Introduction: why modernization of operator panels is critically important for Ukrainian enterprises

Ukrainian industry is facing an acute need for updating technological lines. A significant part of the equipment installed in the 1990s and 2000s uses proprietary HMI panels (Human-Machine Interface). Such devices operate on closed software, require obsolete programming cables and have been discontinued by manufacturers many years ago. The use of obsolete equipment creates serious risks for production continuity.

Maintenance of such systems becomes economically unviable. Spare parts are practically unavailable or offered at excessive prices as stockpiles of unknown origin. The absence of integration with modern industrial internet of things (IIoT) networks makes it impossible to meet the requirements of modern energy audits and European environmental standards. Transition to open standards of industrial automation is the only way to reduce operational risks and increase production efficiency.

According to the standards ISO 22400 (Key Performance Indicators for production operations) and the requirements of EU directives regarding energy efficiency, a modern system must ensure transparent data collection in real time. In this guide, we will thoroughly examine the process of migration from outdated interfaces to flexible solutions based on open protocols.

Assessment of obsolete systems: audit prior to modernization

Before making a decision on replacing equipment, the plant's chief engineer must conduct a full technical audit of the existing operator panel park. The drawback is the "if it's working, don't touch it" approach, as the costs incurred from sudden line stoppages significantly exceed the investments in planned updates.

During the audit, the following parameters are recorded:

• Physical dimensions of the cut-out in the enclosure (compatible enclosures must be selected or transition plates must be used).
• Types of signals and presence of discrete/analogue inputs directly connected to the panel.
• Dependency of the controller (PLC) logic on specific functions of the old HMI.

Modern Alternatives: Technology Comparison

The modern market offers a wide range of equipment based on open operating systems (Linux-embedded) and standard protocols. Reliability and compatibility are key factors when selecting components for modernizing Ukrainian plants. UNITEC-D GmbH supplies certified equipment that meets strict CE and UkrSEPRO standards.

As an example of a reliable replacement in demanding operating conditions, the use of high-performance control and interface modules, such as components from the VICKERS XG2V6CW10 series, can be considered. These ensure stable operation of hydraulic and pneumatic drives in harsh industrial environments (metallurgy, machinery, cement industry). They guarantee precise pressure regulation up to 350 bar and operating temperatures from -20°C to +70°C.

Comparative characteristics table

ROI Calculation: Demonstrating Financial Viability

Enterprise management often delays modernization due to capital expenditures (CAPEX). However, the calculation of total cost of ownership (TCO) clearly shows the economic benefit of switching to new equipment.

Let's take a typical machining workshop with 10 machines under control of obsolete panels:

• Average cost of line downtime: 2 500 EUR per hour.
• Number of annual failures due to software failure or display malfunction: 4 cases per year per line.
• General time losses: 16 hours per year per line = 40 000 EUR annual losses.
• Cost of the modernization package (HMI + license + engineers' work): 4 800 EUR per one point.

Formula for calculation of simple payback period (Payback Period):

Additional consideration is given to energy savings. Modern energy-efficient panels and optimized data processing cycles reduce energy consumption by the equipment by 3-5%. For enterprises with continuous cycles, this provides additional savings of thousands of euros per year.

Step-by-step Implementation Plan (Roadmap)

In order to minimize production downtime during installation works, the transition to new standards is carried out according to a clearly defined schedule:

1. Phase 1: Planning and Reverse Engineering (Weeks 1-2). Reading the existing project, backing up the PLC, analyzing the tag address space, purchasing equipment through UNITEC-D E-Catalog.
2. Phase 2: Development of New PLC Program (Weeks 3-4). Conversion of graphic displays into the environment of a modern development environment (for example, CODESYS or another open IEC 61131-3 editor), testing the logic in simulation mode.
3. Phase 3: Pre-installation (During short scheduled maintenance). Installation of mounting panel transition adapters, laying new shielded Ethernet cables according to the requirements of DSTU EN 50174.
4. Phase 4: Commissioning Works and Start-up. Final communication testing with the controller, sensor calibration, operator training.

Technical difficulties and ways of their overcoming

Modernization of old systems is always accompanied by certain engineering challenges. The main ones:

• Protocol Incompatibility: The old PLC does not support Modbus TCP or OPC UA. Solution: Installation of industrial gateways (protocol converters), which translate proprietary data packets into standard Ethernet networks.
• Supply Voltage Change: Old panels were supplied from non-standard voltages or unstable networks. Solution: Integration of modern switched-mode power supplies supporting a wide input voltage range (85-264 VAC) and voltage surge protection according to standards EN 61000-4.
• Resistance of personnel: Operators are used to the old interface. Solution: Creation of an intuitive graphical design according to ergonomic standards ISO 9241 with hints and colored alarm indication (Alarm Management according to NAMUR NA 102).

