Legacy Control System Migration is, or at some point will be, a very important topic for every manufacturing facility. According to recent statistics, $65 billion worth of installed legacy process control systems have 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.
Cross Company has proven experience in migrating legacy hardware and software systems. Our proven process begins with a risk analysis and site review and discussion with our customer to discuss the end goals and critical aspects of each application. We have the knowledge and expertise to extract the critical information from the existing configurations, graphics, and documentation and even your experienced operations and engineering personnel, a critical area of knowledge often overlooked.
Based on this assessment, we guide our customers through specific recommendations on a migration path best suited for your requirements to minimize cost, risk, and associated downtime.
From a simple HMI upgrade to a GMP validated system and even development of a five to ten-year migration plan for an entire facility, Cross Company can provide complete planning, engineering and commissioning to guide you through this process to successfully achieve your migration and business objectives.
Batch conversions in accordance with S88
Network upgrades – serial and legacy communication upgrades
Platform evaluations and comparisons
System configuration and application conversion
UL508A Panel design and build
Startup and commissioning services
Cross Company has successfully performed upgrades to current supported platforms from the following legacy systems.
ABB Mod 30 Mod 300
Allen Bradley SLC 500, PLC2, PLC5
GE FANUC, 9030, 9070, PAC Systems RS3i
Honeywell UDC 2500, 3200, 3500
Siemens Moore APACS, S5, S7, TI 505
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
Virtually any other brand of PLC/DCS
Fix 32 and IFIX
RSView 32 and legacy Panelviews
Proprietary and Visual Basic HMI’s
Because the associated consequences are so severe, we can all be grateful that the concept of Legacy Migration is very simple. Legacy migration is a process in which obsolete control system hardware and software are upgraded to maintain the current standards – simply, the current technology – so that you can continue to run your facility with a mitigated risk of failure.