Long story short

For Benchmark Telecom, a Belgian specialist in Mobile Network Roll Out including temporary and event services, CTRL Engineering modernized the existing PLC control system of the XL Ranger – a mobile telecom platform built around a military-grade 30 m spindle mast.

While the mechanical and hydraulic system of the mast was still robust, the existing control hardware and software were legacy and obsolete, making operation and maintenance increasingly difficult.

CTRL Engineering retrofitted the existing control system, replacing the original PLC logic with a modern and reliable solution. The result is a stable, safe, and future-ready installation that ensures dependable communication wherever it is deployed.

The PLC control and modernization expertise Benchmark Telecom lacked internally was excellently provided by CTRL Engineering, meeting all our expectations and even exceeding them in remote control. We are very satisfied with the collaboration.🏆

Bart Rogiers, CEO @ Benchmark Telecom

The Challenge: outdated control on a military-grade mast

The XL Ranger is based on a retrofitted military mast that was originally developed for Defense applications and redesigned and adapted by Benchmark for use as a mobile communication platform. Although the mechanical and hydraulic components remained extremely durable, the electrical and control system had reached the end of its lifecycle.

The original PLC software was closed-source and unmodifiable, while the hardware components were no longer supported or replaceable. Documentation was limited, and the system lacked remote monitoring, making it difficult to track performance or diagnose issues in the field. Benchmark Telecom requested a complete modernization to bring the XL Ranger in line with current industrial standards, ensuring continued reliability, safety, and serviceability — while keeping the robust mechanical foundation intact.

The solution: a complete retrofit with modern control architecture

Together with Benchmark, CTRL Engineering began by reverse-engineering the existing I/O wiring and sensor interfaces to fully understand the original mast logic, hydraulic behaviour, and safety interlocks. Based on these insights, a new control sequence was developed that faithfully reproduced the safe operating procedures while enhancing flexibility and diagnostic capabilities.

The legacy software and hardware were replaced with a new, modular PLC program written in Structured Text and implemented on a Beckhoff PLC platform. A new operator screen was created in TwinCAT HMI, giving users an intuitive and modern interface for real-time control and monitoring.

In parallel, the electrical schematics were completely redrawn in EPLAN, and a new control cabinet was designed and built using modern industrial components that comply with current safety and performance standards. To make the system smarter, on request of Benchmark a GPS tracking and a wind sensor were integrated for real-time awareness, while remote control and monitoring now run securely through an IXON edge device – enabling safe access, diagnostics, and updates from anywhere.

Results: reliable, serviceable, and ready for the field

After the retrofit, the XL Ranger now operates smoothly, safely, and reliably on its 30 m military-grade spindle mast. The new control architecture ensures precise control of the hydraulics, while the redesigned electrical cabinet guarantees long-term robustness and ease of maintenance. Operators benefit from a modern HMI interface that delivers intuitive control, real-time feedback, and clear visualization – enabling safe deployment even in demanding field conditions.

On request of Benchmark Telecom, the modernization of the PLC restores full control and serviceability over both hardware and software. The system can now be monitored and managed remotely through the IXON edge platform, offering real-time insight into operational status and environmental conditions. The XL Ranger remains mechanically as strong as ever — but now with the intelligence, safety, and connectivity of a modern control system.

Why it matters to you?

This project demonstrates how legacy and military-grade machinery can be transformed into modern, maintainable, and connected systems without compromising on reliability. By combining expertise in control engineering, software design, and electrical integration with EPLAN, CTRL Engineering enabled Benchmark Telecom to extend the lifespan of a proven mechanical platform and prepare it for today’s connected world — ensuring reliable communication when it matters most.