Retrofit of existing control systems

In many of the machines and systems used in automated production, older, partly analogue control generations often work reliably and without any problems. However, the discontinuation of a proven control system in existing machines and systems unsettles many users. This and most of the existing control technology can still be used. A retrofit and conversion to the 300S+ control system from Yaskawa make it possible.

If the control technology in existing machines and systems gets old, it no longer corresponds to the required state of the art and often no longer meets today's safety standards. In addition, it is difficult to obtain spare parts and is often no longer possible due to product discontinuation. This can lead to unexpected downtimes and high maintenance costs.

Striving for sustainability in the company also means using existing technology for as long as possible. A retrofit creates the prerequisite for this. This means that by replacing old or discontinued hardware components - e.g. the control system - machines are brought back up to the latest state of the art. This offers ecological and economic advantages. The existing systems and production processes are technically upgraded so that reliability, efficiency, competitiveness and future security are guaranteed again.

300S+ control system

Such a retrofit is possible, for example, with the 300S+ control system from Yaskawa. Since its beginnings in the 1990s, it has developed into a real heavyweight on the market. Over 1.5 million components of the high-speed control system are now installed in countless machines worldwide. The current version 300S+ impresses with its speed: it is around ten times faster than comparable systems. On the other hand, the PLC CPUs offer a significantly larger memory size of up to 8 MB (fully remanent) and more additional benefits than the previous models, all at a lower price.

Against this background, the 300S+ system with SPEED7 technology asserts itself as a reliable and robust control system even for the most demanding applications.
Last but not least, the system not only enables exceptional processing speeds and capacities, but also has another advantage: the 300S+ series, whether compact CPU or fully equipped PLC automation system, adapts to a wide range of requirements and applications. For example, suitable front connectors for the integrated I/O channels ensure particular flexibility.

Retrofit made easy

Proven technology with high spare parts availability over the long term: This creates the conditions for safe, smooth operations and trouble-free operation during production. The replacement and commissioning take place during a planned downtime so that production can be started again quickly afterwards. The output and performance of the machine are increased, higher productivity and quality are achieved and the service life is renewed. In addition, an increase in performance, higher productivity and better quality are achieved. Maintenance and user-friendliness are optimized and the overall service life of the machine is extended. The use of fanless CPUs also reduces the energy requirements of the control technology.

It is precisely this flexibility that opens up interesting perspectives when it comes to replacing existing solutions. In view of the current changes in the automation industry, this offers a compatible alternative when it comes to retrofitting existing control systems. Many system series from market-dominating manufacturers have been in successful use for many years.
Therefore, functionality, availability, practical experience and spare parts management are not only reasons for many operators and maintenance staff to continue using the system. While digitization at the management level continues to advance rapidly in automated production, older, partially analogue control generations are still often used in machines and systems. Functionality, availability, practical experience, spare parts management and other advantages are reasons for many operators and maintenance staff to continue using them.

Several options are available

There are several general options for retrofitting the existing control system - even if the original manufacturer is phasing out the system or has already discontinued the system. In addition, the system meets high standards for clever memory management, data security and comprehensive communication capabilities via modern protocols, for example through an integrated Ethernet connection and a wide variety of supported buses.

A variety of on-board communication interfaces, including Ethernet, Profibus-DP and serial RS485, as well as optional extensions ensure excellent connectivity and integration into existing networks.

In general, the 300S+ controllers can be programmed using proven platforms such as STEP7 and the TIA Portal from Siemens or via the Yaskawa WinPLC7 software. This opens up complete freedom in the development and maintenance of projects. With external storage options via MMC/SD cards up to 2 GB and battery-buffered RAM, the 300S+ system offers advanced and reliable memory management, including automatic backup functions.

Yaskawa IOs and accessories are also fully compatible with the previously market-dominating system. All hardware components can therefore be exchanged 1:1 and used in parallel in mixed operation. The CPUs can also continue to be used largely unchanged, so that the existing software can remain. Yaskawa supports the corresponding adjustments in the CPUs with special support, the "TASK FORCE 300" service offer, as well as with download options and other useful functions on the Yaskawa website.

