RSLOGIX 5/500 Discontinuation: How Ignition HMI and the ANC-100e converter are Modernizing Legacy DH+ Systems
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For decades, Allen-Bradley PLC-5 and SLC 5/04 controllers have been the backbone of industrial automation. The massive automotive plants and the facilities across North America, these "workhorse" PLCs continue to run critical processes reliably. We are reviewing the Ignition HMI to DH+ converter.
The proprietary Data Highway Plus (DH+) network relies on is becoming an island. As the hardware used to "talk" to these networks—like the 1784-PKTX and 1784-U2DHP—hits obsolescence, manufacturers face a grim choice: perform a multi-million dollar "rip and replace" migration or find a way to bridge the legacy gap.
The combination of the ANC-100e DH+ to Ethernet Converter and Ignition SCADA by Inductive Automation offers a third, more profitable path: Modernization without Replacement.
The Crisis of Legacy DH+ Communications
Historically, connecting to a PLC-5 required specialized, expensive, and now obsolete hardware. If you wanted to see your data, you needed:
- 1784-KT / PKTX Cards: Required old desktop computers with ISA or PCI slots.
- 1784-U2DHP: A USB-to-DH+ cable that is increasingly difficult to find and maintain.
- RSLinx Classic: Expensive per-node licensing that creates a bottleneck.
This legacy architecture is "Single-Threaded." In many plants, if a maintenance engineer plugs in their laptop to troubleshoot a PLC-5, the HMI loses its connection, or the SCADA system begins to lag. In a modern data-driven world, this "one user at a time" limitation is a production killer
The ANC-100e as a Bridge: Ignition HMI to DH+ converter
The ANC-100e functions as a high-speed gateway that converts DH+ packets into standard Ethernet/IP. Unlike older converters, it acts as a native node on the DH+ network.By installing an ANC-100e, your legacy network is suddenly "visible" to your entire plant's Ethernet backbone.
This transition moves your architecture from a closed loop to an open, accessible system:
Legacy: PC → RSLinx → Obsolute Card → DH+ → PLC
Modern: Ignition → Standard Ethernet → ANC-100e → DH+ → PLC
Why Ignition + ANC-100e is the Ultimate Upgrade
When you pair this gateway with Ignition, you aren't just fixing a communication problem; you are unlocking a full SCADA, MES, and IIoT platform.
1. Zero Obsolete HardwareThe most immediate benefit is the elimination of specialized interface cards.
The ANC-100e uses standard RJ45 Ethernet cables. If a PC fails, you can replace it with any modern machine, install Ignition, and be back online in minutes. There is no need to hunt for "new old stock" cards on eBay.
2. Simultaneous Multi-User AccessThis is the "Game Changer."
Because the ANC-100e handles the protocol conversion at the hardware level, it can manage multiple requests. An operator can view a dashboard on a tablet, a manager can pull a report via a web browser, and an engineer can perform remote programming—all at the same time, without interrupting each other.
3. Native Integration & Technical SimplicityIgnition’s strength lies in its ability to use native drivers.
To connect to a PLC-5 through the ANC-100e, you simply:Open the Ignition Gateway.Add a new device using the Allen-Bradley PLC5 driver.Enter the ANC-100e IP address as the Hostname.Set the Connection Path (e.g., 1,1,2,3 for DH+ node 3).This simplicity reduces commissioning time from days to minutes.
4. Unlocking the Power of SQL and Big DataLegacy RSLinx systems were never designed for data logging.
Ignition allows you to take that "trapped" PLC-5 data and stream it directly into SQL databases like MySQL or Microsoft SQL Server. This enables:Historical Trending: Watch how a motor's temperature has changed over six months.OEE Calculations: Track the real efficiency of 30-year-old machines.Automated Reporting: Generate compliance reports for water/wastewater regulators automatically.
5. Remote Access & VPN MobilityIn a global economy, your best engineer might be in another city.
With the ANC-100e, your DH+ network is part of your IP infrastructure. This means with a secure VPN, you can troubleshoot a PLC-5 in a factory in Queretaro from an office in Houston.
The ANC-100e uses standard RJ45 Ethernet cables. If a PC fails, you can replace it with any modern machine, install Ignition, and be back online in minutes. There is no need to hunt for "new old stock" cards on eBay.
2. Simultaneous Multi-User AccessThis is the "Game Changer."
Because the ANC-100e handles the protocol conversion at the hardware level, it can manage multiple requests. An operator can view a dashboard on a tablet, a manager can pull a report via a web browser, and an engineer can perform remote programming—all at the same time, without interrupting each other.
3. Native Integration & Technical SimplicityIgnition’s strength lies in its ability to use native drivers.
To connect to a PLC-5 through the ANC-100e, you simply:Open the Ignition Gateway.Add a new device using the Allen-Bradley PLC5 driver.Enter the ANC-100e IP address as the Hostname.Set the Connection Path (e.g., 1,1,2,3 for DH+ node 3).This simplicity reduces commissioning time from days to minutes.
4. Unlocking the Power of SQL and Big DataLegacy RSLinx systems were never designed for data logging.
Ignition allows you to take that "trapped" PLC-5 data and stream it directly into SQL databases like MySQL or Microsoft SQL Server. This enables:Historical Trending: Watch how a motor's temperature has changed over six months.OEE Calculations: Track the real efficiency of 30-year-old machines.Automated Reporting: Generate compliance reports for water/wastewater regulators automatically.
5. Remote Access & VPN MobilityIn a global economy, your best engineer might be in another city.
With the ANC-100e, your DH+ network is part of your IP infrastructure. This means with a secure VPN, you can troubleshoot a PLC-5 in a factory in Queretaro from an office in Houston.
The most significant risk in automation is the "Big Bang" migration—replacing everything at once. It’s expensive and prone to errors. The ANC-100e and Ignition allow for Phased Modernization:
- Phase 1: Install the ANC-100e to stabilize communications and remove obsolete PC cards.
- Phase 2: Implement Ignition to begin logging data and creating web-based HMIs.
- Phase 3: Use the data gathered to identify which PLCs actually need replacing, and migrate them one by one as budget allows.
Data Highway Plus to Ethernet (S02)
In today’s episode of The Automation Show, I unbox and setup an ANC-100e Data Highway Plus (DH+) to Ethernet Converter Data Highway Plus to Ethernet bridge from Automation Networks. For more information about the show (and how you could win an ANC-100E) check out the “Show Notes” located below the video. The Automation Show, Episode 2 Show Notes: NOTE: Would you like your … Continue readingData Highway Plus to Ethernet (S02)
