Rockwell Automation (Allen-Bradley) System Upgrades
TDL upgrades running Rockwell Automation systems in Vietnam: Allen-Bradley PLC-5 and SLC 500, older ControlLogix and CompactLogix controllers, PanelView terminals, RSView32 and FactoryTalk View, ControlNet and DeviceNet networks, and PowerFlex and Kinetix drives. Each upgrade starts from a survey of what is installed and ends with a planned cut-over, updated drawings and program backups.
What TDL upgrades
PLC-5 and SLC 500 to ControlLogix or CompactLogix
Program conversion and testing, existing I/O kept or replaced according to the survey, DH+, Remote I/O and DH-485 moved to EtherNet/IP.
Older ControlLogix and CompactLogix controllers
Controllers moved to current ControlLogix and CompactLogix platforms, keeping the application and the plant's tag names.
PanelView and HMI/SCADA
PanelView, PanelView Plus 6 and RSView32 applications converted to PanelView Plus 7 and FactoryTalk View SE.
ControlNet and DeviceNet to EtherNet/IP
Networks replaced in stages with the I/O, drives and HMI that depend on them.
Redundant controllers
Critical units moved to redundant ControlLogix with redundant I/O where the process needs it.
Drives
DC drives and older AC drives replaced with PowerFlex, legacy servo drives with Kinetix.
How an upgrade runs
1. Survey and installed base
Controllers, I/O, networks, HMI, drives, software versions and program backups recorded and checked against Rockwell's published lifecycle status.
2. Path and scope
Target platform for each system, and what is kept (I/O, wiring, panels) or replaced, written into the scope before pricing.
3. Program conversion and bench test
Programs converted and tested on a bench before site work; the parts a conversion tool does not handle are redone by hand.
4. Panels and FAT
New or modified panels built in TDL's workshop and tested in a factory acceptance test.
5. Cut-over plan
Cut-over planned unit by unit, line by line or in one shutdown, agreed with the plant.
6. Commissioning and handover
Site acceptance, as-built drawings, program backups and training for the plant's engineers.
Related services
PLC & Control System Migration
Allen-Bradley PLC-5, SLC 500 and MicroLogix, GE Fanuc, Siemens S5 and HIMA systems upgraded to ControlLogix and CompactLogix; ControlNet and DeviceNet to EtherNet/IP; older HMI/SCADA (RSView32, Citect, PanelView) to FactoryTalk View and PanelView Plus 7. Drive upgrades: DC drives to PowerFlex, legacy servo drives to Kinetix. Site survey, code conversion, FAT/SAT and planned cut-over, onshore and on offshore platforms.
Industrial Networks & OT Security
EtherNet/IP networks on Stratix managed switches, with redundancy by DLR rings, PRP and HSR. VLAN segmentation, firewalls and secure remote access following IEC 62443 zone and conduit principles. Interfaces to third-party systems over Modbus and OPC UA.
Control Panel Engineering
Control and marshalling panels: design, schematics, fabrication, wiring and factory acceptance testing before shipment. Ex-rated enclosures for hazardous areas.
