How do I best upgrade a multiworkstation app using DSC from LV7.2 to 8.6?

I have an extended, properly functioning process control and data acquisition application running across multiple workstations (roughly 10). The workstations share information with each other and with process controllers via DSC and OPC.
We're currently running at version 7.1, and this spring we want to update to the current version of Labview (which, by then, will be 8.6.1; we are on the SSP).
I understand that the tag engine/database have changed significantly between 7.1 and the current version of the DSC, and wonder if there is a good roadmap for executing this upgrade to minimize downtime on our tool?
Kevin Roche
Advisory Engineer/Scientist
Spintronics and Magnetoelectronics group
IBM Research Almaden

Hi Ben -- we do not log history or events in the DSC, so that is not an issue.
The application is controlling a multi-chamber (7 connected vacuum chambers arranged in a star configuration) thin film deposition system. The basic control, interlocks, and safety/process security of the vacuum components is done via a series of Opto22 "brains", which are essentially simple processors running programs to control IO for valves and temperature control systems. They communicate with each other via Ethernet.
There is an OPC server for the Opto22 brains, which runs on one workstation dedicated to use as a gateway between LabVIEW and the network of brains. A DSC tag database is set up on that machine to access some of the IO states and variables in the brains, and then the other workstations have tag databases that reference those tags (the brains' communications interfaces can be overwhelmed if too many workstations access them simultaneously, so we use a single workstation as the gateway). Via the gateway, a workstation may read/manipulate some of the io states directly, and make other requests of the brains' software by setting flag variables in the strategies running therein.
Each chamber also has a complex motion control system for process manipulation, as well as extensive serial/parallel communications to control the gas systems, deposition power supplies, etc. The process software on each workstation makes available a "snapshot" of its process state available via memory tags in the DSC, so that the workstation controlling the central chamber can detect when a task in an outer chamber is completed and move samples between the different chambers.
All the workstations, brains, and motion control systems are interconnected via an Ethernet network independent of our building intranet. There is one additional workstation that maintains a process database, where each workstation can record each process task and the samples affected by it.
Everything is working at this point, but we recognize that we are overdue to bring the system up to the current level.
In particular, guidance as to a possible way to upgrade the gateway tag DSC database and then the others referencing it in advance of recompiling all the software, if that is possible.
Kevin Roche
Advisory Engineer/Scientist
Spintronics and Magnetoelectronics group
IBM Research Almaden

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