Migrating Your SLC 500 Control System
23/07/2025
To optimise productivity and minimise risk, it’s important to adopt migration solutions that reduce the challenges of maintaining legacy equipment. NHP and Rockwell Automation can help you develop a tailored modernisation strategy. This strategy can be implemented all at once or in phases, depending on your priorities and budget, facilitating a smooth transition from SLC™ 500 to CompactLogix™ 5380 control systems.
Benefits of the CompactLogix™ 5380 control system
High performance
- Dual one gigabit (Gb) Ethernet port enables high-performance I/O and integrated motion on EtherNet/IP up to 32 axis
- Controller firmware is optimised for maximum performance
Security capabilities
- Digitally signed and encrypted controller firmware
- Controller-based change detection and logging
- Role-based access control to routines and Add-On Instructions
- Ability to enable and disable all embedded ports
- IEC 62443-4-2 Certification Security certified CompactLogix 5380 Controller, Security Level 1 (SL1)
Enhanced productivity with Logix
- Two Ethernet ports for Dual-IP or support for Device Level Ring (DLR) and linear topologies for up to 180 nodes
- Supports up to 31 local I/O modules and memory from 0.6…10 MB
- Onboard display allows for enhanced diagnostics and troubleshooting
- USB port supports local programming, troubleshooting and firmware updates
Getting started: Analysing your automation system
With industry knowledge and worldwide services support, Rockwell Automation will partner with you to ensure a smooth transition from your SLC™ 500 to CompactLogix™ 5380 control system
Step 1
Document existing system layout and define future system requirements
Begin your migration planning by documenting your existing system as a reference point. This will enable you to consider the available options and find a solution that best meets your existing and future requirements.
Step 2
Plan migration
Once you have your overall migration approach, use Integrated Architecture® Builder (IAB) tool to help plan the details. The SLC migration wizard embedded in IAB will guide you through the system configuration process. You can decide which are the components to reuse or replace. If you choose to reuse the SLC I/O, IAB will verify module support and power supply loading and help you lay out the new EtherNet/IP network. The 1492 I/O conversion system in IAB helps to minimise the risk of wiring errors by preserving existing field wiring connection during I/O conversion.
Moving forward: Executing your project
Whether you choose to migrate all at once or in phases, we have the tools and experience to guide you through the transition. Our approach to modular automation coupled with backward compatibility allows you to maintain productivity as you upgrade portions of your automation system.
Phase 1
Application code conversion
Save time and engineering resources when converting your SLC™ 500 application code by using the embedded conversion utilities in RSLogix 5000® or Studio 5000 Logix Designer® application. Converting your PanelView™ Standard application to a PanelView Plus 7 application is as simple as importing the existing project into FactoryTalk® View Machine Edition software.
Advantages of application code:
- Converts code using automated code conversion
- Leverages powerful constructs and features to improve the application
Advantages of Human Machine Interface (HMI) application:
- No further modification will be required, most of the time
- Utility generates conversion log, which identifies features that are not supported by the selected new hardware
- Enhanced features and graphics
- Better integration with controllers
Phase 2
Replace the SLC controller and/or module
Mount and wire the CompactLogix™ 5380 system and replace the SLC first slot module (SLC processor or communication module) with the SLC EtherNet/IP™ communication module (1747-AENTR). Using this module helps you retain your existing SLC I/O and preserve existing field wiring, while allowing your SLC I/O chassis to be controlled from your new CompactLogix controller. This approach simplifies the migration process, reduces risks associated with rewiring the I/O and saves valuable time, which allows you to get your application into production quickly.
Advantages:
- Maintain existing field wiring
- Ability to revert to SLC I/O, if needed
Phase 3
Replace other system hardware and review investment
If your control system has legacy or competitive variable speed drives, motion control, sensors, or motor control centers, Rockwell Automation can help migrate those products as well. We have a worldwide service group that can do the migration work, assist and train operators or provide the maintenance services once the migration is complete. We can also review your network needs and asset management for your entire facility.
Phase 4
I/O replacement
In the final phase of the migration process, the 1492 I/O conversion system is used to replace SLC™ 500 with CompactLogix™ 5380 control system. Because I/O replacement represents a large investment, we provide an approach that is right for your schedule and budget. The 1492 I/O conversion system allows I/O conversion from SLC™ I/O to the Compact 5000™ I/O without removing existing field wiring connections. This helps to reduce conversion time, labor costs and reduce potential downtime risk that could result from wiring mistakes during the migration. Planning your migration is more manageable as the I/O can be swapped one rack at a time or all at once. In either case, you can run both new and old I/O architectures simultaneously. Additionally, I/O cross-reference documentation assures correctness and provides historical backup for future troubleshooting or diagnostics.
How to plan a smooth migration
Gain clarity on process steps, key considerations, and tools available for a successful self-led transition.
Learn More
StepForward™ program for SLC™ 500 controllers
What is the StepForward™ program?
Customers who return their existing Rockwell Automation® products will receive a credit when they purchase new participating Rockwell Automation® products.
What is the credit amount listed in the StepForward™ program?
Customers will receive the credit amount based on the credit multiplier* x list price of the new products. (Conditions apply).
When is the effective date for the StepForward™ program for SLC™ 500 controllers?
It is effective from now until December 2025
Contact us
Get in touch with your local NHP Account Representative or email us:
Australia | 1300 NHP NHP | nhpservice@nhp.com.au
New Zealand | 0800 NHP NHP | servicenz@nhp-nz.com