R - Retrofit
E - Engineering
I - IIot

• Retrofit & PLC Modernization
• Energy Optimization
• Operator Interface & Visualization
• IIoT & Smart Services (Remote Monitoring)

About the project
The client's cooling installation was controlled by a Siemens S5 PLC, an obsolete system that made maintenance difficult and expansion impossible. In addition, the installation had low energy efficiency, an obsolete operating interface, and a lack of remote monitoring, which limited the flexibility of the maintenance team. Reditech was hired to modernize the entire control system and prepare it for the future.

Challenge

• The main challenges of this project were:
  
• The Siemens S5 PLC was at the end of its life cycle and is no longer supported
• Lack of remote monitoring and control
• Low energy efficiency of the cooling groups
• An outdated operating interface without modern visualization
• Need for a reliable, future-proof platform

Our contribution

• PLC retrofit and modernization:
• Replacement of the Siemens S5 PLC with a modern Siemens S7-1200 controller
• Migration of all I/O signals, logic, and alarm systems to the new architecture
• More stable system thanks to modern hardware and error detection

Energy optimization:

• Implementation of energy-saving algorithms for the cooling groups
• Intelligent switching logic that controls the cooling installation more efficiently
• Improved temperature control for lower energy consumption

Operator interface and display:

• New Siemens Comfort Panel with modern and intuitive screens
• Clear visualization of temperatures, statuses, alarms, and energy consumption
• Better user experience and faster system management

IIoT and Intelligent Services (remote monitoring):

• Activation of Siemens Smart Services for secure remote access
• Operators and maintenance teams can now monitor and control the system remotely
• Faster interventions and less need for on-site presence

Results for the customer:

• Complete modernization of the cooling installation
• Better energy efficiency and lower operational costs
• Remote operation and monitoring, thanks to Smart Services
• User-friendly operator interface with improved visualization
• Future-proof platform with long-term support
• More efficient management and higher reliability of the installation

REDI pillars in this project:
R – Retrofit
Upgrade of an end-of-life S5 PLC to a modern S7-1200 solution
E – Engineering
Rewiring, PLC migration, energy optimization, and HMI integration
I – IIoT
Remote monitoring and control through Siemens Smart Services