Machine Retrofits

Scope of Work

Full control system replacement on otherwise functional machines. We handle the electrical engineering, panel design/build, programming, and commissioning. Your operators shouldn't have to relearn the machine.

What We Deliver

• New control panels meeting current standards
• Converted and tested programs
• Modern HMI with familiar operation
• Complete documentation package
• Hands-on training during commissioning

Investment Range

Depends heavily on machine complexity and scope. Basic PLC swap on a standalone machine: $20K-$50K. Full control system retrofit on a complex production machine: $75K-$200K+. We'll scope it accurately - surprises kill projects and relationships.

Downtime

We minimize it. Engineering and panel build happen offline. Pre-cutover testing catches issues before your machine is apart. Typical cutover windows: 3-5 days for basic retrofits, 1-3 weeks for complex systems. We work weekends and off-shifts to protect production.

ROI

We can help you build the business case. Parts availability risk, maintenance time reduction, efficiency gains from better diagnostics, integration benefits. Most retrofits pay back within 12-24 months even before considering avoided catastrophic failure costs.

Prioritization

We can assess your risk and help you prioritize which machines to address first based on criticality and parts exposure. Not everything needs to be done at once - but waiting for failure is the most expensive option.

This Is Your Wheelhouse

Retrofits should make your life easier, not harder. Modern diagnostics instead of cryptic fault lights. Remote access capability for troubleshooting. Parts that are actually available. Documentation that exists.

Conversion Approach

We maintain operational logic wherever possible. Your operators shouldn't have to relearn the machine. If the old sequence worked, the new sequence should feel the same - just more reliable and maintainable.

Knowledge Transfer

We document what we find during the retrofit - the tribal knowledge that exists nowhere else. The "jiggle this relay" fixes become proper solutions. The mystery I/O points get identified and documented.

Spare Parts

New systems mean available parts. We spec current-production components, not close-out inventory. And we give you a real recommended spares list, not just "buy one of everything."

Training

Your team learns the new platform during commissioning - hands-on, not classroom. They're part of startup so they own it immediately.

Migration Methodology

Full I/O inventory mapped to new system before we start. Address conversion tables for PLC migrations. Test plans that verify every function, not just "motor runs." Side-by-side comparison of old vs. new behavior.

Dealing with Unknowns

Legacy systems have surprises. Undocumented modifications. I/O that's connected but unused (or is it?). Hardwired interlocks hidden in junction boxes. We plan for discovery time and don't pretend we'll know everything on day one.

Panel Design

New panels meet current NEC and NFPA 79 standards. Proper wire routing, terminal labeling, and service clearances. Designed for the technician who has to troubleshoot it at 3am, not for engineering aesthetics.

Program Structure

We convert logic thoughtfully. Old PLC-5 spaghetti doesn't become ControlLogix spaghetti - we restructure where it improves maintainability. But we don't change operational behavior without reason and testing.