Project references
| Project | Year | Original system | Upgraded to |
|---|---|---|---|
| JVPC Rang Dong Field – RO Water Maker PLC Upgrade, SLC 500 to CompactLogix 5380 | 2026 | SLC 5/03 with 1746 I/O · HMI on DH-485 | CompactLogix 5380 with 5069 I/O · existing PanelView relinked over EtherNet/IP |
| Crown Da Nang – Body Maker Control Upgrade to ControlLogix 5580 | 2026 | DeviceNet I/O and drives · PanelView Plus HMI | ControlLogix 5580 · EtherNet/IP · POINT I/O · PowerFlex 755 and PowerFlex 525 · PanelView Plus 7 · IO-Link |
| Phu My Fertilizer Plant – 40-PK-5001 Ammonia Compressor Control Replacement | 2025 | Allen-Bradley PLC-5 | Redundant ControlLogix 5580 with redundancy modules · FLEX 5000 I/O · PanelView Plus 7 Performance 12-inch HMI |
| PVEP DMDP-A Platform – Offshore Compressor Control System Upgrades | 2024 | ControlLogix on ControlNet, 1756-IT6I thermocouple inputs, PanelView Plus 6 | ControlLogix on EtherNet/IP (1756-EN2TR), 1756-IRT8I inputs, PanelView Plus 7 Performance |
| BSR – Steam Turbine Generator (STG) Network & HMI Upgrade | 2024 | ControlNet network, RSView32 HMI | Redundant EtherNet/IP network, FactoryTalk View SE |
| Phu My Fertilizer Plant – Tripper Car Control System Upgrade | 2023 | Allen-Bradley SLC 500 | ControlLogix 5580 XT · Flex XT remote I/O · EtherNet/IP DLR · ControlNet fibre link |
| Phu My Fertilizer Plant – Natural Gas Compressor Control System Migration | 2023 | GE Fanuc PLC and GE SCADA | Redundant ControlLogix 5580 with redundancy modules · 1715 redundant I/O · EtherNet/IP |
| Crown Dong Nai – Cupper Line 1 PLC-5 to ControlLogix Upgrade | 2023 | Allen-Bradley PLC-5 | ControlLogix 5570 · PanelView Plus 7 · PowerFlex 755 and PowerFlex 525 · resolver-based cam module · Guardmaster safety relay |
| CFT Copper – PLC-5 and DC Drives Upgrade for Mill, Furnace and AMPS | 2021 | Allen-Bradley PLC-5, HMI and DC drives | ControlLogix · DC drives · FactoryTalk View |
| Pha Lai II Thermal Power Plant – Subsidiary Systems Migration | 2020 | Allen-Bradley PLC-5 / Citect | ControlLogix / FactoryTalk View SE |
| Vietsovpetro Central Compressor Platform – EDG and Switchgear Control System Upgrade | 2020 | SLC 5/01 (EDG panel) and SLC 5/03 (switchgear monitoring) on DH-485 | CompactLogix with 1769 I/O · FactoryTalk View SE local station · Modbus TCP to the platform ICSS |
| Dinh Co GPP – CC01 Turbo Expander Control System Upgrade | 2019 | Allen-Bradley SLC 500 | Redundant ControlLogix, PanelView HMI |
| Phu My Fertilizer Plant – FAM Conveyor and Libra Packing Control System Upgrade | 2015 | ControlLogix 5555 · RSView32 | ControlLogix 5570 · FactoryTalk View |
| Ba Ria Gas Distribution Station – Piping Monitoring Control System Upgrade | 2014 | Allen-Bradley PLC-5 · RSView32 | Redundant ControlLogix · FactoryTalk View SE server and clients · EtherNet/IP DLR remote I/O |
Service packages
- End-of-life module / CPU replacement, keeping the existing program
- PanelView Plus 6 → Plus 7 upgrade, migrating the FactoryTalk View ME project
- Legacy HMI/SCADA migration to FactoryTalk, AVEVA or Ignition
Technical articles
- MicroLogix 1500 faults: FAULT LED, S:6 major error code and how to get back to RUN
- PLC-5 to ControlLogix Migration: Converting the Program, Keeping or Replacing 1771 I/O, and What the Tool Won't Do
- Upgrade Paths for Legacy Allen-Bradley Systems: SLC 500, MicroLogix, 1768, PanelView, FLEX I/O, ControlNet
- CompactLogix 1769-L31, L32E, L35E, L23E end of life — migration path to 5370/5380
- 1756-ENBT end of life — replace with 1756-EN2T, EN2TR or EN4TR?
- PowerFlex 755 to 755TS Migration: What Stays, What Changes and a Plant Checklist
Frequently Asked Questions
Can the existing program be reused?
Usually, yes. Rockwell provides conversion of PLC-5 and SLC 500 programs to Logix, but I/O addressing, block transfers, messages and some instructions have to be reworked by hand and tested before site work.
Do we have to rewire the field I/O?
Not always. Depending on the platform, the existing I/O can stay in service for a period, or be replaced with conversion systems that reuse the field wiring. The survey decides which.
How long does the plant have to stop?
It depends on the scope. TDL plans the cut-over around the plant's shutdown windows; for example, an offshore SLC 500 to CompactLogix upgrade was completed within an 8-day shutdown.
Can only the HMI or only the network be upgraded?
Yes. HMI, network and controller upgrades can be done separately, for example replacing PanelView terminals without changing the PLC.
Planning a Rockwell Automation upgrade?
Speak directly with our engineers. Your RFQ, scope of work or drawings are answered by the engineers who program and commission the systems, from the first review of the existing system to the proposed solution.
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