VARIOFACE PLC/DCS migration and upgrade

PLC/DCS migration and upgrade

With the VARIOFACE PLC/DCS migration portfolio, you can migrate I/O signals quickly and easily from an old to a new I/O system via plug-and-play. Maintaining the existing field wiring enables seamless integration, minimizes wiring errors, reduces the number of loop checks, and cuts downtime. This increases the efficiency and reliability of your system.

Your advantages

  • Fast, straightforward upgrade to modern PLC/DCS control systems with specially tailored solutions
  • Short process downtime due to plug-in migration components
  • Simplified planning and minimization of loop checks by retaining the existing field wiring
  • Space-neutral PLC replacement without control cabinet modifications with the easy-to-install and service-friendly mounting rack

New products

VARIOFACE Migration Solution floating in space

Upgrade to Siemens SIMATIC® ET 200SP HA

Plug-and-play migration without rewiring

Using the VARIOFACE Migration Solution, you can quickly migrate I/O signals from ET 200M/S7-300 to ET 200SP HA via plug-and-play. The existing field wiring is retained. This reduces wiring errors, loop checks, and downtime, resulting in greater efficiency and reliability.

Main features

  • Migration system with module, cable, and rack
  • Migration of analog and digital I/O cards
  • Versions for 24 V and 120 V/230 V
  • Connection: D-SUB or Push-in connector
  • Module width: 40 mm (standard) / 47 mm (special design)
  • Halogen-free cable solutions
  • Temperature range: -20°C ... +60°C

Your Advantages

  • Quick and straightforward upgrade to SIMATIC® ET 200SP HA with precisely tailored and tested solutions
  • Short process downtime due to plug-in migration components
  • Simplified planning and minimization of loop checks by reusing the existing field wiring
  • Space-neutral PLC replacement without control cabinet modifications with the easy-to-install and service-friendly mounting rack

Plug-and-play: Efficient PLC/DCS upgrade

Upgrade from the SIMATIC® ET 200M/S7-300 to the ET 200SP HA The easy way to make your system fit for the future

Removal of the old SIMATIC® ET 200M/S7-300
Installation of the mounting rack and migration modules
Installation and connection of the new SIMATIC® ET 200SP HA
Removal of the old SIMATIC® ET 200M/S7-300

  1. Detach the old ET 200M/S7-300 front adapter with the existing field cabling
  2. Remove the old controller

Installation of the mounting rack and migration modules

  1. Install the mounting rack in place of the old controller
  2. Place the corresponding migration modules on the rear mounting level
  3. Connect the respective front connectors and connecting cables to the migration modules

Installation and connection of the new SIMATIC® ET 200SP HA

  1. Mount the new ET 200SP HA I/O system on the front level of the mounting rack
  2. Connect the connecting cable to the corresponding I/O cards

The VARIOFACE Migration Solution mounting rack Quick conversion without structural modifications

The robust mounting rack enables a space-neutral upgrade without the need to modify the control cabinet. The continued use of the existing DIN rail drill holes and the wired ET 200M/S7-300 front connectors ensures short setup times. The pull-out and tilt mechanism with locking function in 15° increments ensures good access and prevents collisions with other fixtures.

Your advantages

  • Space-neutral replacement of the ET 200M/S7-300 without control cabinet adaptations with the second mounting level
  • Quick conversion with continued use of existing DIN rail drill holes and wired front connectors
  • Easy accessibility and collision-free installation of the ET 200SP HA with the pull-out and tilting mechanism with incremental locking mechanism
  • High stability and durability with a robust stainless steel chassis with reliable mechanics

The VARIOFACE Migration Solution for your PLC/DCS upgrade in detail

Interactive image map: VARIOFACE Migration Solution – mounting rack with migration modules and SIMATIC® ET 200SP HA
VARIOFACE Migration Solution: “Mounting rack”
Despite the greater installation height of the ET 200SP HA, the mounting rack still allows for 1:1 replacement of the old PLC. By installing the ET 200SP HA on the level in front of the cable ducts, no modifications are necessary. A pull-out and tilt mechanism facilitates mounting and servicing.
VARIOFACE Migration Solution: “Mounting rack”
VARIOFACE Migration Solution: “Migration module”
Migration modules specially adapted to the old I/O cards take the place of the old components on the rear level. The wide range of modules supports numerous I/O card types.
VARIOFACE Migration Solution: “Migration module”
VARIOFACE Migration Solution: “Cable sets”
Suitable cable sets connect the migration modules to the new I/O system. Specially angled D-SUB connectors ensure a low installation depth. Preassembled Siemens “K0” terminal blocks are available for the 230 V I/O cards.
VARIOFACE Migration Solution: “Cable sets”
Migrationsmodule für digitale I/O-Signale, 120 V/ 230 V
Spezielle Migrationsmodule für digitale I/O-Karten mit 120 V/230 V ermöglichen die schnelle und sichere Ankopplung der Signale von der ET  200M/S7-300 an die ET 200SP HA. Die Module eignen sich speziell für I/O-Karten mit 20‑ bzw. 40‑poligen ET 200M/S7‑300‑Frontsteckern.
Migrationsmodule für digitale I/O-Signale, 120 V/ 230 V
Migrationskabel mit Siemens K0-Terminal Blöcken
Die vorkonfektionierten Migrationskabel mit original Siemens K0‑Terminalblöcken eignen sich speziell für digitale I/O‑Karten mit 120 V/230 V. Die Kabelsets sind optimal auf eine 2‑Level‑Installation mit Montage‑Rack abgestimmt.
Migrationskabel mit Siemens K0-Terminal Blöcken

Already using VARIOFACE system cabling? Plug-and-play: Replace cables and continue production

Migration made easy: If you are already using system cabling from Phoenix Contact, all you need to do to switch to your new SIMATIC® ET 200SP HA is to replace the system cables.
Your field wiring remains untouched: Old cables out, new cables in, and production can continue quickly.

Migration of existing system cabling components to new I/O system

Step 1:

  • Disconnect the front connector with the existing field cabling
  • Remove the obsolete hardware

Step 2:

  • Mount the new ET 200SP HA I/O system
  • Connect the new connecting cables to the appropriate I/O modules
E-paper
System cabling for Siemens SIMATIC® ET 200SP HA

Find everything you need to know about the plug-and-play concept for new installations and migrating from the ET 200M here.
Make your process automation fit for the future with the SIMATIC® ET 200SP HA and our system cabling. Benefit from efficient planning, installation, and commissioning.

Open the e-paper
Product brochure: System cabling for the Siemens SIMATIC® ET 200SP HA

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VARIOFACE Migration Solution – migration modules with cables
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