Case study: modernization of a packaging line at a Ukrainian food industry company

Input data: The bulk material packaging line used 2002 panel controllers with a cracked touch layer and absence of spare parts in Ukraine. The equipment readiness level (OEE) was only 71% due to constant system hangs.

Виконані роботи: Інженери UNITEC-D провели повний цикл модернізації. Встановлено сучасну відкриту панель діагоналлю 10 дюймів, інтегровано промисловий комутатор та оновлено кабельні лінії. Використано компоненти для точного контролю виконавчих механізмів, аналоги яких забезпечують роботу гідросистем під тиском до 250 bar.

Results (KPI after 6 months of operation):

• OEE coefficient increased from 71% to 89%.
• Operator response time to errors has decreased by 40%.
• Fully eliminated downtime due to operator interface failures.
• Full compliance with NACS requirements and food production safety standards.

Receiving, Testing and Validation

After completion of the installation, a standard set of tests is carried out according to the FAT (Factory Acceptance Test) and SAT (Site Acceptance Test) protocols:

"Жодна модернізована система не допускається до повноцінної експлуатації без перевірки часу реакції аварійного зупину (Emergency Stop loop verification) та тестування на стійкість до електромагнітних перешкод згідно з EN 61000-6-2."

Backup software is checked, operation permits are formed, and the company's technical documentation is updated in Ukrainian according to the standards ДСТУ.

Conclusion

Moving away from outdated proprietary HMI panels towards open standards is a strategic investment in the stability and competitiveness of Ukrainian manufacturing. Transitioning to certified components with open protocols reduces the risk of unplanned downtime, lowers maintenance costs, and guarantees easy integration into future Industry 4.0 architectures. Order reliable industrial components, controllers, and related equipment directly through UNITEC-D E-Catalog.

References and Normative Basis

• ISO 22400: Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management.
• EN ISO 13849-1: Safety of machinery — Safety-related parts of control systems.
• DSTU EN 50174: Information Technology. Installation of Cable Systems.
• NAMUR NA 102: Fieldbus standardization for safety-related applications.
• Directive 2009/125/EC of the European Union concerning ecodesign requirements for energy-related products.

Introduction: The Need for Modernization

Modern production systems require high efficiency, compliance with standards, and cost reduction. Outdated systems, such as HMI panels, often lose support, increase the risk of failures, and do not meet modern environmental and energy standards. According to the standard EN 50081-1, outdated systems may cause higher levels of CO₂ emissions, affecting compliance with EU Ecodesign.

Evaluation of the old system before retrofit testing

Before starting the modernization, a detailed evaluation of the current system is necessary. It is important to determine the following parameters:

Modern alternatives: Modernization using open standards

Modernization of control systems using open standards ensures greater flexibility, efficiency, and compliance with regulations. One of the most effective options is retrofitting based on Festo DNC-100-200-PPV-A-S6. This component complies with standards EN 60947-1 and ISO 13849-1, providing an increased level of energy efficiency and reduced maintenance costs.

ROI Calculation: Return on Investment

Calculation of return on investment (ROI) includes analysis of energy cost savings, reduction in downtime and reduction in maintenance costs. Let's consider an example:

Annual energy saving: (12.5 - 6.8) kW × 1,000 hours × 0.12 €/kW·h = € 642.

Annual cost saving on restoration: (4.2 - 1.8) hours × € 120/hour = € 288.

Annual savings on maintenance costs: (1,200 - 600) € = € 600.

Annual saving overall: € 642 + € 288 + € 600 = € 1,530.

Modernization cost: € 1,200.

Payback period: € 1,200 / € 1,530 = 0.78 year (9.4 months).

Implementation Plan: Phased Approach

Implementation of modern HMI panels should be phased, in order to minimize production stoppages:

1. Планування: Визначення критичних систем та сценаріїв впровадження.
2. Замовлення: Замовлення компонентів Festo DNC-100-200-PPV-A-S6 через UNITEC-D E-Catalog.
3. Installation: Installation of new components using appropriate tools and means.
4. Connection: Connection of new components to the existing system.
5. Committee: Conducting testing and verifying compliance with standards.

Technical challenges during retrofit testing

Technical problems may arise during modernization:

• Protocol Incompatibility: The use of open standards may require adaptation of existing protocols.
• Selection of the correct components: It is important to select components that comply with standards EN 60947-1 and ISO 13849-1.
• Обслуговування: Необхідна підтримка від кваліфікованих експертів.

