No Time to Waste: Why You Need to Replace Your PLC-5 ASAP

When the PLC-5 was released, it increased processing power, memory, and accepted many IO modules, all within one controller. Along with the improvements from former controllers, it gave processing facilities remote access to operations, the ability to log data, it could withstand harsh environments, and it could handle intricate processes more quickly than before.

Now, new technology has scaled these advancements to bring new benefits to processing facilities.

As facility shutdowns and turnarounds are occurring less frequently, it’s time to plan your next PLC 5 migration before your spare parts or outdated hardware become scarce or fail. Developing a strategy for your control system will enhance reliability, minimize unexpected risks and downtime, and allow you to benefit from the advancements in modern PLC solutions.

Threats and risks of continuing with PLC-5

It has been 38 years since the PLC-5 was introduced, and seven years since Allen-Bradley discontinued this unit. The once admired PLC-5 is subject to a myriad of risks. Reduced reliability means that the mean time to failure (MTTF) and mean time between failure (MTBF) decreases, in turn increasing the chance of unplanned downtime which can result in thousands of dollars worth of lost production.  The number of spare parts available worldwide has not changed since 2017. That’s 7 years of chewing up inventory that is not and will not be replenished. Additionally, unsupported software leaves organizations unable to defend against new cybersecurity risks. As demand for the product goes down, resources with the expertise and knowledge to work on these systems will begin to dwindle.

Opportunities and benefits to replacing it

These risks do not need to become reality; organizations can upgrade their PLC-5s to a new PLC system that:

• Enhances performance, reducing MTBF and MTTF.
• Increases processing efficiency, handling more complex tasks at an increased rate and offering more capacity for memory storage.
• Has advanced features and functionality, providing real-time monitoring and analysis to bring process visibility to your fingertips.
• Integrates with different networks, allowing the system to connect to different devices on your current network.
• Features modern diagnostics That monitors the controller to ensure it is functioning correctly and alerts you if it is not.
• Reduces maintenance and energy costs by managing inventory for quality control and reducing cycle times (allowing processes to be task based, rather than continuous). In turn creating incredible cost saving and better asset utilization.
• Offers service and support, covering issues with warranties and ensuring replacement parts are available
• Is scalable, supporting growing facilities and processing needs with available hardware and the ability to add additional IO as needed.

Conclusion

With all the downsides to sticking with the PLC-5 and all the upsides with replacing it, the choice to replace your PLC-5 as soon as possible is clear.

If you still have PLC-5s integrated into your site, you may be overwhelmed with where to begin, read the next blog post about 6 key considerations when replacing a PLC-5, download our guide to modernizing obsolescent PLC-5s in industrial facilities (below), or speak to one of our experts today!

Talk to one of our experts

Sources:
InnoTech SMEs
Larson, K. (2023, June 20). Lessons chevron learned in modernizing its plcs. Control Global.
Magill, K. (2022, October 12). Schneider Electric moves to modernize equipment and machinery at 2 US plants. Supply Chain Dive.
Nicolas. (2023, March 16). Industrial Equipment Modernization. Solutions TREXO.
PLC-5 controllers: Allen-Bradley. Rockwell Automation. (n.d.).
ABB Top aluminum producer and recycler novelis to increase uptime following ABB Modernization. News. (2023, August 16).