What does the migration of a Siemens S7-300 PLC to S7-1500 look like?

Migration of PLCs from the S7-300 series to the newer S7-1500 generation requires transferring the project from the Step7 Classic environment to TIA Portal. Such a PLC migration includes conversion of code logic, reconfiguration of hardware, and adaptation of the network to the Profinet standard, which allows transforming obsolete systems into modern control standards.

How does a PLC migration project proceed from inquiry to commissioning?

After receiving an inquiry, our team thoroughly analyzes your needs and the specifics of the project. Then our dedicated Team Leader contacts you to discuss details, schedule, and scope of work. After the offer is accepted, we begin implementation, providing regular progress reports and maintaining open communication at every stage. After implementation is completed we conduct training and offer after-sales support.

How long does PLC migration take and what does the duration depend on?

The typical preparation phase for commissioning a project can last from several weeks to several months. The duration depends on the scale of the undertaking, the number and complexity of machines, their components, as well as the functions and processes handled. The more complex the system, the more time is needed for analysis, design, programming, and testing.

What do the costs of PLC migration depend on and how is the pricing determined?

The cost of PLC migration depends on the complexity of the system, the number of controlled devices, the complexity of the control logic, as well as the need to integrate with higher-level systems, required tests, and documentation. An accurate estimate is possible after a detailed specification of the technical requirements.

Do you provide on-site support during commissioning?

Yes, the nature of our work requires it. We provide on-site support during testing and production start-up, ensuring smooth system implementation and minimizing downtime.

Do you conduct training for operators and engineers?

Yes, in almost every project we undertake we conduct training for operators and maintenance personnel. The scope, duration, and location of the training are always agreed individually with the client.

Migration of PLC controllers

Q: Is PLC migration possible without documentation?

Technically, PLC migration without documentation is possible. In some cases the process proceeds smoothly, but if the old code is unreadable, recreating the logic can prove problematic. To avoid surprises, every such project we undertake begins with an audit, which allows us to realistically assess the level of difficulty and estimate the project before starting work.

We provide comprehensive support in PLC controller migration for automation integrators and machine manufacturers who are seeking a stable technological partner. We transform existing applications into modern control standards, ensuring a trouble-free start of modernized production lines.

What does the PLC controller migration service include?

Migration of PLC controllers We carry out projects based on a full implementation cycle – from a detailed analysis of the existing infrastructure, through adaptation of control logic, up to commissioning and on-site technical assistance. We tailor the software architecture and hardware configuration each time to the specifics of the process, replacing outdated systems with modern automation platforms. Our activities aim to increase reliability and ensure the continuity of operation of machines and production lines. Our competencies in this area include:

Analysis of the existing infrastructure and technical documentation.

Selection of appropriate controller hardware and industrial networks.

Migration, reprogramming and optimization of the existing control logic.

Integration with higher-level systems, such as MES, SCADA or HMI.

Configuration and commissioning of industrial networks (Profinet, ProfiBus, Ethernet, ModBus).

Testing the functionality and performance of the new control system.

Production launch and technical support.

Training of operators and maintenance personnel.

Why is it worth entrusting us with the migration of PLC controllers?

Our many years of experience in implementing complex automation projects for global industry leaders allows us to offer not only technical support but, above all, practical know-how. We understand the challenges our clients face, delivering solutions that actually streamline production.

Your safety is nasz priority

Implementing a control system is an investment that must be predictable and safe. We limit production risk to a minimum thanks to clear procedures:

A rigid division of responsibilities in the contract: We clearly define the technical conditions and system boundaries (who is responsible for the cables, who for the signals, and who for the higher-level integration), which eliminates decision-making delays during start-up.

Fixed scope of work: We precisely list the functions, HMI screens and signals to be migrated before running the first line of code. You know exactly what will work and how after the modernization.

Checklist-based startups: We carry out each stage — from backing up the old program, through dry runs, to the final start of the machine — according to rigorous checklists, which precludes omission of critical interlocks or safety systems.

We prioritize transparent communication and partnership-based relationships.

Control system migration projects entail significant responsibility and time pressure. Therefore, transparent and clear communication is key to efficiently tracking work progress and rapidly responding to unexpected technical challenges on-site. To ensure full predictability at every stage of implementation, we base our cooperation on three simple principles:

Dedicated lead engineer: You contact the project’s technical lead directly. This is the engineer who is responsible for the system architecture, knows the status of the work and is the decision-maker on our side, which shortens the response time during key start-up phases.

