Retrofit: A new life for old machines
How KEB's service provides support for implementation
Does an existing machine appear to have served its purpose? If so, a retrofit solution may be an option for bringing old machines and plants back up to the latest state of the art. KEB Automation's service not only supports users during commissioning or repairs, but is also the first point of contact for the implementation of retrofit projects. Niels Haase, Service Support Coordinator at KEB, explains exactly how these projects work, what they offer and when retrofitting is not an option.
Why is it worthwhile for plant and machine manufacturers to consider retrofitting?
Niels Haase: In retrofit projects, ageing components such as frequency inverters are replaced with new ones. This ensures that machines and plants continue to operate safely and efficiently, thereby extending the overall service life of the machine. It is therefore not always necessary to purchase a completely new machine. And this has the major advantage that the costs for the user are significantly lower than for installing a new machine. In addition, the existing infrastructure can still be used and production capacities can be continuously utilised, as individual drive components can usually be replaced in a relatively short time.
What role do requirements for the energy efficiency of applications or the availability of certain components play, for example?
These points are often decisive factors when it comes to retrofitting. Reduced energy consumption makes economic and ecological sense. However, it is often also essential in order to comply with relevant energy efficiency regulations. Integrating modern inverter technology from KEB into existing systems and machines can be the ideal solution here. In many cases, the declining availability of certain parts and components is also a reason for deciding on a retrofit. This is the case, for example, when the manufacturer discontinues a product.
And last but not least, the nature of production is also changing in general: processes are now digitally networked and many machines still date from the ‘analogue era’. Here too, we can take measures in KEB's Service Support division to make older machines fit for Industry 4.0.
What exactly can KEB ‘make fit’ in the course of retrofit projects?
Retrofit solutions from KEB can involve, for example, retrofitting machines with C6 X1 Web HMIs. We can also implement control hardware such as the C6 COMPACT 3 embedded automation device. One focus of our retrofit projects is certainly on inverter technology. The COMBIVERT F6 and S6 drive controllers represent the latest generation of drive controllers, which feature safety technology that is already integrated into the drive. With a smaller installation space, the drives offer more performance and can therefore also improve the performance of older machines. When it comes to retrofitting, we are primarily talking about the integration of new hardware. However, adjustments and upgrades are also possible on the software side. This is because it is not possible to convert every application to the F6 converters on a one-to-one basis. We support our customers with software solutions to replicate the functions of the predecessor model F5 in the F6 and implement customised solutions.
What should customers keep in mind if they are using COMBIVERT F5 but would now like to switch to Generation 6?
The switch from F5 to F6 or S6 is indeed a very important issue. COMBIVERT F5 is no longer available for sale and is currently still being serviced. Repairs to F5 converters will be possible until 2032. To ensure that machine and plant manufacturers are still reliably equipped after support for the F5 has been discontinued, it is all the more important to switch to the F6/S6 in good time – also from the point of view of the long-term availability of components. We are happy to support our customers in switching to the new converter generation.
Are there any cases where retrofitting is not possible?
We always discuss the most economical and sensible solution with the customer. We are usually able to meet even very complex requirements. However, there are of course technical limitations where it becomes clear that retrofitting is not the right approach. This is the case, for example, if the machine is in a severely worn and damaged condition. It is also difficult to replace components if the documentation is insufficient.
What should I do if I am interested in a retrofit project with KEB?
If you are interested in KEB's retrofit offering, please contact our service department directly – either via your usual contact person or using the contact details listed on the KEB homepage in the Service section. You can also send us an enquiry via the customer portal or, of course, contact the responsible sales representative at KEB, who will then forward the enquiry to us. We will then discuss all the details of the procedure with the customer, check the requirements and start implementation. In this way, we have already given machines all over the world a new life.
What KEB's service offers
With its global service network, KEB is there for you quickly and with expertise. Our team is also available at any time to answer your questions about replacement deliveries or repairs.
- Retrofit solutions
- Commissioning
- Support for series commissioning
- Optimisation
- Repairs
- Troubleshooting advice
- Replacement deliveries and exchange of KEB components
- Project planning / simulation of motor models (HIL)
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or call us on: +49 5263 401-536
