Legacy Control System Migration

Migration is or at some point will be a very important topic to every manufacturing facility. According to recent statistics, $65 billion worth of installed legacy process control systems has reached the end of their reasonable life cycle. Many companies do not have the financial resources to perform a complete replacement of equipment or the technical resources to develop a strategy for migration and replacement to more current technologies.

Cost-Effective Migration Strategy

Cross Company Integrated Systems has an extensive amount of experience in integrating many hardware and software platforms and can assist customers in this process. We start by performing an on-site risk analysis and site review. From the acquired information, we can make specific recommendations on a migration path best suited for your requirements to minimize cost, risk, and associated downtime.

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Services Provided

From a simple HMI upgrade to the development of a five to ten-year migration plan, Cross Company can provide the complete planning, engineering and commissioning to achieve your migration and business goals.

We have the knowledge and expertise to extract the required information from the existing legacy configurations, graphics, experienced operator knowledge or old documentation in your facility. Based on this information, we can then provide a complete turnkey solution for your migration needs.

Our turnkey services include:

  • Design specification
  • Development
  • Functional specification development
  • Migration analysis and recommendations
  • Cost analysis for migrations
  • Configuration programming
  • Project documentation
  • Panel build and design
  • Acceptance testing
  • Startup and checkout services

Deployment strategies include:

  • Human machine interface replacement
    Provide a new HMI for communication to legacy system controllers
  • Application conversion
    Conversion of older systems to new releases on current operating platforms
  • Improved Network Gateways
    Replacing old serial interfaces with Ethernet, Fiber or Wireless devices
  • I/O replacement
    Installation of new I/O modules while preserving the wire terminations
  • I/O interfaces
    Maintaining the existing I/O subsystem to be controlled by a new controller
  • Code optimization
    To aid in a future migration by properly documenting the control system
  • Enhanced batch manager
    For S88 Compliance and improved operation

Supported Hardware Platforms:

  • ABB Mod 30 Mod 300
  • Allen Bradley SLC 500, PLC2, PLC5, CompactLogix, FlexLogix, MicroLogix, ControlLogix
  • GE FANUC, 9030, 9070, PAC Systems RS3i
  • Honeywell UDC 2500, 3200, 3500
  • Siemens Moore APACS, S5, S7, PCS7
  • Sixnet EtherTRAK, VersaTRAK RTU’s
  • Square D PLC’s
  • Fisher Provox S10 and S20 series IO
  • Bailey Net 90 and INFI 90
  • Foxboro SPECTRUM or SPEC 200
  • Rosemount RS3
  • Virtually any other brand of PLC

Supported Software Platforms:

  • Wonderware
  • Iconics
  • Citect
  • Factory Link
  • Cimplicity
  • Indusoft
  • Proprietary HMI’s