Transition from PLC Screens to Industrial Linux Panels: ZMA and GDT Integration

Amazeng Technical Team
7 min read
PLCHMIIndustrial LinuxTransitionQtYocto

Introduction

PLC screens (Operator Panel) used for decades are reaching end-of-life. Transition to new-generation industrial Linux panels is inevitable. However, this transition requires major investment. So how can you modernize while protecting your existing investments?

Traditional Architecture vs Modern Architecture

Old System (10+ Years Ago)

PLC → Operator Panel (HMI) → Serial Communication (RS232/RS485)
  • Monochrome display, limited graphics
  • Closed source code
  • Difficulty finding spare parts
  • Limited connection options

Modern System

PLC → ZMA/GDT → Modbus TCP → Industrial Linux Panel → Cloud
  • Touch screen, high resolution
  • Open source code
  • Easy backup
  • IoT integration

Transition Strategies

Strategy 1: Direct Replacement

Simplest method: Remove old panel, install new Linux panel.

Advantages:

  • Full features
  • Modern UI
  • IoT ready

Disadvantages:

  • High cost
  • Software rewrite required
  • Training period

Strategy 2: Middle Layer (with ZMA/GDT)

Using Amazeng solutions for gradual transition:

Old PLC + Operator Panel
        ↓
    ZMA/GDT Module (Bridge)
        ↓  
    New Linux Panel

Advantages:

  • Existing system preserved
  • Gradual transition
  • Low risk

ZMA with PLC Integration

Use Case Scenario

Your old PLC system:

  • Omron PLC (CP1E)
  • Touch screen (NS-10)

Modernization Steps:

  1. Add ZMA-1000: For load cell/analog sensor data
  2. Add GDT: For existing 4-20mA / 0-10V sensors
  3. Add Linux panel: As new display
  4. Modbus TCP connection: Between PLC and Linux panel

Connection Diagram

Old PLC ──┐
           ├── Modbus TCP ──→ Linux Panel (ZMA/GDT data + PLC status)
Old HMI ──┘

Advantages

  • PLC program unchanged
  • Existing I/O preserved
  • New features added
  • Gradual transition

Industrial Linux Panel Options

1. Qt-Based Panels

  • Yocto + Qt: Customizable UI
  • Qt Designer: Visual programming
  • QML: Modern animations

ZMA Integration:

// Qt with ZMA reading
modbus_t *ctx = modbus_new_tcp("192.168.1.100", 502);
modbus_connect(ctx);
uint16_t registers[8];
modbus_read_input_registers(ctx, 0, 8, registers);
// Send to QML

2. HDMI + SBC Solution

  • Raspberry Pi 4: Industrial use
  • Docker: Easy installation
  • InfluxDB: Data storage

3. Ready HMI Solutions

  • 7" / 10" Touch: Modbus TCP ready
  • Python Script: Automation
  • n8n Integration: Workflow

GDT for Existing Sensor Protection

Situation: 4-20mA Sensors

Your existing 4-20mA sensors:

  • Pressure transducers
  • Temperature sensors
  • Level sensors

Solution: GDT Series

4-20mA Sensor → GDT-xxx → Modbus RTU/TCP → Linux Panel

GDT digital transmitter provides Modbus output while preserving your existing analog sensors.

Transition Plan

Phase 1: Preparation (Month 1-2)

  • Map existing system
  • Define requirements
  • Plan budget

Phase 2: Pilot (Month 3-4)

  • Select single line
  • ZMA/GDT integration
  • Linux panel testing

Phase 3: Full Transition (Month 5-6)

  • All lines
  • Training
  • Commissioning

Conclusion

Transition from PLC screens to industrial Linux panels is a great opportunity. With ZMA and GDT series:

  • Existing investments protected
  • Risk minimized
  • Modern features added

Learn more about ZMA Data Acquisition and GDT Digital Transmitter.

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