Solution: Use of components supplied by UNITEC-D, which comply with all standards and requirements.

Case study: Before/after scenario

Let's consider an example of a real production facility that has implemented modern HMI panels Festo DNC-100-200-PPV-A-S6:

• After modernization:
  • Energy efficiency: 82 %
  • Energy consumption: 6.8 kW
  • Recovery time: 1.8 hours
  • Cost of correction: € 1,200
  • Service cost: € 600
• After modernization:
  • Energy saving: € 642
  • Cost saving on restoration: € 288
  • Cost saving on maintenance: € 600
  • Annual saving: € 1,530
  • Payback period: 9.4 months

System Check and Acceptance

After installing new components, testing must be carried out according to the standards EN 50081-1 and ISO 13849-1.. It is important to confirm:

• System functionality
• Compliance with regulations
• Cost reduction

After successful testing, the system can be considered accepted.

Conclusion: Refer to UNITEC-D E-Catalog for obtaining modern components

Modernization of control systems is critical to ensuring the efficiency, compliance, and economic viability of production. United-D provides reliable components that meet all standards, including EN 60947-1, ISO 13849-1 and EU Ecodesign. Refer to UNITEC-D E-Catalog for obtaining modern components.

List of references

• Festo Product Guide
• EN 60947-1:2015 – Electrical Equipment – Open Field Measurement Space
• ISO 13849-1:2015 – Safety of machinery – Functional safety – Part 1: General requirements
• EU Ecodesign Directive 2009/125/EC

1. Introduction

In today's industrial environment, legacy operator interfaces (HMIs) are becoming a critical bottleneck. Proprietary systems developed decades ago limit the integration with modern network protocols such as OPC UA or MQTT, which are necessary for the implementation of Industry 4.0 principles. Outdated hardware increases the risks of unplanned downtime due to a shortage of spare parts and the inability to update software. According to energy efficiency requirements and safety standards such as EN 60204-1, modernization of the control system is a necessary step to maintain the competitiveness of the enterprise.

2. Evaluation of outdated systems

Before making a decision on replacement, it is necessary to assess the technical condition of the existing equipment.

3. Modern alternatives

The transition to open standards allows unifying the management architecture. As an example of modernization, consider the use of Danfoss panels 9051678.

4. Calculation of return (ROI)

Consider the case of upgrading a production line with 5 HMI panels.

• Cost of modernization (equipment + engineering works): 15,000 EUR.
• Average downtime due to legacy HMI failure: 4 hours per month.
• The cost of an hour of downtime: EUR 2,500.
• Annual losses from downtime: 4 * 12 * 2,500 = 120,000 EUR.
• Expected downtime reduction after replacement: 90%.
• Annual savings: 108,000 EUR.
• Payback period: less than 2 months.

Energy savings and reduced maintenance costs provide an additional positive economic effect.

5. Implementation roadmap

To minimize the impact on the production process, a step-by-step approach is used:

1. Planning and auditing: Compilation of a complete list of signals and integration points.
2. Preparation: Setting up Danfoss 9051678 in laboratory conditions.
3. Logging: Implementation on one, non-critical section of the line.
4. Full migration: Installation and commissioning during planned PPR (planned preventive maintenance).

6. Technical challenges

The main difficulty lies in transferring logic from proprietary software to open standards. To solve this problem, we use intermediate data gateways and automatic tag conversion tools. It is important to ensure full compatibility with existing PLCs, which is achieved by using standard communication drivers.

7. Example (Case Study)

At a polymer processing plant, replacing 10 legacy HMIs with Danfoss 9051678 reduced operator response time to critical emergency messages by 40% and eliminated 100% of downtime due to legacy display failures. MTBF increased from 18,000 to 55,000 hours.

8. Commissioning and testing

After installation is carried out:

• Testing communication with the PLC (validation of tags).
• Checking emergency signals (error simulation).
• Security testing (checking user access levels).
• The final protocol of acceptance in accordance with the requirements of internal quality standards.

Summary

HMI modernization is not just replacing hardware, it is a strategic step to ensure stability and compliance with modern security standards. UNITEC-D GmbH provides both the supply of the components themselves and full technical support for the migration process. Check out the available retrofit solutions in our UNITEC-D E-Catalog.

References

• EN 60204-1: Machine safety. Electrical equipment of machines.
• ISO 9241: Ergonomics of human-system interaction.
• EU Directive 2009/125/EC (Ecodesign).