Moeller PS416: troubleshooting, replacement and retrofit
The PS416 is the modular controller from Klöckner Moeller for larger plants, programmed with Sucosoft S40. We maintain existing PS416 plants and replace them with Siemens S7-1500 if required.
Typical situations
- The PS416 memory card is old, and there is no current backup.
- The CPU or bus module fails sporadically, and the plant stops unexpectedly.
- The program has been changed over the years, and the documentation is missing.
- The plant is to be extended, which no longer makes sense with the PS416.
Retrofit to S7-1500
In the retrofit we replace the CPU and modules with a Siemens S7-1500. The field wiring via terminals is retained wherever possible. This significantly shortens conversion and downtime. The program logic is rebuilt in a structured way and tested with you.
Project example: PS416 to S7-1500
Other Moeller systems
Moeller PS4
PS4-141, PS4-151, PS4-201, PS4-341: programming, replacement and retrofit.
Learn moreMoeller PS3, PS306, PS316
Older controllers with DOS software: back up the program and replace the controller.
Learn moreMoeller PS24
Replace rack-based systems, e.g. with Siemens S7-1500.
Learn moreProgram read-out and decompiling
No software project any more? We retrieve the program from the PLC and make it readable again.
Learn moreBreakdowns and spare parts
Plant down, module faulty: fast help and bridging solutions.
Learn moreOperator panels MI4, VTP2, Galileo
Replace old Moeller panels with modern Siemens or Beckhoff panels.
Learn moreFrequently asked questions
Our PS416 has no current program backup. What should we do?
Have the program backed up while the controller is running. Otherwise, if the CPU or memory card fails, the program may be lost.
Can the existing wiring remain during the retrofit?
Often yes. The signals are rewired to the new modules, while terminals and field wiring remain. We check this during the survey.
How long is the plant down during the conversion?
With preparation and testing in advance, the downtime can usually be limited to a weekend or a planned shutdown.
Which controller runs your plant?
Send us the type, year of manufacture and a photo of the control cabinet. You will get an honest assessment of whether repair, data backup or a retrofit makes sense.