 40 40

Fieldbus
Module

How to Get Started: Identifying the Right Options for You

Understanding Your Needs

We can help by:

Providing recommendations to optimize the
performance of your automation assets
Evaluating older equipment more susceptible to failure
Setting performance baselines
for continuous improvement
Performing an Installed Base Evaluation to
use as a foundation for your migration plan

Rockwell Inventory Analysis

Sample Customer
Anytown, USA

4/28/2004

Insufficient
Excess
Catalog No.
Series Installed Base? Rec Spares Qty in Stores Qty in Stash Insufficient Excess List Price Extended Price Extended Price
100-A09ND3
B
Yes
1
0
0
$100.00 $
1
0
100.00 $
10F R 4031
Y es
1
0
1
$4,310.00 $
0
0
$
10V 4151
Y es
0
0
0
$4,149.00 $
0
0
$
10V 4160
Y es
1
0
0
$2,651.00 $
1
0
2,651.00 $
10V 4251
Y es
1
0
0
$2,784.00 $
1
0
2,784.00 $
140M-C2E-C10
B
Yes
1
0
0
$175.00 $
1
0
175.00 $
15F R 4031
Y es
1
0
0
$4,460.00 $
1
0
4,460.00 $
O E M P a rt N o
O E M_ D e s c ription
P a ne ls
15P 8171
Y es
1
0
0
$12,778.00 $
1
0
12,778.00 $
L B L 0Y5e7s -B
C O N T R O L 3I N* S T R U ME N0T S MO N I3T O R $5,507.00 $
5
15V 4151
0
0
$ 16,521.00
Sample Customer
77C 4
15V 4160
Y 0e0s -2
1
0 C O N T R O L S0Y S . E N C O D1 E R R A I L 0
$4,980.00 $
4,980.00 $ 1
1 7 5 5YTe s
1 7 4 6 -A 1 0
B
1
0 C H P A N E L M0A T E P O W E1R P R O 1 700 0
$480.00 $
480.00 $ 0
4 2 -1Y6e1s0 0 -0 1
Area:
1 7 4 6 -I A 1 6
C
1
0 C H P A N E L M0A T E A C C E 1L E R A T I O N
0 M O D $305.00 $
305.00 $ 0
8 7 -0Y2e0s0 8 -0 1
1 7 4 6 -I A 8
A
1
0 C H M O N I T O0R
$210.00 $
1
0
210.00 $ 1
A 1 0 FY N
1 7 4 6 -N O 4 I
A
e s0
1
0 CH
0
$885.00 $
1
0
885.00 $ 1
Location:
1 7 4 6 -O A 1 6
D
1
0 C H D R IV E 0
$425.00 $
1
0
425.00 $ 1
E A 2Y7 0e sP N
1746-OW16Sample Customer
C
1
0 C H P A N E 0L M A T E
$325.00 $
1
0
325.00 $ 1
L R Yes
86414
1 7 4 6 -O W 8
A
Y8e s
1
0 D A Y T O N 1 200 V A C 1 2 A R1E L A Y
$220.00 $
0
220.00 $ 1
5
Z
4
6
Print/Serial No:
Bar Code No:
1 7 4 6 -O X 8
A
1
0 D I V E R S I F I E0D E L E C . P H1A S E S E Q0
$265.00 $
265.00 $ 1
S L AY-4e4s0 . A S A
Area: 1 7 4 6 - P 2
Panel Name/ID:
C
1
0 D Y N A P A R E0N C O D E R 1
$475.00 $
0
475.00 $ 0
M0 6Y1e2s8 8
INCINERATOR
1 7 4 6 -P 4
A
1
0 F IF E P C B 0
$735.00 $
1
0
735.00 $ 0
2 3 8 0Y5e-s0 0 2
1 7 4 7 -L 5 4 2
B
Y es
0
0
0
$2,175.00 $
0
0
$
2 3 8 0 6 -0 0 3
F IF E S E E K C O N T R O L
0
OEM:
Location:
1 7 4 7 -L 5 4 2
D
Y es
1
0
0
$2,175.00 $
1
0
2,175.00 $
2 4 5 0 3 -0 0 5
F I F E A MP & P O W E R S U P P L Y
0
190E-NND2-CC10X
B
Yes
1
0
0
$324.00 $
1
0
324.00 $
5 4 4 0 4 -0 0
HAC H P C B
0
1 9 3 -B S B 1 2
B
Y es
1
0
0
$0.00 $
1
0
$
Description:
Print/Serial No:
Bar Code No:
4 -0 7Y-4e2s 9 7 -9 6 5 0
1 9 3 -B S B 1 6
B
1
0 H O N E Y W E L0L A N A L O G 1I N P U T 0
$0.00 $
$ 0
Catalog No.
Ser Rev
Notes 1 9 3 -B S B 4 2
D C 2Y0e0sC -2 -2 1 A -1 0 010 0 0 -0
$0.00 $
B
0 H O N E Y W E L0L
1
0
$ 8
100-A09ND3
B
D C 2Y0e0sH -0 -0 0 0 -1 F -010 0 0 -0
1 9 3 -B S B 8 0
B
0 H O N E Y W E L0L U D C M I N I1 P R O
$87.00 $
0
87.00 $ 8
D C 3Y0e0sE -E -2 0 0 -2 0 -010 0 0 -0
250T-TC1-DIN-NCR
ACROMAG TRANSMITTER
1 9 3 -B S C 3 2
B
0 H O N E Y W E L0L U D C 3 0 0 01
$0.00 $
0
$ 3
General Comments:
D C 3Y0e0sK -E -2 A 0 -2 1 -010 0 0 -0
1 9 3 -C P C 4 5
0 H O N E Y W E L0L U D C 3 0 0 01V E R S A P0R O
$57.00 $
57.00 $ 1
193-BSC32
B
R M7Y8e9s5 A 1 0 1 3
$72.20 $
1 9 3 -E A 5 D B
B
1
0 H O N E Y W E L0L B U R N E R 1C O N T R O0L
72.20 $ 1
BP1000
APC 1000 SERIES CPU
Survey Results
20F R 4032
1
0 H O N E Y W E L0L B U R N E R 1C O N T R O0L
$3,000.00 $
3,000.00 $ 2
R M7Y8e9s5 A 1 0 1 4
L B L 0 5 7 -B
F
CONTROL INSTRUMENTS MONITOR
2AX 3000
No
0
0 H O N E Y W E L1L B U R N E R 0C O N T R O1L
$530.00 $
$ 4 530.00
Rack
Slot Qty
Catalog No.
Ser Rev
NotesR M7 8 9 5 B 1 0 1 3
HONEYWELL UDC MINI
DC200H-0-000-1F-0000-0
0
0 H O N E Y W E L0L B U R N E R 0C O N T R O0L
3 0PRO
F R 403 1
$4,800.00 $
$ 5
R M7Y8e9s5 B 1 0 1 4
1
SLA-440.ASA
DIVERSIFIED ELEC. PHASE SEQ
0
0 I /P T R A N S D0U C E R C T R L0 A I R I N C 0.
$4,800.00 $
$ 0
HONEYWELL3 0 F R 4 0 3 2
DC200C-2-21A-100000-0
5 0 0 -YAeHs

