PLC, HMI and servo · Upgrade and migration
PLC and HMI migration, upgrade and retrofit
When a PLC, HMI or servo family goes obsolete, the risk is not the next failure but the one after it, when no spare is left. We repair the old system to keep you running, then plan and carry out the move to a current platform: audit, program conversion, I/O mapping, panel changes, staged testing and cut-over with a rollback plan.
Common migration paths
| From (legacy) | To (current) | Detail |
|---|---|---|
| Siemens S5 (S5-90U to S5-155U) | S7-1200 / S7-1500 with TIA Portal | Siemens migration |
| Siemens S7-300, S7-400, Step 7 | S7-1500, ET 200SP, TIA Portal | Siemens migration |
| Allen-Bradley PLC-5, SLC 500, MicroLogix | ControlLogix, CompactLogix, Micro800 | Allen-Bradley migration |
| Mitsubishi A and QnA series, FX1/FX2/FX3 | Q, iQ-R, iQ-F (FX5) | Mitsubishi migration |
| Omron C200H, CQM1, CS1, CJ1 | CJ2, NJ, NX1P | Omron migration |
| Modicon Quantum, Premium, TSX Micro | M580, M340 | Planned per site |
| GE Fanuc 90-30, 90-70 | PACSystems RX3i | Planned per site |
| Old HMIs: PanelView, Siemens OP/TP/MP, Pro-face GP, Mitsubishi GOT | PanelView 5000, Siemens Comfort and Unified, Pro-face GP4000/ST6000, GOT2000 | HMI replacement |
| Servo: Simodrive 611, Kinetix 6000, MR-J2S, Sigma-II | Sinamics S120, Kinetix 5700, MR-J4/J5, Sigma-7 | Servo system upgrades |
How a migration runs
Audit
Hardware, I/O, program, network.
Plan
Platform, I/O map, panel changes.
Convert
Program and HMI rebuilt and commented.
Test
Simulation, then panel test.
Cut-over
Staged start-up, rollback ready.
What you get
- Audit report with the risk of each obsolete part
- Converted and commented PLC program and HMI screens
- Updated electrical drawings and I/O list
- Factory test record and site commissioning sheet
- Training for your maintenance team
- Spares list for the new system
Keeping the old system alive
Until cut-over, we repair PLC, HMI and CNC modules at component level and supply obsolete spares from stock or sourcing.
Questions
Can you keep the old system running until the migration?
Yes. We repair the legacy PLC, HMI and drive modules and source obsolete spares, so the machine keeps running while the new system is prepared.
Do you need our original program?
A backup helps a lot. If there is none, we upload what is in the PLC and document it before conversion.
How long is the shutdown?
Most of the work is done before cut-over: program conversion, panel building and testing. The shutdown is planned for the shortest window the plant can give, with a rollback plan.
Do you migrate HMIs without changing the PLC?
Yes. An HMI can often be replaced on its own when the old panel fails and spares are gone.
Send the nameplate or encoder label
A clear photo of the motor nameplate and, if the cover is off, the encoder label is enough to start. We reply with whether it can be repaired and a quote.
Message received
Our team replies by email or WhatsApp, usually the same working day. For a line-down motor, WhatsApp +91 97866 22233.