Record the installed system
Capture full model suffixes, drawings, software versions, option cards, network roles and machine photos.
Engineering migration
Move the machine, not just the part number
An automation migration is a controlled rebuild, not a catalog swap. Start with the installed part numbers, source projects, drawings, I/O, networks and required machine behaviour. Then compare candidate hardware, rebuild the agreed logic and screens, test failure states and commission with a rollback plan. Every cross-brand candidate remains subject to engineering review.
Five steps from evidence to site acceptance
Define what must stay
List the required sequence, I/O, alarms, recipes, motion, safety, certificates and operator workflow.
Compare candidate hardware
Check ratings, terminals, mounting, protocols, device files, environment and lifecycle evidence.
Rebuild and bench-test
Re-implement the agreed logic, screens and communication, then test I/O and failure behaviour away from production.
Commission with a rollback plan
Back up the old system, document acceptance tests and keep a clear route back if site validation fails.
What carries over, and what must be checked again
| Area | Useful source evidence | Revalidate in the target system |
|---|---|---|
| Control | Sequence, comments, I/O list and alarm intent | Instructions, data types, scan timing, libraries and interlocks |
| HMI | Screen flow, tags, recipes and alarm text | Drivers, ports, tag map, cutout and project ownership |
| Network | Topology, node list, roles and data map | Device files, timing, diagnostics, security and fault response |
| Safety | Risk assessment and required machine functions | Architecture, devices, validation and applicable certification |
- No one-click program conversion is promised.
- A matching protocol name does not prove the same network behaviour.
- Safety and certification are reviewed separately from standard control.
- Availability, documents, timing and commercial scope are confirmed at RFQ.
Start from the installed brand or exact part number
The candidate route depends on the component class. Start from the family the installed part belongs to, or send the part number and we will map it.
Standards references: IEC 61131-3 programming languages and the EtherCAT Technology Group ESI reference.
Migration questions engineers ask before committing
Can a PLC program be converted automatically to another brand?
Do not assume it can. The old project is an engineering reference. Logic, tags, hardware configuration, libraries, communications and timing must be reviewed and often rebuilt in the target software.
What files should I collect before a PLC migration?
Collect the editable source project, current backup, I/O list, electrical drawings, network map, software and firmware versions, alarm list, recipes, option-card details and photos of every nameplate.
Can I keep the existing HMI during a controller migration?
Sometimes. Reuse depends on the exact HMI, available drivers, ports, firmware, tag structure and project access. Confirm these before choosing the controller or promising screen reuse.
How do I compare an old VFD with a candidate drive?
Start with the motor nameplate, supply, load, current, speed range, braking, duty, terminals, control method, communications, enclosure and safety functions. Model power alone is not enough.
What makes an industrial network migration risky?
Matching protocol names do not prove the same device roles, data map, cycle timing, diagnostics or failure response. Record every node and confirm the target device files and topology.
How long does an automation migration take?
Timing is confirmed after the source files, machine scope and site-access window are reviewed. Missing passwords, undocumented logic, proprietary libraries and safety validation usually add uncertainty.
When should I keep the existing automation platform?
Keep it when the machine depends on unsupported safety, proprietary networks, validated libraries, mandatory certificates or a maintenance standard that the candidate system cannot meet.
What do you need to review a migration request?
Send the installed part numbers, editable project or backup, drawings, network and I/O details, required machine behaviour, destination, quantity and target date. Unknown items can remain open.
Request migration review
Send what you have today
A model list, drawing, backup or short machine description is enough to start. Missing items stay open until confirmed.