Detailed Installed Base

Panel Name/ID:
FINISH OVENS
OEM:

Detailed Installed Base

Description:

General Comments:
Survey Results
Rack

Slot

Qty
5
4
4
1
3
4
4
4
1
1
1

1746-NO4I

1746-OW8

1746-IA16

RM7895B1013

1746-A10

RM7895B1014

100-A30N*3

193-CPC45

100-A38N*3

193-BSB80

193-BSB12

193-BSB16

1746-P2

1
1
1
1
1
1
1
1
1

D e ta ile d I ns ta lle d B a s e

HONEYWELL UDC MINI PRO

DC200H-0-000-1F-0000-0

P S 5 R -B 2 4
R R 2 K P -U

OEM UNKNOWN 24V POWER SUPPLY

NO P/N VISIBLE

LR86414
A-B CONTACTOR (NEED VOLTAGE)
DC200C-2-21A-100000-0

I H C 2 4 -2 . 4
C

C C 1 5 -3
A-B CONTACTOR (NEEDI H
VOLTAGE)
I H N 1 2 -1 . 7
TELEMECANIQUE

I H N 2 4 -3 . 6
L B 1201
HONEYWELL UDC3000 VERSA PRO
L B 301
CH PANELMATE
A P I -4 0 0 8
HONEYWELL
H D -9 9 3 9
H 6 6 0 0 -S S 5 W -0 1
IDEC RELAY

