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Mukilteo, WA
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Inspiration. Innovation. Industrial Integration.

Legacy Migration - Not all About Reducing Risk

With almost 40 years of experience helping companies build and automate everything from bread lines to bridges, we KNOW that trying to determine whether to repair or replace a legacy system can be a frustrating decision. Systems Interface is here to help make it as painless as possible.

Manufacturers are concerned about the risk aspects of legacy control systems. Not just the higher costs of a less reliable supply of replacement components but also the increasing scarcity of knowledgeable resources capable of maintaining the legacy assets. A more recent major risk is that legacy systems can pose a cybersecurity vulnerability.

The upside of mitigating the obsolescence risk is a resulting modern ethernet-connected control system platform that enables investment in process optimization and digital transformation. The modern platform enables the use of ethernet and IO-Link smart sensor technology for smart machine/process performance and reliability improvements. Modern control system platforms can also participate in a secure centrally-managed infrastructure.

Our Approach

Why Trust Your Legacy Migration to Us?

With a quarter or more of our business being legacy migrations, we have extensive knowledge and experience with most vendor migration methods and tools. We have migrated Allen-Bradley, Siemens, TI, Modicon, and other major systems. 

Our team has experience migrating systems from small 100 I/O standalone systems to large distributed 2500+ I/O systems to ControlLogix®. Through our project experience deploying systems and migration solutions, we can help you develop a migration strategy that considers both production risk and budget. We are confident that through our extensive project experience, we can provide you with a cost-effective and risk-reduced path. If you’re not ready to fully dive in, we can also develop a phased approach plan to meet your needs and help get you prepared.

Tools & Resources

Migration Strategies and Tools Overview

Rockwell conversion technologies brochure

Modernization Overview

The modernization of PLC-5 Controllers and 1771 I/O to ControlLogix.

Rockwell 1771 Swing Arm Production Selection Guide

In situations where downtime is limited, this is a great option for reducing time to physically migrate PLC-5 to ControlLogix.

1756-RIO For Large System Phased Migration

ControlLogix Remote I/O Communication Module.

RSView32 to FactoryTalk View SE Modernization

Modernizing your HMI will help get you ahead of the smart manufacturing trend.
On PLC Migration projects of this nature, Systems Interface will work with you to upgrade the original schematics, convert the ladder logic to the new platform and fully test the control system once installed.

The amount of downtime required can vary, and we can schedule the migration to have minimal impact on your plant. We can arrange for after-hours, weekend, or scheduled maintenance downtime as well.

Systems Interface engineers are familiar with Allen-Bradley, Siemens, Texas Instruments, GE, Toshiba, and other manufacturers.
Future Proof Matters

Ready to Discuss your options?

Embrace the future by migrating your legacy systems to secure, efficient, and cutting-edge technology. Legacy migrations for industrial control systems are not just an option; they are a necessity for the sustainability and growth of your operations
Inspiration. Innovation. Industrial Integration.