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As a new engineer inheriting a 15-year-old production line with mixed Siemens S7-300 and Mitsubishi FX series PLCs, what's the smartest migration path that balances cost, training, and minimal downtime?

ThomasRobinson

ThomasRobinson

2025-12-15

answer

Hey there! I totally get your situation - inheriting a 15-year-old mixed PLC system can feel overwhelming. Here's a smart migration strategy that balances all your concerns:

For the Siemens S7-300, the natural upgrade path is to S7-1500 using Siemens' TIA Portal migration tools. The good news is Siemens has a migration wizard that makes this relatively straightforward, and you can preserve most of your existing program logic. The TIA Portal is the modern platform you'll need to learn, but it's more intuitive than the old SIMATIC Manager.

For the Mitsubishi FX series, you have a few options. Mitsubishi offers migration paths from older FX models to newer FX3U or FX5 series. Using GX Works 2 or 3 software, you can convert your existing programs with minimal changes. The FX5 series gives you more modern features while maintaining compatibility.

Here's the smartest approach:

1. Start with a phased migration - tackle one system at a time during scheduled maintenance windows
2. Consider keeping the existing I/O wiring where possible to save costs
3. Get training on both TIA Portal and GX Works platforms - many online resources exist
4. Document everything thoroughly before starting - you'll thank yourself later

The key is not trying to do everything at once. Pick the most critical or problematic system first, get comfortable with the migration process, then tackle the rest. This approach minimizes risk while giving you hands-on experience with both platforms.

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