Page 2 of 3

P a ge 3 of 2 1

D e ta ile d I ns ta lle d B a s e

ID E C P O W E R S U P P L Y
ID E C R E L A Y
I N T E R N A T I O N A L P O W E R P /S
I N T E R N A T I O N A L P O W E R 2 4 V D C P /S
I N T E R N A T I O N A L P O W E R 1 2 V D C P /S
I N T E R N A T I O N A L P O W E R 1 2 V D C P /S
I N T E R N A T I O N A L P O W E R 2 4 V D C P /S
K E Y E NC E S E NS O R
K E Y E NC E S E NS O R
MI N U T MA N S E R I N P U T L O O P T R A C K R
N A IN C . D E T E C T O R
N O R T H A ME R I C A N MF G C O N T R O L L E R

Page 1 of 3

CH DRIVEI H A 2 4

EA270PN
193-CPC45
HONEYWELL BURNER CONTROL
100-A38N*3
CA2K10
HONEYWELL BURNER CONTROL
RR2KP-U
A-B CONTACTOR (NEED VOLTAGE)
DC300K-E-2A0-21-0000-0

P a ge 4 of 2 1

Installed Base
Evaluations

1
1
1
1
1
1
2
0
0
1
0
0

S tore s
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

S ta s h
0
0
1
1
0
0
0
0
0
0
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
2
2
0
1
2

Learning About Current

Migration Programs
Packaged migrations can help with your
planning and execution. We have a wide
range of experience on Rockwell Automation
and non-Rockwell Automation equipment,
and can create custom migration
packages/approaches for your
individual needs.

MIGRATION SOLUTIONS
BAILEY NET/INFI 90

Your equipment is your livelihood. Day in and day out, its what enables you to get quality product to your customer on time, every time. As your
equipment ages, its inevitable that questions about part sourcing, service, potential productivity gains from new technology, and increased risks of
downtime become stronger. You need to work with a supplier that has the product, service, and industry knowledge to partner with you on an
upgrade strategy that will help you maximize your competitive advantage in the years ahead. Rockwell Automation and its partners will work out the
right plan to fit your control needs and your long-term goals. We can help you migrate all at once or in stages, at the pace that is comfortable for
you and that fits your budget.

WE CAN GET YOU FROM HERE...

Uncertain parts and service sourcing
Limited network options
Weakening technical service
High repair costs
High downtime risks
Questionable reliability of older electronics
No warranty coverage
Old equipment that lacks production efficiency

...TO HERE
Component product backed by the outstanding support of
Rockwell Automaion
Open, integrated architecture for increased flexibility
Re-use of engineering practices to reduce development time
and costs
Maximizing returns from existing assets through greatly
improved control and monitoring
Quickest response to customer or market demands
Easy access to plant and production data from business
systems for better management decision making
Single environment for integrated motion, process and safety
control

ALL AT ONCE OR STEP-BY-STEP

STEP 1. REPLACE OPERATOR CONSOLES
WITH NEW HMI PC HARDWARE &
SOFTWARE

Step 1

Tag Database Conversion Utilities , custom faceplate libraries and graphic conversion
services not only make Operator Interface conversions much more cost effective, but
give you greater flexibility regarding the final product. This means that you can
account for how operators use your equipment, and design interfaces that help
maximize their productivity. In the end, this will allow you to give your operators
the tools they need to get quality product to your customers.

STEP 2. INTEROPERATE LOGIX

CONTROLLERS IN CONJUNCTION WITH
YOUR CURRENT SYSTEM

Step 2

Do you want to expand your system or simply upgrade your aging DCS system?
Either way, start now by adding Logix controllers to your current system. You can
Legacy
System side-by-side with your current system while using common
utilize
Logix controllers
HMI interfaces. This way you can add production capacity and manufacturing
flexibility while incorporating new technology in your manufacturing environment.
This will allow you to quickly benefit from many aspects of Integrated Architecture
including greater MES/ERP connectivity and tighter IT integration.

