01
Problem
Technological aging of the machine’s electrical infrastructure, combined with the absence of electrical schematics, made fault diagnosis and intervention more difficult, prolonging maintenance activities. Limited availability of replacement parts for the hydraulic proportional control card and the use of older-series safety relays also presented challenges to the equipment’s long-term maintainability. These conditions created a need to modernize the electrical and control infrastructure, establish technical documentation, and simplify maintenance while preserving the existing machine investment.
02
Solution
The electrical control panel was upgraded, and electrical schematics reflecting the machine’s connections were prepared. The hydraulic proportional control card, which was difficult to replace, was removed from service, and its control function was implemented through a Siemens analog output. The older-series safety relays inside the panel were also replaced with current models. The electrical and control infrastructure was thereby reorganized to simplify maintenance and troubleshooting.
05
Result
The renewed panel components and newly prepared electrical schematics made the machine easier to understand and maintain. Dependence on the old proportional control card was eliminated, and the safety relays were replaced with current models. The modernization simplified maintenance and spare parts management, supporting the preservation of the existing machine investment and the extension of its service life.
Existing system assessment: Evaluation of the electrical control panel, field wiring, and control arrangement.
Electrical control panel upgrade: Renewal of aging panel components and the wiring arrangement as part of the modernization.
Electrical schematic preparation: Documentation of the machine’s electrical connections to support maintenance and troubleshooting.
Hydraulic proportional control upgrade: Removal of the existing proportional control card and implementation of its control function through a Siemens analog output.
Improved maintainability: Establishment of a documented electrical infrastructure to simplify fault diagnosis and component identification.