When a machine has been running reliably for many years, discovering that its control panel is obsolete can be a worrying situation.
The original manufacturer may no longer support the control equipment, replacement components may be difficult to source, and the panel itself may be showing signs of age.
The obvious question is:
Does this mean the whole machine needs to be replaced?
In many cases, the answer is no.
An obsolete control panel doesn’t necessarily mean an obsolete machine
Industrial machinery can remain mechanically sound and productive for many years. However, the electrical and control components inside the machine can become obsolete much sooner.
Drives, PLCs, contactors, relays, HMIs and other control components are continually being replaced by newer technology.
This can leave businesses with a machine that is mechanically capable of continuing to operate, but with an electrical control system that is becoming increasingly difficult to maintain.
Replacing the entire machine simply because the control panel is obsolete may therefore be unnecessary.
Can the existing machine be upgraded?
In many situations, an existing machine can be upgraded with a new or redesigned control panel while retaining much of the original machinery.
This could involve replacing obsolete components with modern equivalents and designing a new control system around the existing machine.
Depending on the application, this may include:
Replacing obsolete drives or inverters
Upgrading PLCs
Replacing outdated HMIs
Replacing contactors, relays and other control components
Updating safety circuits
Reproducing or updating electrical drawings
Designing a completely new control panel
Integrating the new panel with the existing machine
The exact solution will depend on the machine and its existing control system.
What about an obsolete drive?
An obsolete drive is a common reason for considering a control system upgrade.
For example, Lenze 8200 and 8400 drives are now obsolete, meaning replacement and support options can become increasingly difficult.
However, the fact that the drive is obsolete doesn’t automatically mean that the motor, gearbox or machine itself needs to be replaced.
In many cases, the drive can be replaced with a modern equivalent while retaining the existing motor and mechanical equipment, subject to checking compatibility.
We have also looked specifically at the options available when a Lenze 8200 or 8400 drive becomes obsolete.
What are the advantages of replacing the control panel?
A control panel upgrade can potentially extend the useful life of an existing machine while bringing the electrical control system up to date.
It can also provide other benefits, including:
Improved reliability
Replacing ageing or obsolete components can reduce the risk of failures caused by equipment that is becoming difficult to source.
Improved support
Modern components are generally easier to source and support than obsolete equipment.
Better availability of spare parts
Using current components can make future maintenance easier and reduce reliance on increasingly scarce obsolete parts.
Potential improvements to the machine
A control system upgrade can sometimes provide an opportunity to improve the operation of the machine, such as adding a modern HMI, improving monitoring or upgrading the drive system.
Does the whole control panel always need replacing?
Not necessarily.
Every machine is different, and sometimes only certain components need to be replaced.
For example, if a particular drive has become obsolete, it may be possible to replace the drive while leaving the rest of the control panel untouched.
In other situations, the age and condition of the existing panel may make a complete replacement the more sensible option.
The important thing is to assess the existing equipment before deciding what needs to be replaced.
What should you do if your control panel is obsolete?
If your machine is still mechanically sound and continues to perform the job you need it to do, don’t automatically assume that you need a new machine.
Start by assessing the existing control system.
Identify which components are obsolete, which are still supported and whether suitable modern alternatives are available.
A replacement control panel can then be designed around the requirements of the existing machine.
This approach can sometimes provide a more practical and cost-effective alternative to replacing an otherwise perfectly usable machine.
How Modern Drives & Controls can help
Modern Drives & Controls Ltd designs and manufactures bespoke industrial control panels and provides electrical engineering solutions for existing machinery.
We can assess obsolete or ageing control systems and help identify suitable replacement options.
Depending on the application, this can include control panel design and manufacture, drive and inverter replacement, PLC and HMI upgrades, electrical drawings and documentation, panel testing and commissioning.
Our aim is to help businesses keep their existing machinery productive while bringing outdated control systems up to date.
Don’t replace the machine just because the control panel is obsolete
An ageing or obsolete control panel doesn’t necessarily mean the end of the machine.
If the mechanical equipment is still suitable for the job, upgrading the electrical control system could give the machine many more years of useful service.
If you’re dealing with an obsolete control panel or struggling to source replacement components, contact Modern Drives & Controls Ltd to discuss your requirements.