STEP 3. REPLACE LEGACY CONTROLLERS,

I/O, MODULES, RACKS, AND POWER
SUPPLIES
Replace obsolete CADEWS Stations and remaining obsolete controllers and I/O
with a new Integrated Architecture Process Automation System. You can connect
existing field devices to this new system with legacy termination panels and
custom cables which will reduce your projects commissioning time and overall
cost. The end result is a system with added production capacity, manufacturing
flexibility, and total system support. With the proper planning, this can be
accomplished
while gaining the maximum life out of your current equipment
Integrated
Architecture
and positioning yourself to cover future manufacturing needs.

STEP 4. OTHER ENHANCEMENTS THAT

WOULD INCREASE THE PERFORMANCE OR
MAINTAINABILITY OF YOUR EQUIPMENT
Because Rockwell Automation is a comprehensive supplier, we can help in other
areas as well. We carry everything from sensors to motor control centers, so we can
discuss all your needs. But it does not stop there, we have a worldwide service group
that can help during each step of your migration and provide the maintenance
services once its complete. We can also review your network needs and review asset
management for your entire plant.

WE HAVE A PLAN

Step 3

Rockwell Automation provides many migration options. If

you want or need to upgrade your systems all at once, we have
the expertise and resources to get the job done quickly to
minimize your potential loss of production. If you want to
schedule your migration over time, we will work with you to
create a plan that fits both your schedule and budget.
Rockwell Automation not only has the products and services,
but the industry knowledge to make sure your new equipment
does what its supposed to do - make you money.

All trademarks and registered trademarks are the property of their respective companies.

Publication MIGDCS-PP001A-EN-P March 2006

Copyright 2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Packaged
Migration Solutions

Op Station 1

Redundant Servers

Op Station 2

EWS

Replace obsolete Engineering Workstations and remaining

obsolete controllers and I/O with the PlantPAx Distributed
Control System. You can connect existing field devices to this
new system with legacy termination panels and custom cables
which will reduce your projects commissioning time and overall
cost. The end result is a system with added production capacity,
manufacturing flexibility, and total system support. With the
proper planning, this can be accomplished while gaining the
maximum life out of your current equipment and positioning
yourself to cover future manufacturing needs.

Ethernet
AW51

Nodebus

ControlLogix 1

Op Station 1

Op Station 2

Phase III Tools: Foxboro IA to ControlLogix Control

Strategy Library, Configuration Conversion Services,
Foxboro IA Cable Solution

ControlLogix 2

Redundant Servers

EWS

Ethernet

ControlLogix 1

Creating a Plan

Target areas offering the greatest

Return on Investment (ROI)
Schedule based on your planned downtime
Sequence to reduce overall project time
Define and highlight successes

Executing the Plan

A wide variety of programs/services are available from

Rockwell Automation and its partners, including:
Design
Project Management
Programming
Installation
Commissioning/Start-up
Maintenance

ControlLogix 2

Phase III: Replace legacy controllers, I/O,

modules, racks and power supplies

Phase IV: Other enhancements that

would increase the performance or
maintainability of your equipment
Because Rockwell Automation is a comprehensive supplier,
we can help in other areas as well. We carry everything
from sensors to motor control centers, so we can discuss all
your needs. But it does not stop there, we have a worldwide
service group that can help during each step of your migration
and provide the maintenance services once its complete.
We can also review your network needs and review asset
management for your entire plant.
Phase IV Tools: Migration and Conversion Services,
Advanced Process Control Capability, Process Safety,
High Availability Systems, Batch Control

Practicing Continuous Improvement

Performance Assessments can be used to measure your success
based on the defined metrics in your plan. These tools can also be
used to plan and evaluate your future migration needs.

For more information, visit us

at www.rockwellautomation.com/
solutions/migration/ or contact your
local Rockwell Automation Sales office or
authorized Allen-Bradley distributor.

For more information

Visit us at www.rockwellautomation.com/solutions/migration/
or contact your local Rockwell Automation Sales office or authorized
Allen-Bradley distributor.

PlantPAx, ControlLogix and Rockwell Automation are trademarks of Rockwell Automation, Inc. All other trademarks or registered trademarks are property of their respective companies.

Publication MIGDCS-PP008C-EN-E September 2015

Supersedes Publication MIGDCS-PP008B-EN-E July 2012

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.