PLC Migration & Obsolete Control System Conversions

When a PLC platform reaches end-of-life, the risk isn't just losing support - it's a single point of failure sitting on a production line with no replacement parts available. Sigma Automation & Controls specializes in migrating obsolete control systems to current platforms, preserving your process logic and machine behavior while eliminating the downtime risk of unsupported hardware. We handle the conversion from legacy platforms (PLC-5, SLC 500, and other end-of-life systems) to current Allen-Bradley, Siemens, and other supported architectures, with a process built to minimize production impact. 

• PLC-5 and SLC 500 to Studio 5000 / current ControlLogix migration
• Legacy Siemens, GE, and other obsolete platform conversions
• Logic translation and re-architecture, not just line-by-line porting
• Panel and wiring updates to match new hardware footprints
• HMI conversion alongside PLC upgrades (legacy HMI to FactoryTalk View, Ignition, or other current platforms)
• Updated electrical schematics and documentation as part of every conversion
• Phased migration planning for lines that can't tolerate extended downtime

A PLC conversion done poorly doesn't just risk downtime during the cutover - it can bury problems in logic that was ported without being understood. We treat every conversion as a chance to re-document and clean up the system, not just replace the hardware. You get a machine that's easier to support going forward, not just one that runs on newer parts. 

•  Rockwell has announced or issued end-of-life for your PLC platform
• Replacement parts are becoming difficult or expensive to source
• A recent failure exposed how much risk was sitting on unsupported hardware
• You've inherited a facility with undocumented legacy systems