Description:
The ProSoft Technology AN-X2-AB-DHRIO is a powerful, standalone communication gateway designed to bridge legacy Allen-Bradley data highway networks with modern Industrial Ethernet systems. It provides a critical connectivity path, allowing contemporary controllers (like ControlLogix or CompactLogix) over EtherNet/IP to seamlessly communicate with and manage devices on older Data Highway Plus (DH+) and Remote I/O (RIO) networks. This enables data exchange, control, and integration without the need to immediately replace existing PLC-5. SLC 500. or other legacy hardware, protecting investments and simplifying modernization efforts.
Application Scenarios:
A manufacturing plant has a production line controlled by a legacy Allen-Bradley PLC-5 over a DH+ network. The management wants to integrate this line’s data (production counts, machine status) into a new plant-wide SCADA system and a modern ControlLogix controller for overall coordination. Rewiring and replacing the entire PLC-5 system would be prohibitively expensive and cause extended downtime. The ProSoft AN-X2-AB-DHRIO provides the solution. It is installed on the control cabinet’s DIN rail. Its Ethernet port is connected to the plant’s EtherNet/IP network, and its DH+ port is connected to the existing blue hose DH+ network. The gateway is configured to map specific data tables from the PLC-5. Instantly, the ControlLogix and SCADA can read and write to the PLC-5 as if it were a native EtherNet/IP device, solving the critical pain point of integrating legacy automation assets into modern IIoT architectures without costly rip-and-replace.
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Technical Principles and Innovative Values:
Innovation Point 1: Dual-Protocol Bridging with Data Mapping. The core innovation of the AN-X2-AB-DHRIO is its ability to act as a transparent bridge between two entirely different industrial protocols. It can be configured as an EtherNet/IP adapter, presenting a set of data arrays (tags) to a Logix controller. Internally, it maps these arrays to specific read/write operations on the DH+ or RIO network, such as reading N files from a PLC-5 or writing to O files. This abstraction allows modern controllers to interact with legacy devices without needing native support for the old protocols.
Innovation Point 2: Integrated RIO Scanner Functionality. Beyond simple DH+ pass-through, the module incorporates a full Remote I/O (RIO) scanner. This means a modern ControlLogix controller, via the EtherNet/IP network and the AN-X2-AB-DHRIO, can directly scan and control legacy 1771 I/O racks (like PLC-5 style I/O) as if they were local or remote I/O on the Logix backplane. This is a powerful feature for integrating discrete legacy I/O into a new system without changing the field wiring.
Innovation Point 3: Standalone Operation and Web-Based Management. Unlike some communication cards that must reside in a controller chassis, the AN-X2-AB-DHRIO is a standalone device. This provides tremendous flexibility in network topology and physical placement. Its built-in web server allows for easy configuration, real-time diagnostics, and data monitoring through a standard browser, simplifying setup and troubleshooting without specialized software on every engineer’s laptop.
Application Cases and Industry Value:
Case Study: Water Treatment Plant Control System Modernization.
A large municipal water treatment plant had a control system based on multiple Allen-Bradley PLC-5s communicating over DH+, with some remote sites using 1771 I/O on RIO. The goal was to gradually migrate to a centralized PlantPAx DCS based on ControlLogix without disrupting 24/7 operations. The ProSoft AN-X2-AB-DHRIO gateways were deployed strategically. One was used to bring a critical PLC-5 controlling chemical dosing into the new EtherNet/IP network. Another was used to integrate a bank of 1771 analog input modules from a remote clarifier. The system integrator stated: “The AN-X2-AB-DHRIO was the linchpin of our phased migration. We could ‘virtualize’ the old PLC-5 logic into the new ControlLogix step-by-step while the gateway maintained the live connection to the field. It de-risked the entire project and allowed the plant to operate continuously, saving an estimated 3 weeks of potential downtime.”
Case Study: Automotive OEM Legacy Press Line Integration.
An automotive manufacturer needed to collect production data from a 20-year-old press line controlled by SLC 5/04 PLCs on DH+ for a new Manufacturing Execution System (MES). Running new cabling for Ethernet was not feasible in the short term. An AN-X2-AB-DHRIO was installed. It connected to the existing DH+ network and the plant’s Ethernet backbone. The gateway was configured to poll the necessary data table words from the SLCs. The MES server, using standard EtherNet/IP messaging, could then read this data directly from the gateway. The plant engineer reported: “For the cost of one gateway and a day of configuration, we unlocked decades of machine data. The AN-X2-AB-DHRIO made our old press line look like a modern EtherNet/IP device to the MES. We achieved our production visibility goals without any modification to the reliable, albeit legacy, control system.”
Related Product Combination Solutions:
ProSoft RadioLinx (e.g., 915MHz Ethernet Radio): Can be paired with the AN-X2-AB-DHRIO to create a wireless bridge for DH+ or RIO networks, connecting remote assets without costly cabling.
Allen-Bradley ControlLogix PLC: The modern controller that typically acts as the EtherNet/IP scanner/client, using the AN-X2-AB-DHRIO to access legacy data.
Allen-Bradley PLC-5 or SLC 5/04: The legacy controllers on the DH+ network that are accessed through the AN-X2-AB-DHRIO gateway.
1771 I/O Racks (e.g., 1771-IBD): Legacy Remote I/O racks that can be scanned directly by the AN-X2-AB-DHRIO’s built-in RIO scanner function.
ProSoft Configuration Builder (PCB) Software: The dedicated software (though often configurable via web) for advanced setup and management of ProSoft modules like the AN-X2-AB-DHRIO.
Red Lion (ProSoft) N-Tron Switches: Managed industrial Ethernet switches that can be used to build a robust network infrastructure to connect the AN-X2-AB-DHRIO and other devices.
Allen-Bradley 1783-ETAP: A DIN-rail mounted Ethernet tap/power supply that can provide both Power-over-Ethernet (PoE) and a network connection to power and connect the AN-X2-AB-DHRIO.
Installation, Maintenance, and Full-Cycle Support:
Installation of the ProSoft AN-X2-AB-DHRIO is straightforward. The compact module is mounted on a DIN rail. It requires a 24V DC power source. Network connections involve: 1) An Ethernet cable from the plant network to its EtherNet/IP port, and 2) Connection to the legacy network—either a DH+ tap (using a 1784-CP10 or equivalent cable) to the blue DH+ trunk, or a RIO drop cable to a 1771-ASB adapter module. The device is assigned an IP address (via BOOTP/DHCP or serial port) and then configured via its web interface.
Configuration involves setting the DH+ node address and baud rate to match the existing network, and then defining the data mapping tables—specifying which PLC files on which DH+ node correspond to which data arrays in its EtherNet/IP tag space. The web interface provides clear diagnostics, including status of both network links and activity indicators. Common issues include incorrect DH+ node address conflicts, baud rate mismatches, or improper termination on the DH+ network. Firmware updates are available from ProSoft to add features or fix issues. We supply the genuine ProSoft AN-X2-AB-DHRIO gateway. Our technical support can assist with network planning, configuration templates, and troubleshooting to ensure a smooth integration of your legacy and modern systems.
Bridge the gap between your legacy control systems and modern industrial networks. Contact us for the genuine ProSoft AN-X2-AB-DHRIO gateway and expert integration support.
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