🔄 Retrofitting Machinery? Don’t Overlook the Electrical Design

Whether you’re upgrading an old production line or repurposing a single piece of equipment, mechanical changes alone aren’t enough. Retrofitting machinery comes with a wide range of electrical challenges—from compatibility issues to code compliance—and overlooking them can result in unexpected downtime or safety hazards.

In this post, we’ll break down why electrical design is just as important as mechanical planning when retrofitting industrial machinery—and what you should watch for.

⚠️ 1. Matching New Equipment to Old Infrastructure

Older machines often weren’t designed to work with today’s drives, PLCs, or sensors. You may run into issues like:

• Outdated control voltage (e.g., 120V coils on new 24VDC systems)

• Undersized panels or power supplies

• Wiring that doesn’t support modern I/O needs

Retrofitting means more than just wiring in a new part—it may involve panel redesign, load rebalancing, or communication protocol upgrades.

🔌 2. Are You Still Code Compliant?

A retrofit can trigger a need for compliance updates under the Ontario Electrical Safety Code (OESC) or CSA standards. Even small changes—like relocating a disconnect or replacing a VFD—might require:

• Updated arc flash labelling

• ESA inspections and permits

• Rewiring to meet current bonding and grounding requirements

These aren’t just technicalities—they protect your staff and equipment.

📊 3. Controls Integration: Will It “Talk” to the Rest of Your Line?

Adding or upgrading machinery often requires control system changes:

• Can the new system communicate over Ethernet/IP, Modbus, or Profibus?

• Do you need to reprogram existing PLC logic or add a new HMI?

• Will your safety relays or interlocks still function properly?

If electrical and control design isn’t considered early, you may end up with a bottleneck or safety gap on an otherwise modernized line.

🔍 4. Hidden Opportunities During Retrofits

Retrofitting is also a chance to make other low-cost improvements while the machine is already open:

✅ Add diagnostics (e.g., IO-Link sensors)✅ Install energy-efficient drives or soft starters✅ Rewire for future expansion✅ Update panel layouts or labelling for easier maintenance

These small changes can save you time and money long-term, especially when planned alongside the retrofit.

Final Thoughts

Machinery retrofits are often driven by mechanical needs, but ignoring the electrical side can lead to delays, non-compliance, or unnecessary cost. Whether it’s a simple motor swap or a full production line overhaul, getting the electrical design right is key to a safe, efficient upgrade.

Need Help with a Retrofit?

If you’re planning a retrofit, consider involving an experienced electrical contractor early. The right team can help you assess your current setup, design for compliance, and ensure a smooth installation with minimal downtime.