Proven system with high speed

A step-by-step retrofit saves significant costs compared to a new purchase. In addition, only short production downtimes are usually necessary. At the same time, however, the quality of the systems is increased and functionality and performance expanded. Last but not least, occupational safety also benefits from modernization.

With the 300S+ control system, users, as well as machine builders and maintenance staff, benefit from greater safety in the entire work environment and long-term investment security. While other providers are phasing out their product lines, Yaskawa ensures the long-term availability of the 300S+ control systems.

With the option of individually expanding the integrated RAM, the 300S+ system grows with the requirements of your applications and thus offers a future-proof solution. Yaskawa offers a 36-month guarantee not only for the new components, but for the entire expanded control system. Another advantage is that all components are available directly from stock and will be available until at least 2030. The fact that the integrated microchips are based on Yaskawa's own technology contributes to this high delivery performance.

Three examples from very different industries show where and how the 300S+ control systems unfold their characteristic strengths.

Building automation in the automobile plant

Yaskawa controllers of several generations were installed in a production line of an automobile plant. The decentralized structure was implemented with CPUs, communication processors and slaves from the VIPA 200V family and communication processors and slaves from the SLIO family, together with the corresponding digital and analog signal modules.

At the time, there were many arguments in favor of the 300S and SLIO families for the decentralized stations. The 300S CPU family combines the classic compact 300 design with enormous weight advantages thanks to the integrated SPEED7 technology. In addition, there is the usual variety of interfaces, which makes it one of the fastest and most powerful control systems in the world. Thanks to the consistent programmability with STEP7 code and VIPA's own programming tools, the system can be used universally and can be retrofitted at any time.

Higher energy efficiency in the cosmetics group

The heating system of a large cosmetics group was to be modernized in order to save energy. The existing heating was replaced by district heating and a new control system. There were several reasons for the company to use PLC technology here and not systems such as BACnet, KNX or LON, which are usually used in building technology. PLC technology can be found everywhere in industry and there are employees there who are very familiar with it. Spare parts are in-house and the customer can usually fix faults or changes themselves without delay. In addition, the STEP7 compatibility, the interfaces to PROFIBUS and the CPU's ability to process and reliably store large amounts of data were also reasons for choosing Yaskawa.

Two 315SN-NET CPUs now control the entire power distribution - together with decentralized SLIO modules. Two 315-4NE12 Ethernet CPUs ensure the right temperature throughout the building. 18 Vipa SLIO modules are connected decentrally throughout the factory via 4.5 km of Profibus cable, reinforced by repeaters. They control the power distribution on site and ensure that the yield per unit of consumption does not exceed the desired value - otherwise the quantity is throttled. The success of the modernization has already been confirmed.

Expectations were exceeded. Heating costs were significantly reduced, which further supports the company's goal of sustainability.

Conversion and modernization of bottling plants

A bottler of non-alcoholic beverages used the conversion and modernization of its bottling plants to be prepared for future requirements with the latest control technology. Today, 140 digital I/Os and around 15 analog inputs in the pasteurization and bottling area alone are no problem for the CPU 317SN/NET. The CPU even manages the connection to other decentralized signal modules via Profibus and the visualization connection via the integrated Ethernet interface with ease.

The control system takes over the entire control and monitoring of the pumps and valves during pasteurization as well as the regulation of the temperatures, which lie within a narrowly defined tolerance range. Valves, flow meters, conductivity meters, frequency converters, pumps and the visualization are integrated into the control and regulation circuit. The subsequent filling machine and packaging are also integrated. There is a lively exchange of data between the pasteurizers and the filling machine using I/O coupling.

The filled packages then move on, automatically controlled by the PLC, to the palletizers, where they are labeled fully automatically and then automatically packaged for transport in a film wrapper, which is also controlled by Yaskawa. Yaskawa controllers were thus able to handle the additional requirements in the communication area, e.g. the extended process data communication and the visualization, without any problems.

Author: Konstantinos Monastirlis Technical Competence Manager & Channel Partner Manager – Value Stream Controls Yaskawa Europe GmbH, DE-Nuremberg