PLC and software
PLC control system modernisation
We assess the existing PLC, switch to your preferred control system and adapt the control programs and the functions of your machine.
Made in Styria
PLC retrofit for existing machines
Planning, conversion and commissioning from a single provider.
Send a no-obligation inquiry and discuss technical details directly
New control systems for proven machines
Services in detailA retrofit is worth considering when the mechanical parts are still sound but the control system is outdated.
We review the controller, software and peripherals using the available documentation. Together, we determine which components can be reused and where replacement is necessary.
PLC retrofit services
Visualisation
WinCC, operator screens and interfaces
We update the existing operator screens, messages and communication interfaces for drives, peripherals and higher-level systems.
Electrical design
EPLAN and cabinet modifications
We assess the electrical installation and plan cabinet modifications. Wiring and components may be retained where suitable.
Testing and handover
Functional checks and commissioning
We test machine functions and interfaces, commission the modified control system and document current software versions.
Reference project
Control-system retrofit for a small-parts warehouse
We replaced the S7-300 with an S7-1500 and updated the visualisation and warehouse management software.
- Previous controller
- SIMATIC S7-300
- New controller
- SIMATIC S7-1500
- Retained
- Existing warehouse machinery
From assessment to restart
Assess the installation
Review hardware, program versions, interfaces and documentation. Define the required functions and clarify outstanding questions at the machine.
Prepare the conversion
Plan the hardware, software and control cabinet modifications. Agree the sequence of work, functional checks and how production will restart.
Convert and commission
Carry out the conversion during the agreed production shutdown. Check signals, machine functions and interfaces before restarting the machine.
Hand over and support
Hand over software versions and documentation. Agree any further support on site or through documented remote access.
What determines retrofit costs
An estimate needs a defined scope and an understanding of the existing installation.
Costs depend on factors such as:
- Number of controllers, I/O and connected systems
- Available program versions and documentation
- Changes to visualisation, interfaces and wiring
- Testing requirements and available shutdown window
Practical questions
Before planning a PLC retrofit
Can the existing PLC program be retained?
That depends on the controller currently in use and its planned replacement. Parts of the program can often be reused; others need to be adapted or rewritten for the new controller.
What if programs or circuit diagrams are missing?
A retrofit may still be possible. Missing circuit diagrams can be reconstructed from the wiring. If no usable program is available, the machine's operating sequence needs to be recorded as the basis for a new program.
Can drives and peripherals remain in use?
Yes, if they are in working order and compatible with the new controller. This depends on their connections and how they exchange signals and data.
How long will production be stopped?
The duration depends on the conversion work and the checks that follow. We complete planning and programming before the shutdown where possible. We agree the time needed for work on the machine with your production team.
What happens after commissioning?
You receive the current program versions and the agreed documentation. If questions, faults or further changes arise later, we can provide on-site or remote support by arrangement.
Tell us about your machine
A short description is enough to start. Feel free to contact us even if documents are missing.