DCS Upgrade & Migration

Modernize your PCS 7 system with a proven migration strategy that protects production, reduces risk, and prepares your plant for the next decade.

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PCS 7 Upgrade & Migration

Why Upgrade PCS 7?

Older PCS 7 and S7-400 systems face hardware obsolescence, limited vendor support, and security gaps.

  • Reduce risk from obsolete CPUs and IO
  • Align with supported PCS 7 versions
  • Improve diagnostics and historian capabilities
  • Prepare for future expansions and integrations

Typical Triggers

  • Frequent hardware or network issues
  • Corporate IT/security requirements
  • Planned plant life extension

Our PCS 7 Migration Approach

We use a phased approach to minimize downtime and risk.

  • Discovery workshop and system assessment
  • Target architecture and BOM definition
  • Lab or test system for early validation
  • Planned cutover windows with rollback options

Scope Examples

  • S7-400 → 410-5H or S7-1500 conversions
  • ET200M → ET200SP HA migrations
  • New OS servers, clients, and historian
  • Virtualization on ESXi or Hyper-V

What You Receive

We provide documentation your operations and management teams can rely on.

  • Updated architecture drawings and network maps
  • Migration and testing procedures
  • Training for operators and maintenance
  • Post-migration support options

Start with a System Review

We can often begin with a remote review of your PCS 7 project and hardware list.

Request a PCS 7 Review

Our Migration Process

1

Assessment & Workshop

We start with a remote or on-site workshop to review your current PCS 7 version, hardware, networks, and operations requirements.

2

Architecture & BOM

We design a target architecture (AS, OS, networks, virtualization) and prepare a detailed bill of materials including Siemens licenses.

3

Migration Plan

We define step-by-step migration phases with cutover windows, testing, and rollback strategies to minimize downtime and risk.

4

Implementation & Testing

We execute the migration, perform FAT/SAT, and verify redundant controllers, OS servers, and networks are operating correctly.

5

Training & Handover

We provide targeted training for operations and maintenance personnel, plus documentation and remote support options.