MAINTAIN PRODUCTIVITY & REPLACE IPCS

Industrial PC hardware replacement in retrofit

When an industrial PC, IPC, or panel PC fails in a production plant, a simple replacement is rarely sufficient. In many existing systems, the industrial PC is closely integrated with machine software, operating system, interface cards, drivers, fieldbus communication, and the existing control technology. Replacing the wrong hardware can prevent the machine from starting or render critical functions unavailable.

Retrofit GmbH supports industrial companies in Germany with retrofitting industrial PCs, including hardware replacement, IPC exchange, repair, replacement devices, hardware migration, and software transfer. The goal is to continue operating existing machines, reduce downtime, and avoid costly system modifications or complete reprogramming whenever possible.

+49 7032 9541231

ENSURE TECHNICAL COMPATIBILITY

IPC replacement without unnecessary plant modifications

Replacing an industrial PC in a retrofit differs significantly from replacing a standard office PC. In production facilities, the functionality of an industrial PC often depends on numerous technical details.

A modern industrial PC is not automatically compatible with older machine software. New motherboards, processors, chipsets, or interfaces often no longer directly support older operating systems. Therefore, every hardware replacement must be technically reviewed and planned.

When does a hardware replacement become necessary?

the industrial PC no longer starts
the motherboard is defective
Power supply, fan, RAM, SSD or hard drive failure
The IPC overheats
The industrial computer has been discontinued.
no identical replacement device is available
old data carriers no longer work reliably
Interface cards or drivers are causing problems
the existing machine software must be retained

Technical details for IPC replacement:

Operating system & machine software
Drivers & Chipset
Interface cards & fieldbus cards
License dongles
serial interfaces & parallel port
Ethernet communication & PLC connection
HMI or panel function
existing images or backups

OLD SOFTWARE ON NEW HARDWARE

Practical hardware replacement for existing systems

Industrial PCs perform key tasks in production facilities. They serve as machine PCs, visualization computers, HMI PCs, panel PCs, control computers, or interfaces between operators, PLCs, drives, and process data.

Retrofit GmbH checks whether a defective industrial PC can be repaired, replaced by a compatible replacement device, or migrated to suitable replacement hardware.

Component & motherboard replacement

Professional replacement of defective IPC components, power supplies, RAM, storage media (SSD/HDD) and complete mainboards.

Operating system & image backup

Securing existing system images and preparing them for transfer to compatible replacement systems.

Virtual machines as an option

Examining the possibility of continuing to run old machine software in a protected virtual environment.

Retrofit: Definition and Understanding

Classical understanding of retrofit

In a classic retrofit, the machine’s mechanics often remain largely unchanged. At the same time, the entire electrical system is replaced with a new generation of electronics. This can include new controllers, new drive technology, new HMI systems, new cabling, and new programming. Such a complete retrofit can entail significant investment, depending on the machine and its scope. As a general guideline, costs in practice are sometimes cited as being in the range of approximately 60–80% of the cost of a new machine. It is important to note that if the mechanics remain unchanged, the machine’s output does not automatically increase in many cases. Therefore, the economic benefits must always be evaluated in relation to costs, the machine’s condition, spare parts availability, software dependencies, and production requirements.

Retrofit GmbH's understanding of retrofitting

Retrofit GmbH understands retrofitting in a practical, targeted, and cost-effective way. Not every machine requires a complete overhaul. Often, it makes more sense to retain the existing machine’s mechanics and selectively repair, replace, or procure critical electrical or electronic components. These include, for example: industrial PCs, IPCs, panel PCs, HMI PCs, PLCs, frequency converters, servo controllers, HMI panels, control boards, power supplies, interface cards, and electronic assemblies, as well as discontinued industrial electronics. When replacing industrial PC hardware, the focus is not solely on the new hardware. Crucially, the existing machine functionality, software environment, and technical connectivity are preserved wherever possible. The emphasis is on the continued economic viability of the system – not on a blanket overhaul.

Possible procedure for replacing industrial PC hardware

The exact process depends on hardware, software, operating system, interfaces, and machine connectivity. Generally, a project can be carried out in several steps.

Recording of the existing industrial PC

The following information is recorded: type, serial number, operating system, data carrier, interfaces, expansion cards, software, error pattern and machine connection.

Analysis of the software environment

The existing machine software, drivers, licenses, dongles, operating systems and images are checked to the extent technically possible.

Hardware compatibility check

Chipset, interfaces, cards, storage media, drivers and possible replacement hardware are evaluated for compatibility.

Selecting the right solution

Depending on the outcome, repair, hardware replacement, replacement device, software transfer, image transfer, virtualization or a combination of several measures may be considered.

Implementation and testing

The chosen solution will be implemented and tested within the scope of technical possibilities. Additional on-site testing may be required for complex machine integrations.

Key information at a glance

FAQ: Frequently asked questions about industrial PCs and hardware replacement

Can an old industrial PC be replaced with new hardware?

Yes, that’s possible. However, the crucial factor is whether the operating system, machine software, drivers, interface cards, and machine connection are compatible with the new or suitable replacement hardware.

Can the existing machine software be used?

In many cases, the transfer can be tested, for example through image backup, software migration, or reinstallation. The technical feasibility depends on the condition of the storage medium, operating system, drivers, and hardware dependencies.

Why does old software often not run on new hardware?

New motherboards, chipsets, processors, and interfaces often no longer directly support older operating systems. Furthermore, suitable drivers for older interface cards or fieldbus cards are often lacking.

Which operating systems can be considered when replacing hardware?

Depending on the starting point, systems ranging from MS-DOS to Windows 95, Windows 98, Windows NT, Windows 2000, Windows XP and Windows 7 up to Windows 10 or Windows 11 can be considered.

Is a virtual machine an alternative to replacing the hardware?

A virtual machine can be useful in certain cases when older software needs to be used. However, it is not always possible. Interfaces, real-time requirements, dongles, fieldbus cards, and machine connectivity must be examined.

Can an industrial PC be replaced without reprogramming the machine?

This may be possible if the software environment, operating system, and interfaces can be preserved or technically transferred. However, without testing, this cannot be reliably guaranteed.

Do you have a defective industrial PC, an obsolete IPC, or an existing system with outdated machine software? Have your options checked now!

+49 7032 9541231