PLC Controller Migrations
Outdated PLC controllers pose daily risks:
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Sudden failures with no quick repair options
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Lack of spare parts-weeks of waiting for components
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Unplanned, costly production downtime
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No security updates-exposure to cyberattacks and data loss
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Rising maintenance costs for old equipment and increasingly difficult access to specialists
Without migration, these issues escalate until they eventually halt production for days or weeks-along with revenue, delivery deadlines, and your reputation with customers.
If you recognize any of these signals, it’s time to act before downtime becomes a reality.
- Inventory of existing controllers, input/output modules, communication interfaces, and software.
- Assessment of the new controller's compatibility with the current hardware and software.
Analysis of the current system
- Analysis of the existing PLC code (if available).
- Conversion of the program to the new controller (manual or automatic, if migration tools are available).
- Testing the functionality of the code on the new PLC.
PLC program migration
- Adjustment of communication protocols (e.g., Ethernet/IP, Profinet, Modbus).
- Updating the configuration of operator interfaces (HMI) and supervisory systems (SCADA).
Integration with SCADA/HMI systems and communication networks
- Defining performance requirements, input/output counts, communication protocols, and functionalities.
- Selecting the appropriate PLC model that meets the application's requirements.
Selection of a new PLC controller
- Checking the compatibility of existing I/O modules with the new controller.
- Replacing modules with new ones if required.
- Adjusting wiring and configuration.
Modernization of input/output systems
- Conducting tests in a simulated environment.
- Testing on the object under real conditions.
- Optimization and verification of correct operation.
Testing and launching
Stages of PLC conrtoller
migration:
Benefits of PLC controller migration:
Modern controllers are less prone to failure and offer better diagnostic mechanisms.
Increased reliability and safety
New PLCs support advanced communication protocols and the cloud.
Better integration with IT systems
Faster processing of tasks and more memory for more complex programs.
Greater efficiency
Elimination of issues related to the lack of spare parts and technical support for old devices.
Reduction of failure risk
Social media
Company data
Contact
KRS: 0001192368
NIP: 7343660745
33-300 Nowy Sącz
Gen. Józefa Bema St. 35
Manserw Sp. z o.o.