1. pl
  2. en

PLC Controller Migration and Replacement

PLC (Programmable Logic Controller) migration involves replacing old or obsolete controllers with modern devices. This is necessary when the existing controllers are no longer supported by the manufacturer, have limited performance, or require modernization to improve reliability, flexibility, and integration with modern automation systems.

Migration from Old PLC Controllers to Modern Solutions
  • Inventory of existing controllers, I/O modules, communication interfaces, and software.
  • Assessment of the new controller’s compatibility with 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 (manually or using migration tools if available).
  • Testing the correctness of the code on the new PLC.

PLC Program Migration:

  • Adapting communication protocols (e.g., Ethernet/IP, Profinet, Modbus).
  • Updating operator interface (HMI) configurations and supervisory (SCADA) systems.

Integration with SCADA/HMI Systems and Communication Networks:

  • Defining performance requirements, number of inputs/outputs, communication protocols, and functionalities.
  • Choosing the appropriate PLC model that meets application requirements.

Selection of a New PLC Controller:

  • Checking the compatibility of existing I/O modules with the new controller.
  • Replacing modules if necessary.
  • Adjusting wiring and configurations.

Modernization of Input/Output modules:

  • Conducting tests in a simulated environment.
  • On-site testing under real conditions.
  • Optimization and verification of proper operation.

Testing and Commissioning:

Stages of PLC Controller Migration:

Benefits of PLC Controller Migration:

Modern controllers are less prone to failures and offer better diagnostic mechanisms.

Increased Reliability and Safety

New PLCs support advanced communication protocols and cloud integration.

Better Integration with IT Systems

Faster process execution and more memory for complex programs.

Higher Performance

Eliminates issues related to the lack of spare parts and technical support

Reduced Risk of Failures

Serwis dla przemysłu

Social media

Contact

kontakt@manserw.pl

+48 698 655 244