PLC migration
The overview below describes migration paths for existing PLCs. We start with the software, I/O and communication already in place. We assess what can be prepared during production and what requires downtime for each installation.
Platform overview
| Existing platform | Migration path |
|---|---|
| Siemens S5-90/95 | S7-1200 or S7-1500 |
| Siemens S5-100/115 | S7-1500 |
| Siemens S5-135/155 | S7-1500 / ET 200SP |
| Siemens S7-300 / ET 200M | S7-1500 + TIA Portal |
| Siemens S7-400 | B&R Redundant CPU / Siemens S7-1500H (redundant) |
| Allen-Bradley PLC-5 | B&R X20 / APC / Siemens S7-1200 / S7-1500 |
| Allen-Bradley SLC 500 | B&R X20 / APC / Siemens S7-1200 / S7-1500 |
| GE Fanuc 90-30 | B&R X20 / APC / Siemens S7-1200 / S7-1500 |
| GE Fanuc 90-70 | B&R X20 / APC / Siemens S7-1200 / S7-1500 |
| Schneider Modicon 984 | B&R X20 / APC / Siemens S7-1200 / S7-1500 |
| B&R 2010/2005 | B&R X20 or Siemens S7-1500 |
| Omron C200H / CQM1 | B&R X20 / APC / Siemens S7-1200 / S7-1500 |
| Pilz PSS3000 | B&R Safety / Siemens S7-1200F / S7-1500F (Safety CPU) |
| WAGO | WAGO / Siemens S7-1200 / S7-1500 / B&R X20 / APC |
These are possible migration directions. The final choice depends on current availability, I/O, communication, software and safety requirements. We assess these for each installation before recommending a replacement system.
Redundancy and safety CPUs
For high availability, we work with B&R Redundant CPU or Siemens S7-1500H. We also include safety CPUs in migration projects, including replacing Pilz PSS3000 with B&R Safety or a Siemens S7-1200F / S7-1500F safety CPU. Redundancy and functional safety are separate requirements: we assess safety functions, I/O and validation for each installation.
We can modernise an older WAGO controller with a new WAGO system or replace it with Siemens or B&R. We select the platform based on the existing software, I/O, communication and required functions.
What needs to change in your installation?
Tell us what is already installed and what you are running into.