Modernize Legacy PLC Systems Without Losing Control of Your Timeline
Control System Migration Services
Legacy PLC, Motion, Drives & HMI
Managing the lifecycle of your control system can be a daunting risk. Migrating your existing control systems mitigates expensive and extensive downtime. A poorly executed upgrade presents the same risk.
Discover how our expert migration team can solve these lifecycle challenges with the experience to execute on schedule.
60
+
Years of Combined GE Experience
Aging PLC Systems Present Growing Operational Risk
Limited hardware and spare parts availability
Loss of internal logic knowledge as experienced engineers retire
Vendor and support constraints
Increased risk of forced outages during failure
Real Results:
How Deep GE Expertise Reduced Downtime by 80%
A conveyor belt manufacturer in North Carolina needed to upgrade from GE 90-30 and 90-70 PLCs, but competitors estimated 4 months of downtime. TAG Solutions got it done in just 6 weeks.
Controlled Migration Through Parallel Conversion
Series 90-70 to RX3i Conversion Rack
This staged conversion approach allows existing GE 90-70 systems to remain operational while the new RX3i platform is installed, validated, and prepared for cutover. By preserving field wiring and leveraging conversion racks, downtime is planned, minimized, and controlled.
Step 1: Existing Series 90-70
Baseline system documented
and validated before transition.
Step 2: Remove Field Terminals
Field wiring preserved to reduce rework
and minimize outage scope.
Step 3: Remove Series 90-70
Legacy hardware removed after
staging preparation.
Step 4: Install RX3i Conversion Rack
Parallel hardware installed to support phased migration.
Step 5: Install Series 90-70 Field Terminals
Existing wiring integrated into new architecture.
Step 6: Close Access Door and Secure
System secured prior to validation testing.
Step 7: Exchange Completed
Cutover executed within planned outage window.
Why Facilities Modernize Legacy GE PLC Systems
Legacy GE PLC platforms such as the 90-30 and 90-70 are increasingly difficult to maintain, support, and expand. Planned modernization helps facilities reduce operational risk and maintain long-term reliability.
Reduce Downtime Risk
Aging PLC hardware and unsupported components increase the likelihood of unexpected outages and extended recovery times.
- Obsolete or unsupported hardware
- Limited spare parts availability
- Time-consuming troubleshooting
Improve System Performance
Modern control platforms improve processing speed, communication performance, and overall system responsiveness.
- Faster scan times
- Improved network communication
- Reduced cycle delays
Reduce Lifecycle Costs
Maintaining legacy systems becomes more expensive as hardware ages and vendor support declines.
- Increasing maintenance costs
- Limited vendor support
- Higher failure risk
Modernize Controls
Aging PLC hardware and unsupported components increase the likelihood of unexpected outages and extended recovery times.
- Obsolete or unsupported hardware
- Limited spare parts availability
- Time-consuming troubleshooting
The TAG Solutions Difference
Our Approach to Migrations
The TAG Solutions Migration Team has developed a proven strategy that will allow you to quickly and easily migrate from Series 90 and RX7i controllers and Series 90 I/O to an Integrated Modern Control System, while maintaining the existing field wiring and physical footprint in your control cabinet.
Proven GE PLC Expertise
Extensive GE migration experience supported by a formalized strategy.
Shutdown-Aligned Execution
Installations scheduled to align with plant outages and turnarounds.
Phased Migration Planning
Upgrades staged to match operational priorities and available budgets.
Vendor-Neutral Solutions
Recommendations focused on the best system for your facility.
Integrated Project Management
Dedicated coordination from planning through system replacement.
Multi-Discipline Engineering
Controls, networking, SCADA, cybersecurity, and electrical expertise.
Onsite Implementation Support
Engineering coordination during installation and system replacement.
Lifecycle Training & Support
Post-migration training and ongoing system support for your team.
Contact
Speak with a TAG Solutions engineer
Speak with a TAG Solutions engineer with direct experience migrating GE 90-30 and 90-70 control systems.