A SMART RETROFIT APPROACH FOR MAINTENANCE TEAMS.
BRINGING ANALOGUE SENSORS INTO THE DIGITAL ERA:
A SMART RETROFIT APPROACH FOR MAINTENANCE TEAMS.
For many maintenance engineers, analogue sensors remain the backbone to reliable measurement in industrial plants. Devices using 4 to 20 mA and 0 to 20 mA signals are valued for their simplicity, robustness and long service life. However, as digitalisation and data driven condition monitoring advance, these legacy sensors often fall outside modern automation systems. Fully replacing them is rarely practical due to cost, time and limited necessity. Maintenance teams instead need an effective way to connect proven analogue technology with today’ s digital requirements.
This is where STEGO’ s new IOC 074 IO-Link Converter becomes relevant. Designed for retrofits and maintenance upgrades, the device enables existing analogue sensors to communicate digitally without requiring replacement. For facilities taking incremental steps towards smarter automation, following a philosophy of evolution rather than revolution, the converter provides an effective middle ground.
A major strength of the IOC 074 is its ability to digitalise up to three analogue channels simultaneously, making it the first converter of its kind. With many machines still using multiple analogue inputs packed tightly into control enclosures, this offers clear gains in wiring efficiency and cost per channel. Its compact size, at 14 millimetres in diameter and 63 millimetres long, allows it to fit easily alongside existing sensor setups, even in confined spaces. with standard M12 connectors and a supplied pipe clip enabling quick and straightforward mounting during planned maintenance work.
Configuration is fully software based through IO- Link tools such as LR-Device. Users can define measurement ranges for temperature, pressure or other parameters without manual scaling or the need for additional hardware. The converter manages automatic signal processing and supplies ready to use digital values directly to the control system. For maintenance teams, this simplifies commissioning, reduces calibration errors and improves data consistency.
Digitising analogue signals also supports predictive maintenance, clearer diagnostics and quicker fault identification. With greater visibility of sensor behaviour including drift, failure trends and out of range conditions, teams can act proactively, reduce unplanned downtime and extend equipment lifespan.
As digital transformation continues to shape maintenance strategies, retrofit solutions such as the IOC 074 offer a practical and cost-effective way forward. Facilities can enhance their proven analogue technology while gaining improved diagnostics, greater process transparency and better operational efficiency, creating a maintenance approach that is ready for the future and aligned with the principles of Industry 4.0.
The IOC 074 is also built for demanding maintenance environments. Its stainless-steel housing rated to IP65, IP66 and IP67 ensures reliable operation in areas exposed to dust, moisture, vibration and other harsh conditions. Installation requires no specialist tools,
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18 AUTOMATION, CONTROL & ENGINEERING