S6 Requirements.docx

FY26 Allen-Bradley PLCs and HMIs S6 Requirements List

Version 0.1 16 September 2026

Presented by:

Requirements List The Corpus Christi Army Depot (CCAD) requires the commercial procurement of authentic, factory-new Allen-Bradley Programmable Logic Controller (PLC) hardware, high-density I/O modules, pre-wired conversion assemblies, and industrial Human-Machine Interface (HMI) operator terminals, inclusive of incidental engineering, turnkey physical installation, logic migration, Operational Technology (OT) cybersecurity hardening, and commissioning.

· 3.0 MB user memory

· Dual configurable 1Gb Ethernet ports

· CIP Security support

· DIN-rail mounted

· 24VDC system/field power

· High-density 5069 discrete input module

· Isolated channel groups

· Removable terminal block compatibility

· High-density 5069 discrete AC output module

· Fused channel protection

· Removable terminal block compatibility

· Universal current (4-20mA) / voltage (o-10V) inputs

· 16-bit resolution

· Channel-to-channel isolation

· Includes mounting chassis plates

· Intermediate conversion blocks

· Pre-molded interface harnesses designed to snap directly onto existing legacy 1746 removable terminal blocks without field wire landing

· Minimum 8 copper 10/100/1000 Base-T ports

· 24VDC redundant power input

· DIN-rail mounted

· Layer 2 management

· CIP/DLR support

· Minimum 10.4” color TFT touchscreen

· Dual Ethernet ports (DLR)

· 24VDC powered

· NEMA 4X / IP66 front rating

· Minimum 12.1” color TFT touchscreen

· Dual Ethernet ports (DLR)

· 24VDC powered

· NEMA 4X / IP66 front rating

· Pre-engineered adapter kits engineered to fit existing legacy PanelView 1000 and PanelView 1250 door cutouts with zero cutting, punching, or drilling of sheet metal

· 120VAC input to 24 VDC output

· DIN-rail mount

· Minimum 10A rating

· NEC Class 2 compliant

· Overvoltage and short-circuit protection

· Field wire audit

· Logic refactoring (.RSS to .ACD)

· Zero-cutout HMI physical installation

· 100% loop check

· Live SAT

· OT cyber hardening

· 16 hours training

Controller & I/O Architecture

1. Processor Compatibility & Sizing: The replacement controllers shall be Allen-Bradley CompactLogix 5380 series processors with integrated safety/standard logic execution, support for Studio 5000 Logix Designer (v32 or later), native CIP Security, and dual embedded gigabit Ethernet interfaces capable of Device Level Ring (DLR) topology.

2. I/O Channel Integrity: The hardware shall provide direct functional equivalence to the legacy SLC 500 system:

· PLC 1: Minimum 32 discrete inputs (120VAC) and 64 discrete outputs (120VAC Triac).

· PLC 2: Minimum 32 discrete inputs (120VAC) and 64 discrete outputs (120VAC Triac).

· PLC 3: Minimum 32 discrete inputs (120VAC), 48 discrete outputs (120VAC Triac), and 16 analog inputs (configurable 4–20mA / 0–10V).

3. Pre-Wired Conversion Kits (Rockwell Bulletin 1492): To prevent wire landing errors and maintain operational cutover deadlines, conversion hardware must mate directly with the existing legacy 1746 removable terminal blocks (RTBs/wiring arms). Manual, point-by-point field wire re-termination is prohibited.

Operator Interface Terminals (HMIs)

1. Display & Operational Characteristics: Touchscreen color displays with high-resolution graphics, native FactoryTalk View ME runtime execution, and dual-port Ethernet.

2. Zero Sheet-Metal Cutout Alteration: All replacement terminals shall be installed using Rockwell OEM adapter bezel kits (Bulletin 2711P adapter plates). The installation shall require zero cutting, drilling, sawing, punching, or grinding of existing enclosure doors, preventing conductive metallic shavings and hot-work hazards inside active control rooms, while preserving a NEMA 4X / IP66 front environmental seal.

Incidental Services: Installation, Cutover, & Commissioning Requirements The following engineering, physical installation, and integration tasks are procured as incidental to the purchase of the supplies to deliver fully integrated and operational automation systems:

Field Discovery & Master I/O Chart Generation

· Because legacy control prints are outdated or nonexistent, the Contractor shall conduct an initial physical audit to verify circuit terminations, wire tags, and register mappings across PLC 1, PLC 2, and PLC 3.

· The Contractor shall generate and deliver a comprehensive Master Input/Output (I/O) Chart (searchable PDF and editable Excel) linking legacy SLC addresses, physical wire numbers, field device descriptions, new Logix tag names, and conversion pinouts prior to panel cutover.

Mandatory Operational Outage Constraint & Daily Business Hours Rule Because the automation systems support mission-critical facility utilities, cutover downtime must be strictly minimized and controlled:

· Total Outage Window: Maximum of eighty-one (81) consecutive elapsed hours per cabinet (Monday 06:00 to Thursday 15:00).

· Daily Business Hours Rule: Active contractor on-site physical labor, wiring, and testing shall occur strictly between 06:00 and 18:00 (6:00 AM to 6:00 PM) Monday through Wednesday, and 06:00 to 15:00 on Thursday (maximum 45 cumulative active work hours).

· Overnight LOTO Security Envelope: Between 18:00 and 06:00, target control cabinets shall remain closed, locked, and de-energized under joint Government/Contractor Lock-Out/Tag-Out (LOTO) controls. No overnight contractor labor is authorized.

· Go / No-Go Decision Board (Wednesday 17:00): Government and Contractor shall review test logs. If point-to-point verification is incomplete, contingency remediation is evaluated.

· Hard Rollback Protocol (Thursday 08:00): If modern hardware or logic displays unresolvable faults by 08:00 Thursday, the Contractor shall execute rollback to legacy hardware within the remaining 7 hours to restore facility operations by Thursday 15:00.

Logic Translation & Tag Refactoring

· Migrate existing RSLogix 500 programs (.RSS) into native Studio 5000 (.ACD) formats, converting legacy register addresses (e.g., , ) into human-readable user-defined tag structures mapped to the Master I/O Chart.

· Migrate legacy PanelView graphic applications (.PBA / .APA) into FactoryTalk View ME (.MER) runtimes, ensuring complete functional equivalence of displays, alarms, setpoints, and security access.

Tier 2 MicroLogix 1400 Fleet Servicing (29 Units)

· Incidental on-site servicing for twenty-nine (29) operational MicroLogix 1400 PLCs during standard business hours (maximum 4 hours per unit).

· Extract and archive verified offline ladder logic (.RSS); update firmware to the latest manufacturer Long-Term Support (LTS) release via ControlFlash Plus; permanently disable unencrypted web daemons (HTTP), BOOTP/DHCP broadcasts, and unauthenticated programming sockets per NIST SP 800-82.

OT Cybersecurity Hardening

· Conformance with NIST SP 800-82 (Rev 4) and UFC 4-010-06.

· Physically cap and administratively disable all unused Ethernet ports on switches, PLCs, and HMIs; disable plaintext protocols (Telnet, HTTP, SNMPv1/v2); enable CIP Security where applicable; deliver an OT Cybersecurity Hardening Report with port scan verification.

Site Acceptance Testing (SAT) & Technical Instruction

· Execute 100% loop check and live load SAT witnessed by the COR during Phase E (Thursday 06:00–15:00), exercising every discrete/analog loop and safety interlock.

· Deliver sixteen (16) cumulative hours of on-site technical instruction to CCAD technicians covering system diagnostics, 1492 module replacement, I/O chart troubleshooting, and program backup/recovery.

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