Communication without language barriers: We select our teams so they can communicate efficiently with all parties involved in the project. This allows for direct, quick arrangements and eliminates misunderstandings at every stage of the migration.

Experience-based consulting: Thanks to years spent on-site, we understand the business and process context of projects. We can take a broader view of the system, recommend optimal solutions, and help make technical decisions.

Experienced team full-time programmers

The automation market suffers from a shortage of specialists, which often causes projects to end up in the hands of unproven subcontractors. At Amister we eliminate this risk. Your system is migrated by our full-time engineers, who are responsible for the success of the implementation.

Familiarity with the standards of automotive giants: Our team possesses specialist knowledge backed by certifications, including the rigorous software development and commissioning standards for the largest manufacturers. We deliver solutions that pass the most demanding technical acceptance tests.

Full responsibility from A to Z: The same engineers who analyze the old system and prepare the new code then implement it on-site. Such personnel continuity eliminates communication errors and guarantees a smooth start-up.

Readable code and easy diagnostics: The experience of our programmers translates into the quality of the program. We create a modern, readable architecture and intuitive diagnostics on HMI screens, so your maintenance team will have no trouble operating and servicing the machine in the future.

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Selected technologies that we use in the migration of PLC controllers

In industrial automation, hardware standards are most often predefined by the plant specification or the corporation’s global guidelines. Our team operates seamlessly within the technological environments specified by the client, ensuring full compliance of the new code with the existing machinery.

Siemens ecosystem (S7-300/400 to S7-1200/1500)

We migrate worn-out Step7 (Classic) systems to the modern TIA Portal environment. We rewrite the code, replace distributed I/O islands and optimize communication, ensuring full compatibility with the new generation of controllers.

Rockwell Automation / Allen-Bradley and GE Fanuc platforms.

We carry out migrations of older controllers (e.g., Allen-Bradley SLC 500, PLC-5 or GE Fanuc systems) to the modern ControlLogix / CompactLogix architecture using Studio 5000. We ensure seamless mapping of existing logic and signals.

Beckhoff and Wago systems

We modernize applications based on PC-based Automation (TwinCAT) and modular WAGO systems. We integrate advanced motion control functions and optimize the distributed architecture on-site.

Migrations and reconfiguration of industrial networks

Replacing a controller is often a necessity to move from old network standards to new ones. We configure and commission stable communication on-site, migrating older networks (e.g. Profibus DP, Modbus RTU, DeviceNet) to modern Ethernet-based standards (Profinet, Ethernet/IP, EtherCAT).

The above list is our main working environment, but it does not limit our portfolio. If your facility uses systems from other leading manufacturers, let us know. We will analyze the architecture of your system and match a team with the appropriate competencies.

Do you want to safely modernize the automation systems in your plant?

Take advantage of our experience in migrating PLC controllers.

In which processes do we perform PLC controller migration?

Our PLC programming services are used across a wide spectrum of industrial sectors. We adapt our solutions to the specifics of each sector, ensuring process optimization and maximization of efficiency.

Pick-and-place

Transfer of control algorithms for fast manipulators and component pick-and-place systems to the new PLC architecture.

Assembly

Safe transfer of sequential logic and control algorithms for lines and assembly stations to a new platform.

Dosage

Update of the software responsible for precise metering, media application and control of dosing systems.

Labeling and marking

Conversion of programs controlling the operation of applicators and synchronization of signals triggering printing.

Quality control

Restoring stable communication between the new controller and inspection systems and measurement sensors.

Testing

Adapting PLC logic to operate test stations, collect data from tests, and transmit it to supervisory systems.

Palletization

Modernization of the control and coordination of signals in the end zones of the lines responsible for arranging products.

Machine operation

Migration of programs controlling the operation of feeders, manipulators and systems for loading and unloading parts.

How do we work with our clients?

Our deployment experience shows that every migration project has its own characteristics — sometimes there are not enough people on-site to actually write the code, and at other times a complete takeover of hardware modernization is required. Therefore, we tailor the form of cooperation directly to your team’s resources and the stage of the work, offering two clear models for dividing responsibilities:

Model 1: Support as a subcontractor

We act as a direct reinforcement of your engineering team. We handle the implementation of controller code and assist during on-site machine commissioning. This is a solution for integrators and machine manufacturers (OEMs) who need additional PLC programmers to meet deadlines stress-free.

