How to Integrate Ignition Software with Your Legacy Systems

Modernizing without starting over—that’s the promise of integrating Ignition software into your legacy automation infrastructure. Whether you’re operating in Torrington, CT, or anywhere across the U.S., this guide will walk you through the practical steps to bridge outdated systems with cutting-edge technology using Ignition by Inductive Automation.

What Is Ignition Software?

Ignition is an industrial automation platform built by Inductive Automation that connects PLCs, HMIs, SCADA systems, databases, and cloud services into a single, unified solution. Its core strength lies in:

• Modular design (via Ignition Modules)
• Cross-platform compatibility
• Unlimited licensing model
• Real-time data accessibility
• Robust integration capabilities

Why Integrate Ignition with Legacy Systems?

Many manufacturers and process-driven businesses are tied to legacy systems due to cost constraints or the complexity of replacements. But failing to modernize can lead to:

• Data silos
• Security vulnerabilities
• Limited scalability
• High maintenance costs

Ignition software solves these challenges by acting as a modern overlay—enabling secure connectivity, visualization, and automation without ripping out old systems.

Benefits of Integration

Step-by-Step Integration Process

1. Evaluate Your Legacy Infrastructure

• Inventory PLCs, HMIs, and databases
• Identify communication protocols used (e.g., Modbus RTU, Serial, OPC Classic)

2. Select the Right Ignition Modules

• Tag Historian: For archiving historical process data/span>
• Perspective: For responsive, mobile-friendly HMIs
• Reporting: Generate real-time PDF or web-based reports
• SQL Bridge: For bidirectional communication with databases

3. Configure Data Connections

• Set up OPC UA server in Ignition
• Bridge legacy protocols via converters (e.g., Ethernet to Serial gateways)
• Use MQTT for lightweight, secure remote data transmission

4. Build HMIs and Dashboards

• Use the Ignition Designer to create intuitive visual interfaces
• Deploy on desktops, tablets, or mobile devices

5. Test, Validate, and Scale

• Simulate production conditions
• Conduct latency and throughput tests
• Validate tags, alarms, and failovers

Why It Matters for Torrington and Connecticut Manufacturers

Torrington and greater Connecticut host many small to mid-sized manufacturing operations that still rely on PLCs and control panels from the 90s or early 2000s. Upgrading these systems entirely may be cost-prohibitive, but working with an experienced Ignition integrator can bring modern analytics, visualization, and remote monitoring capabilities—without full replacement.

Choosing the Right Ignition Integrator

Look for certified partners with experience in both legacy systems and modern SCADA implementations. Top traits to seek:

• Certified Ignition Integrator status
• Experience with multi-protocol systems
• Client case studies and references
• Knowledge of compliance standards (FDA, NIST, ISO)

Sample Use Case: Legacy System + Ignition in Action

Before Integration:

• SLC 500 Series PLCs status
• No remote access or historical data
• Paper-based reporting

After Integration:

• Ignition installed on local gateway server
• OPC UA used for tag access
• Perspective module enables mobile HMIs
• Reports automated and emailed daily

Ready to Modernize?

If you’re in Torrington, CT or operate across the USA, now is the time to integrate Ignition into your legacy systems. Whether it’s real-time visibility, remote access, or data reporting, Ignition makes your old systems feel brand new.

Need help choosing an integrator? We’ll connect you with Pronto System Solutions certified Ignition professionals who know your industry.