Commissioning with an end-to-end test on real target hardware
The most expensive place for a program bug is a stopped plant. That is why the complete system is run through beforehand in the test setup — every button, every message, every sensor.
- the combination that will later run is what gets tested
- 1:1
- the combination that will later run is what gets tested
- downtime window — plannable, not open-ended
- Days
- downtime window — plannable, not open-ended
- commissioning internationally too
- Worldwide
- commissioning internationally too
Before the changeover day, your complete PLC program runs in the test setup on the real S7-1500 or S7-1200, with the Unified visualization running against it in its runtime — exactly the combination that will later work at the plant.
Dry-run testing of the blocks
Every basic function and every sequence is checked against defined scenarios — normal operation, fault cases, limit values. Only once the blocks hold does the complete system go on the test bench.
End-to-end on real target hardware
The new CPU is procured for the project anyway — so it is also used for testing before it goes into the cabinet. In the test setup, what will later count is run through:
- Every input is stimulated individually and the reaction of the control logic is checked.
- Sequences are run through, interlocks are provoked, fault scenarios are triggered.
- The operating concept is tried out on the simulated process — the PLC and Unified runtime as a pair, not just a virtual simulation.
A dress rehearsal for the changeover day
The sequence of the rebuild — swap hardware, download, signal test, trial run — is planned out in advance, with clear fallback points. On site it is a matter of wiring, testing and starting up, not programming.
Related services
Control System Retrofit
Migrate S5, S7-300 or S7-400 to S7-1500/S7-1200 — often without rebuilding the control cabinet.
Control System Retrofit: Migrate S5, S7-300 or S7-400 to S7-1500/S7-1200 — often without rebuilding the control cabinet.PLC Programming (TIA Portal)
Structured programs from a proven block library — tested before commissioning.
PLC Programming (TIA Portal): Structured programs from a proven block library — tested before commissioning.Frequently Asked Questions
What does an end-to-end test mean in practice?
The complete PLC program runs in the test setup on the real target CPU, with the visualization running against it in its runtime. Every button, every message and every sensor is run through individually — including fault scenarios and interlocks. What passes there no longer surprises anyone at the plant.
Why real hardware instead of just a simulation?
The test setup with the real target CPU and the real panel runtime tests exactly the system that will later work at the plant — including communication and runtime behavior. That leaves no question open for the changeover day that could have been clarified in advance.
Does production keep running during preparation?
Yes — the site survey, programming and the complete end-to-end test take place in the test setup, not at your plant. The actual downtime is limited to the rebuild, the signal test and start-up.
Plan your commissioning
From the test setup to start-up — with clear fallback points and a downtime window that is fixed in advance.
✓ Non-binding initial consultation ✓ Response time < 24h on business days