Fault or plant downtime
Systematic analysis of the PLC program, inputs and outputs, communication, drives and machine sequence – remotely or directly at the plant.
Siemens S7TIA PortalWinCC
Siemens PLC Programming, Service & Retrofit
We extend, analyze and modernize control systems in existing machines and industrial plants – prepared remotely, commissioned on site and documented clearly.
20+ years of experience · S7-300/400/1200/1500 · TIA Portal & STEP 7 · Austria and DACH
What needs to be resolved at your plant?
Functional extension
New sequences, operating modes, interfaces and diagnostic functions integrated into the existing program structure.
Retrofit and migration
Phased modernization of S5, S7-300 and S7-400 plants to current Siemens systems, scheduled around existing maintenance windows.
Commissioning
I/O checks, signal tests, sequence verification, corrections and acceptance for new, converted and extended systems.
PLC services for existing plants and new projects
Existing machines and plants
- Reverse engineering of existing control programs
- Backup and review of existing project versions
- Extension of evolved PLC software
- Troubleshooting signals, sequences and communication
- Retrofit during planned maintenance windows
- Clear technical documentation
New machines and plants
- PLC software architecture and sequence control
- Reusable, clearly structured blocks
- HMI and operator concepts
- Communication with drives and third-party systems
- FAT and test preparation
- On-site commissioning and acceptance
S7 Retrofit
Keep operating S7-300 and S7-400 or migrate?
Not every older controller needs to be replaced immediately. We review the program version, hardware, connected peripherals, documentation and available maintenance windows. This produces a clear migration path – from targeted continued operation to phased modernization of individual plant sections.
- 01Secure existing programs and project versions
- 02Map I/O structure, networks and third-party systems
- 03Understand undocumented logic
- 04Define target hardware and migration scope
- 05Prepare software and tests remotely
- 06Perform conversion and signal tests in the maintenance window
- 07Couple legacy and new systems in phases where needed
PLC engineering, visualization and plant connectivity
Siemens PLC programming
Programming, extension and maintenance of SIMATIC controllers for machines, production lines and existing industrial plants.
- Sequence control and state logic
- Operating modes and interlocks
- Diagnostic functions
- Technology objects and motion control
- Communication with drives and peripherals
S7-300S7-400S7-1200S7-1500TIA Portal V15–V21STEP 7 Classic
HMI, visualization & WinCC
Operator interfaces and plant visualization for machine operation, diagnostics and ongoing production.
- Operator screens and plant overviews
- Alarm systems and diagnostic views
- Recipes and user guidance
- Panel and SCADA-level visualization
WinCCWinCC UnifiedComfort PanelsHMI
Commissioning, service & troubleshooting
Structured support for commissioning, troubleshooting and changes during ongoing plant operation.
- On-site sensor and actuator testing
- I/O checks and signal verification
- Analysis of sequence and communication faults
- Program corrections with function testing
- Support for FAT, SAT and acceptance
- Remote analysis where technically possible
Industrial communication and shop-floor connectivity
Provide machine data and control signals in a structured form for visualization, MES, monitoring and IT systems.
- Communication between controllers and third-party systems
- Capture and structure machine data
- Interfaces to MES, dashboards and databases
- Integration through Sync Connect or PlantWatch when it fits the project
PROFINETPROFIBUSOPC UAModbusMQTTMES
PLC programming from Styria
Sync Motion is based in Deutschlandsberg and supports industrial customers in Austria as well as selected projects in Germany and Switzerland. Many engineering tasks can be prepared remotely. Commissioning, signal tests and acceptance take place directly at the plant when required.
StyriaAustriaGermanySwitzerlandRemote and on site
Typical applications
- Machine and plant engineering
- Conveying and bulk materials
- Cement, asphalt and aggregate plants
- Wood and metal processing
- Food and production plants
- Modernization of existing production lines
How a PLC project works
- 01
Clarify plant and task
You describe the controller, plant, fault, required change and available time window.
- 02
Review project status
We review project versions, documentation, interfaces, access and technical prerequisites.
- 03
Define scope and schedule
You receive a clearly defined scope covering effort, schedule, prerequisites and responsibilities.
- 04
Implement and test
Programming, preparation, commissioning, function testing and technical documentation.
Your contact for PLCs and automation
Harald Brida
CTO at Sync Motion
Deutschlandsberg, Styria, Austria
20+
years in automation
100+
projects delivered
S5 → S7
migration & retrofit
Harald Brida has programmed and modernized control and automation systems for more than 20 years – from individual machines to complex industrial plants. His focus is Siemens S7, TIA Portal, STEP 7 Classic, commissioning and the phased modernization of existing plants.
Programs are structured so that sequences, interlocks and interfaces remain understandable later. For retrofit projects, as much work as possible is prepared remotely and scheduled into existing maintenance windows.
- Siemens S7-300/400/1200/1500
- TIA Portal and STEP 7 Classic
- Troubleshooting and commissioning
- S5 and S7 migration
- Plant communication and machine data
- Remote preparation and on-site implementation
FAQ
PLC programming FAQ
What does PLC programming cost?
Costs depend on the controller, project status, documentation, access options, required scope and necessary on-site work. After a short technical clarification, you receive a clearly defined scope with effort and prerequisites.
Which Siemens PLC systems do you program?
The focus is on SIMATIC S7-300, S7-400, S7-1200 and S7-1500 as well as TIA Portal and STEP 7 Classic. For visualization, we support WinCC, WinCC Unified and Siemens panels, among others.
Do you commission systems on site?
Yes. Engineering and preparation can often be done remotely. Signal tests, function tests, commissioning and acceptance are carried out directly at the plant when required.
Can you work with undocumented legacy plants?
Yes, provided the existing program version and technical access allow a structured analysis. At the outset, project versions, I/O, communication and plant behavior are recorded. This determines the scope for troubleshooting, documentation or modernization.
When is an S7-300 or S7-400 migration worthwhile?
Migration should be reviewed when spare-parts risk, missing project versions, extension requirements, outdated visualization or recurring faults make plant operation difficult. A full replacement is not always necessary; modernization can often be planned in clear stages.
Which work can be done remotely?
Program reviews, software changes, block preparation, HMI adjustments, project comparisons and parts of diagnostics can often be performed remotely. Work on signals, hardware, drives and real machine sequences generally requires on-site support.
Do you work outside Austria?
Yes. Sync Motion supports selected projects in Germany and Switzerland and other international assignments where required. Scope and on-site work are agreed before the project begins.
Do you also work for machine and plant builders?
Yes. We can take on clearly defined engineering, visualization, commissioning or retrofit work packages and integrate into existing project structures.
Clarify your PLC task technically
Describe the controller, plant, required change or fault. We will check what information is still needed for a sound assessment.
Discuss a PLC projectUseful details include controller type, TIA or STEP 7 version, available project version, plant location and required time window.