Model 2: Turnkey implementation

We take full responsibility for the modernization. We conduct an audit of the old controller, select new hardware, prepare the software and commission the machine on site. This option is intended for plants that want to entrust the entire migration process to a single contractor.

Industry leaders trusted us

Star Assembly SRL

Sebeș, Romania

Audi

Gyor, Hungary

BMW

Steyr, Austria

Stellantis

Mirafiori, Italy

BMW

Dingolfing, Germany

Daimler

Brühl, Germany

NIDEC

Niepołomice, Poland

Skoda

Mlada Boleslav, Czech Republic

Liebherr

Bischofshofen, Austria

Festo

Budapest, Hungary

Daimler

Untertürkheim, Germany

Dana

Amal, Sweden

Examples of projects with migration of PLC controllers

Implementation of new types on the cylinder head assembly line and the block lines (Škoda Auto) Mlada Boleslav

Project objective: Implementation of new production variants and optimization of cylinder head and engine block assembly processes on existing production lines, while maintaining full backward compatibility.

PLC Automation: The project included modification and adaptation of Siemens S7 controller software (S7-300 family), migration to newer PLC controllers, and integration of Sinumerik panels at selected stations.

Scope of work: Comprehensive changes were made to the PLC code for both automatic and manual stations. The production cycle time was shortened, and advanced press-fitting, gluing, and leak testing processes were integrated and optimized. Integration with the higher-level IMIS system, vision systems, drives, and Trumpf laser engravers was also implemented.

Technologies: PLC controllers: Siemens S7-300, Sinumerik panels; Process devices: Bayer (KWP press-fitting systems, DLP leak tests), Kistler (maXYmos press-fit monitoring), DreiBond (gluing system), Trumpf (laser engraver), Keyence and Cognex (vision systems), Sinamics and SIMODRIVE (drives).

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FAQ – Frequently Asked Questions

What does the migration of a Siemens S7-300 PLC to an S7-1500 look like?

Migration of PLC controllers from the S7-300 series to the newer-generation S7-1500 requires transferring the project from the Step7 Classic environment to TIA Portal. Such a PLC migration involves conversion of code logic, hardware reconfiguration, and adjustment of the network to the Profinet standard, which enables transforming outdated systems into modern control standards.

Is it possible to migrate PLC controllers without documentation?

Technically, PLC controller migration without documentation is possible. In some cases the process proceeds smoothly, but if the old code is unreadable, reconstructing the logic can prove problematic. To avoid surprises, every such project carried out by us begins with an audit that allows us to realistically assess the level of difficulty and to price the project before work begins.

How does a PLC controller migration project proceed from inquiry to commissioning?

Upon receiving an inquiry, our team thoroughly analyzes your needs and the specifics of the project. Then our dedicated Team Leader contacts you to discuss the details, schedule, and scope of work. After the offer is accepted, we proceed with implementation, providing regular progress reports and open communication at every stage. After the implementation is completed, we conduct training and offer after-sales support.

How long does the migration of PLC controllers take and what does the time depend on?

A typical preparation stage for commissioning a project can last from several weeks to several months. The duration of implementation depends on the scale of the undertaking, the number and complexity of the machines, their components, as well as the functions and processes handled. The more complex the system, the more time is required for its analysis, design, programming and testing.

What do the costs of PLC controller migration depend on, and what does the pricing look like?

The cost of migrating PLC controllers depends on the complexity of the system, the number of controlled devices, the complexity of the control logic, as well as the necessity of integration with higher-level systems, the required tests and documentation. An accurate quotation is possible after a detailed specification of the technical requirements.

Do you provide on-site support during startup?

Yes, the nature of our work requires it. We provide onsite support during testing and production launch, ensuring a smooth system deployment and minimizing downtime.

Do you provide training for operators and engineers?

Yes, in almost every project we carry out we conduct training for operators and maintenance staff. The scope, time and place of the training are always agreed individually with the client.

Contact us – we’ll respond within 24 hours!

Do you have questions regarding migration of PLC controllers? Fill out the contact form, and our team will contact you within 24 hours – by phone or by email.

During a conversation or correspondence we will jointly determine the scope of the work and services you are interested in. Then we will carry out an internal analysis of your inquiry to prepare the best possible solution.

We will get back to you with information about the next steps within a maximum of 5 business days.

Take a step towards modern automation – fill out the form right now!

Jakub Urbańczyk

Vice President of the Management Board