Migrations

Many of our customers were frustrated by the limits of their control systems, overwhelmed by the complexity of upgrading, and daunted by the cost and downtime involved.

Common Reasons for Migration

  • No Ethernet/IP or Profinet support

  • Limited memory or scan speed

  • No native support for modern HMIs, safety, or motion

  • Parts scarcity and long lead times

  • No remote access or diagnostics capability

 We guide our customers through a low-stress, value-engineered migrations that were phased and risk-managed to reduce pressure, cost, and disruption.

Moving away from obsolete systems like ControlNet, DeviceNet, and Data Highway to Ethernet-based networks delivers value across your business. It simplifies hiring, reduces the risk of extended downtime, shortens repair times, and makes parts easier to source. Just as important, a modern control platform is the foundation for advanced automation, real-time data, and improved safety—now essential for staying competitive in manufacturing.

Obsolete or Overtaxed Networks

Rockwell Automation (Allen-Bradley)

  • Data Highway (DH)

  • Data Highway Plus (DH+)

  • Remote I/O (RIO)

  • DeviceNet

  • ControlNet

  • RS-232 serial links

  • DF1 protocol

Siemens

  • MPI (Multi-Point Interface) — used in S7-300/400 systems

  • Profibus DP — still in use but increasingly phased out in favor of Profinet

  • ASI Bus (Actuator-Sensor Interface) — used in older decentralized I/O

  • PPI (Point-to-Point Interface) — used with early S7-200 systems

Schneider Electric

  • Modbus RTU (over RS-232/485) — still common but considered legacy

  • Modbus Plus

  • FIPIO (Factory Instrumentation Protocol Input Output) — obsolete fieldbus

  • Uni-Telway — proprietary protocol used in legacy Telemecanique PLCs

Obsolete or Overtaxed PLCs

Rockwell Automation (Allen-Bradley)

  • PLC-5 — Discontinued, limited support; migrated to ControlLogix

  • SLC 500 — Discontinued (2020); migrated to CompactLogix

  • MicroLogix 1000/1200/1400 — Phasing out; replaced by Micro800 series

Siemens

  • S5 Series (e.g., S5-95U, S5-135U) — Long obsolete; migrated to S7 series

  • S7-200 — Discontinued; replaced by S7-1200

Schneider Electric

  • Modicon 084 / 984 / Quantum — Legacy Modicon lines; migrated to M340 / M580

  • TSX Micro / Premium — Replaced by Modicon M340/M241/M251

  • Momentum PLCs — Aging, limited flexibility for modern systems

Obsolete or Overtaxed Drives

Rockwell Automation (Allen-Bradley)

  • 1305 AC Drive — Obsolete; replaced by PowerFlex 70/700/750

  • 1336 PLUS / PLUS II — Discontinued; replaced by PowerFlex series

  • 160 SSC — Legacy; replaced by PowerFlex 4/40

  • Bulletin 1395 — Obsolete DC drive; replaced by PowerFlex DC

  • 1397 DC Drive — Discontinued; migrate to PowerFlex DC

  • PowerFlex 4/40/70 — Still supported but aging; migrated to PowerFlex 520/750 family

Siemens

  • Micromaster 420/430/440 — Discontinued; replaced by SINAMICS G120/G120X

  • Masterdrives — Legacy line; migrated to SINAMICS S120

  • Simovert VC — Obsolete; replaced by SINAMICS family

  • SIMODRIVE 611 — Phased out; replaced by SINAMICS S120/S2100

Schneider Electric

  • Altivar 16/28/58 — Obsolete; migrated to Altivar 312/320/630

  • Altivar 66/71 — Replaced by Altivar 630/Process drives

  • Square D VFD lines (pre-Altivar) — Fully obsolete

  • Telemecanique drives (legacy) — Rebranded and replaced by Altivar line

Get in touch and restore control.

We put your team in control with practical fixes and future-ready factory controls built to last. Contact us to take control. Contact us today to see how Ikonika can help.