Content
# PLC_Conversion_Estimate_By_Routine_v2.pdf
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## Summary
The file contains an engineering estimate for converting a PLC program from an Allen-Bradley MicroLogix 1400 platform to a new, unspecified PLC architecture. It details the estimated hours and scope of work for translating ladder logic routines including input/output mapping, motor control, sequencing, timers, fault handling, and warnings. The document focuses on program translation and validation without including commissioning or on-site startup support.
## Content
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PLC Program Conversion Estimate (by Routine)
Source Platform: Allen-Bradley MicroLogix 1400 (RSLogix 500)
Target Platform: New PLC Architecture (Vendor TBD)
Total Estimated Engineering Effort: 40 Hours
Scope Summary
This estimate reflects the engineering effort required to translate the existing ladder logic program into a new
PLC architecture. Work includes understanding program intent, mapping legacy address-based logic to a
tag-based structure, recreating sequencing logic, timers, counters, interlocks, fault handling, and performing
offline validation.
Routine
Estimated HoursEngineering Justification
Initial Setup and Preparation
2.6
Project scaffolding, tag structure creation, I/O mapping strategy.
MAIN Routine
3.6
Top-level scan control, subroutine calls, global state handling.
INPUTS Routine
2.6
Input mapping, conditioning, internal bit handling.
MOTORS Routine
1.6
Motor interlocks and run-state logic.
TIMER_PRESET Routine
2.6
Timer preset translation and HMI-adjustable setpoints.
WASH_LOAD Routine
4.6
Sequenced load logic with step progression and timing.
WASH_CNTRL Routine
6.6
Primary washer sequencing, counters, and state management.
FILLER_CAP Routine
4.6
Filler and capper sequencing with timers and interlocks.
RTC_CLOCK Routine
1.6
Clock synchronization and real-time clock handling.
WARNINGS Routine
3.6
Warning condition detection and timing filters.
FAULTS Routine
3.6
Fault aggregation, latching, and reset logic.
OUTPUTS Routine
2.4
Output mapping and final permissive logic verification.
Notes and Assumptions
• Estimate includes translation and refactoring effort, not a full process redesign.
• High-sequence routines require additional validation to preserve operational behavior.
• Commissioning and on-site startup support are not included in this estimate.
• Final effort may vary depending on target PLC development environment and required architecture
standards.
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