Migration of Control Systems
Plenty of plants still run controllers and variable frequency drives (VFDs) that are 15 to 20 years old, no longer supported and with no spare parts available. We handle the full migration: surveying the existing logic, porting it to a current platform, replacing obsolete equipment, updating the operator interfaces and testing exhaustively so your process keeps running with no surprises.
When is it time to migrate?
No spare parts available
The manufacturer no longer makes the control card or the I/O module you need. One failure means weeks of downtime waiting for a used spare.
No technical support
Nobody can program, troubleshoot or modify your PLC or VFD because the software is two decades old and can no longer be licensed.
Growing operational risk
Wear components (electrolytic capacitors, fans) have a finite service life. Over the years, the probability of failure rises and spare parts become scarce.
A need for new functionality
Your process has evolved but the controller cannot take more I/O, modern communications or new protection logic.
How we execute a migration
Survey of the existing system
We document the PLC, I/O, HMI, VFDs and the existing control logic. If there are no drawings, we produce them.
Porting the control logic
We reproduce the original logic on the new platform. We do not reinvent your process — we migrate it faithfully and then optimize.
Selection of equivalent equipment
We map every obsolete component to its current equivalent. Danfoss VFDs, Siemens PLCs, compatible HMIs.
Panel retrofit
We build a new panel or adapt the existing one to take the new equipment. We keep mechanical changes to a minimum.
Phased migration
Where possible, we migrate section by section to reduce plant shutdown. Each phase is tested on its own.
Validation and documentation
SAT testing with the real process, parameter optimization, handover of as-built drawings, backups and training.
Migrations delivered
Three steps and typical lead times
Lead times depend on the size of the system. These are typical for a line or station with one PLC and a few VFDs.
- 01 Typical time 1–2 weeks
Survey of the current system
We document the PLC, I/O, HMI, VFDs and logic on site. If drawings or backups are missing, we produce them.
- 02 Typical time 3–6 weeks
Engineering and shop testing
Logic reproduced on the new platform, a new or retrofitted panel and shop tests before anything is touched in the plant.
- 03 Typical time 4–8 h per stage
Cutover in shutdown windows
When the process allows it, we migrate section by section; each stage is tested with the real process before moving on to the next.
If you only need to replace drives without touching the PLC, see our retrofit of obsolete VFDs.
If the migration is part of a larger project, see our industrial automation in Panama.
What clients ask before we start
Short answers to the questions that usually come up in the first technical conversation. Exact lead times are confirmed in the proposal.
Q01 Does the whole plant have to stop for the migration?
Q02 What if there are no drawings or program backups?
Q03 Does the migration change how the process runs?
Q04 Do you also migrate the drives?
Do you have obsolete equipment with no support?
We assess your current system and hand you a migration plan with scope, cost and schedule.
Request a migration assessment