Question 1

How accurate is this estimate?

Accepted Answer

This estimator provides a rough order-of-magnitude estimate based on industry averages. Actual effort depends on code complexity, plant conditions, documentation quality, and team experience. For a precise assessment, upload your code to PLCcheck Pro for block-by-block analysis.

Question 2

What factors increase migration cost the most?

Accepted Answer

The biggest cost drivers are: (1) Missing documentation — adds 50% for reverse engineering. (2) Cross-vendor migration (e.g., Siemens to Rockwell) — requires complete reprogramming. (3) Safety-relevant systems — additional validation and documentation. (4) Large I/O count — more wiring, testing, and commissioning time.

Question 3

How long does a typical S5→S7 migration take?

Accepted Answer

A small S5 program (under 50 blocks) typically takes 2–4 weeks. Medium systems (50–200 blocks) require 4–8 weeks. Large S5-155U systems with 200+ blocks need 8–16 weeks including commissioning. The S5→S7 path is the most common and best-tooled migration — automatic converters handle 60–80% of code.

PLC Migration Estimator

Source & Target Platform