When to modernize?

[Anonymous user]

What are the reasons driving our customers to modernize their dated systems? This article was written several years ago but is still true. https://blog.se.com/machine-and-process-management/2013/05/08/is-it-always-true-if-it-aint-broke-don...

Please share your thoughts. Any questions on modernizing legacy PLC systems?

[RoozeeR]

Problem modernizing (PLC) systems is the funding. When a modernized system is acting the same way as it did before, it's hard to get budget for this.

Main arguments not to modernize are: " it is still functioning, we had any issue in years, we have a lot of spare parts".

My experience finding the best possible arguments to modernize are:

- Cybersecurity. Company's who have to comply to cyber security standards and solutions:

- Old software (Concept, Modsoft, ProWorX, X-Tel) is not supported on latest Microsoft platforms, Windows-XP and even older systems are not allowed by the IT department

- Old (hardware) platforms do not comply to cyber security standards

Interruption of production due to a cyber security issue, will cost a lot of money and reputation. 

Today, cyber security is becoming even more important as  pandemic issues ask for (more) remote monitoring, diagnostic and remote maintenance, which also implies the need for secured remote access.

But always keep your eyes and ears open for other arguments, as customer demands will differ.

[Anonymous user]

In most cases maintenance think about modernisation when installed PLCs are becoming out of service and there no possibility to repair machine anymore in case of failure.

And the biggest problem in this term is the PLC program, who designed it, who will be the designer for the new platform and how to transfer the existing one to the new platform without failure or minimize failure risk,

[Anonymous user]

Modbus Plus migration to Ethernet with existing customers has been a sticky point in the migration path moving forward.

With legacy Modbus Plus modules supporting built in power supply modules and fiber ports such as Quantum Modbus Plus DIO , we need to provide better migration solutions from Modbus Plus to Ethernet for our customers

[AlastairF]

I've been working in this space for any years (from Modicon 484) with quite a few migrations completed.

ModBus Plus is legacy communications and the customers need to move on and change to Ethernet.

ModBus Plus has been great though. Never really saw anything to equal it amongst the competitor comms.

We don't have an equivalent to the ModBus Plus Quantum DIO master (inc built in PSU). In most instances you can get away with a BMXPRA as the front end but where you are replacing Quantum DIO in a full 16 slot rack you can have issues around space.

Once we get 16 slot X80 racks the the task is easier. There will also be a BMEPRA module available at some stage.

Also the X80 PSU doesn't impact on the rack slot count.

Fibre support can be done with BMXNRP module.

For customers who don't want to move from ModBus Plus, they need to sit down and assess their commercial risk in trying to keep it. It's a bit like using an old Win XP PC, you are really pushing your luck.

[Anonymous user]

Excellent points and valid reasons to upgrade older systems. I don't think that customers think of these reasons only does the hardware still work, if so why upgrade it?