How we carry out a retrofit
A retrofit replaces the controller, not the plant. To keep this predictable, we work to a fixed process. If the software is missing, we retrieve it from the controller. You know at all times what is happening and what you will have at the end.
The process at a glance
The route depends on whether your plant's software still exists.
Survey
Record controller, I/O, circuit diagrams and existing software on site.
Is a software project or program printout available?
Read out software
Directly from the running PLC.
Decompiling
The PLC code becomes a readable program again.
Reprogramming and EPLAN
Cleanly documented to current standards, in TIA Portal or Beckhoff TwinCAT. EPLAN is updated or created from scratch.
Conversion
Replacement with a modern Siemens or Beckhoff controller during the planned shutdown.
Commissioning and handover
Signal testing, commissioning, function testing and handover of the plant. You receive the new program unencrypted.
The steps in detail
On-site survey
We record the controller, inputs and outputs, fieldbus system, operator panels and the condition of the control cabinet, review existing circuit diagrams and talk to maintenance staff and operators. The key question is: is there still a software project or at least a program printout? If so, we go straight on to reprogramming.
Result for youSurvey report with hardware and I/O overview and clear next steps
Read out software
If the software is missing, we read the program directly from the running controller or memory card. We have the right equipment for old Moeller systems. The plant can usually keep running.
Result for youBacked-up program from the controller
- Our speciality
Decompiling
This is our speciality. With our own tools we translate the read-out PLC code back into a readable program. We also solve difficult cases such as password-protected programs. This shows what the plant actually does, even if there is no longer any original project or documentation.
Result for youReadable, commentable program as the basis for reprogramming
Reprogramming and EPLAN
The program is rebuilt in TIA Portal or Beckhoff TwinCAT: structured, cleanly documented and to current standards, with visualisation and alarm system. In parallel, we update the EPLAN drawings or create them from scratch.
Result for youTested program, visualisation and up-to-date EPLAN
Conversion
During the planned shutdown, we replace the old controller with a modern Siemens or Beckhoff controller. The field wiring is retained wherever possible. This significantly shortens the conversion.
Result for youNew controller in the existing control cabinet
Commissioning, testing and handover
We check every signal, commission the plant and test all functions. We then hand over the plant with program, EPLAN and documentation. You receive the new program unencrypted and without block protection: it belongs to you, and you are not tied to anyone.
Result for youRunning, fully documented plant and unencrypted program
What you gain as the operator
Predictable downtime
The conversion is prepared and tested in advance. The plant is only down during the agreed time window.
Same function, new basis
The plant behaves as usual. We only implement improvements if you want them.
Spare parts for years
Current Siemens or Beckhoff hardware that your maintenance team knows and can source.
Finally documented
Program, hardware and function are properly documented after the retrofit.
Your program belongs to you
We hand over the new program unencrypted. You can change it yourself or have it changed at any time.
Project examples
PS416 to S7-1500
- Existing system
- Moeller PS416
- New
- Siemens S7-1500, TIA Portal
- Special feature
- Field wiring reused
PS4 to ET 200SP
- Existing system
- Moeller PS4
- New
- ET 200SP with S7-1500 CPU
- Special feature
- Compact design in the existing cabinet
PS24 to S7-1500
- Existing system
- Moeller PS24
- New
- Siemens S7-1500
- Special feature
- Custom-made connector plates, conversion time reduced to a minimum
Frequently asked questions
How long does a retrofit take overall?
From survey to handover usually a few weeks to a few months, depending on plant size and delivery times. The actual downtime is only a small part of this.
Who decides on the target system?
You do. We recommend a system that suits your plant standard and your maintenance team, usually Siemens S7-1500 or Beckhoff TwinCAT.
Will the function of the plant change?
No, unless you want it to. The basis is the agreed functional description. Any improvements you request are recorded separately in it.
Do you also retrofit Siemens controllers?
Yes. Migration from S7-300 and S7-400 to S7-1500 with TIA Portal is also part of our work.
Planning a retrofit?
It starts with the survey. Send us the type and photos, and we will get back to you with a proposed date.