The EU Machinery Regulation applies from 20 January 2027. Planning a modification? → Check from €890 net
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Retrofit: a new control system for machines whose mechanics will last for years

I replace outdated controllers, HMI panels and drives – and check whether the modification is a substantial modification under the Machinery Regulation.

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Left, the old state: S5 controller, relays, wiring without drawings. Right, after the retrofit: S7-1500 with ET200SP and Profinet, wiring in ducts, every device labelled, as-built circuit diagram. Schematic drawing.

When the control system becomes a risk

The mechanics run reliably, but the control system is getting old. For older systems such as S5 or S7-300, spare parts are becoming harder to source.

On top of that, knowledge of the program retires with the colleagues who wrote it. If a component then fails, the machine stands still until a replacement arrives. A planned retrofit, by contrast, can be scheduled for a downtime you choose yourself.

What a retrofit with me includes

  • Survey

    Back up the program, record hardware and circuit diagram, assess the spare parts risk.

  • Retrofit concept

    What is replaced, what stays and how long the machine is down. With a fixed price.

  • Controller replacement

    From S5 or S7-300 to Siemens S7-1500 or S7-1200 with TIA Portal.

  • HMI panels and drives

    New panels, frequency inverters and motors where it pays off.

  • Fieldbus and sensors

    Migration from Profibus to Profinet, connection of IO-Link sensors.

  • Safety technology and CE

    Assessment of substantial modification, risk assessment and retrofitting where needed.

Technology and standards

Target systems
Siemens S7-1500 and S7-1200 with TIA Portal, HMI with WinCC or zenon.
Drives
Danfoss, SEW, Lenze and Schneider Electric.
Fieldbuses
Profinet, Profibus, AS-i and IO-Link.
Standards
EN ISO 12100, EN ISO 13849-1 and EN 60204-1.
Legal basis
Machinery Regulation (EU) 2023/1230 for the assessment of substantial modification.

How a retrofit runs

  1. Initial call

    You describe the machine and its control system. I tell you whether a retrofit is worthwhile.

  2. Site survey

    Together with the Machinery Regulation Check. Afterwards you receive a concept and a fixed price.

  3. Preparation

    The control cabinet and program are built while your machine keeps running. I test the program in advance.

  4. Changeover during downtime

    Replacement, commissioning and training in the time window you set. Plus documentation and program backup.

From practice

Maintenance of a can filling line

More than four years of troubleshooting across the entire line, plus automation projects and the replacement of old Siemens controllers. I led contractors during modifications and shutdowns. So I also know retrofits from the point of view of the maintenance team that has to live with the line afterwards.

All references

Frequently asked questions

Does a retrofit turn my machine into a new machine?

Not automatically. What matters is whether the modification is a substantial modification within the meaning of the Machinery Regulation. I assess this before the retrofit so that you know the consequences.

In detail: spotting a substantial modification

How long will the machine be down?

That depends on the scope and is set out in the retrofit concept. Because the control cabinet and program are prepared in advance, downtime is limited to the changeover and commissioning.

What does a retrofit cost?

After the survey you receive a fixed price. The survey with Machinery Regulation Check costs from €890 net plus VAT and is credited if you place the order.

Renew the control system before it fails

In a 15-minute initial call we clarify whether a retrofit makes sense for your machine.

Book an initial call

Prefer to call? +43 660 800 7100