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Retrofit and Upgrade Services

With our lifecycle services, retrofits and upgrades you‘re on the sure path to sustainable production reliability. We‘ll advise you on maintenance, inspect and repair, secure spare parts and take care of your system integrity once the components reach the end of their service life.
 
 
 
  • About
  • SIMOVERT ML/ML2
  • SIMOVERT MV
  • SIMOVERT S
  • SIMOVERT D
  • SINAMICS PERFECT HARMONY GH180
  • Retrofit for non-Siemens drives

Retrofit and Upgrades for Drives

The modernization of electric drives – also called retrofit – is an essential part of the product lifecycle. Retrofits ensure investment security and optimize availability, reliability as well as energy efficiency of installed drives – which also benefits the environmental impact of a company.

We offer comprehensive services for both Siemens and external products, ranging from simple modifications and upgrades over to the exchange of individual components right up to complex retrofit projects.

Your benefits at a glance

  • Increased availability and total efficiency of the drives
  • Less maintenance effort for advanced product lifecycle
  • Improved efficiency
  • Process optimization
  • Lower risks of down time events thus less unplanned standstill times
  • Better diagnostic options



SIMOVERT ML/ML2

Due to age, spare part supply for SIMOVERT ML/ML2 converters is already restricted. In case of a failure, it is possible that plant downtimes cannot be resolved immediately. To avoid this, Siemens recommends to replace your obsolete SIMOVERT ML/ML2 drives by SINAMICS SM150.

Your benefits at a glance:

  • Spare parts are available for many years to come
  • When completely migrating to SINAMICS SM150, the transformer and motor can be reused


 

SIMOVERT MV

Due to age, spare part supply for SIMOVERT MV converters is already restricted. In case of a failure, it is possible that plant downtimes cannot be resolved immediately. To avoid this, Siemens recommends to replace your obsolete SIMOVERT MV drives by SINAMICS GM150 or SINAMICS PERFECT HARMONY GH150/GH180.

Your benefits at a glance:

  • Spare parts are available for many years to come
  • When completely migrating to SINAMICS GM150, transformer and motor can be reused
  • Switchover to SINAMICS PERFECT HARMONY GH150/GH180 facilitates functions such as cell bypass and/or cell redundancy
  • Optional: SIDRIVE IQ ready


 

SIMOVERT S

Due to age, spare part supply for SIMOVERT S converters is already restricted. In case of a failure, it is possible that plant downtimes cannot be resolved immediately. To avoid this, Siemens recommends, depending on the converter generation, either replacement with the successor product SINAMICS GL150 or upgrading the control unit to SINAMICS GL150 technology.

Your benefits at a glance:

  • Retrofit/Upgrade ensures spare parts supply
  • The transformer, motor and power cable can be reused
  • Optional: SIDRIVE IQ ready

Offering details

Retrofit

SIMOVERT S 1st generation (SITOR modules)

For SIMOVERT S 1st generation with SITOR modules and to be able to continue to use the production units, Siemens offers a complete replacement of your obsolete SIMOVERT S drives by SINAMICS GL150.

Upgrade

SIMOVERT S 2nd generation (thyristor stacks)

The units-of-production of SIMOVERT S converters 2nd generation are made of very robust modules (thyristors). Experience shows that the life expectancy of the thyristors is higher than that of the control electronics. In order to continue using the drives in your production line, Siemens offers a control unit-upgrade to SINAMICS GL150 technology.

When upgrading to the SINAMICS GL150 control technology, the control unit will be replaced and the power section will remain except minor modifications.





SIMOVERT D

Due to age, spare part supply for the SIMOVERT D converters is already restricted. In case of a failure, it is possible that plant downtimes cannot be resolved immediately. To avoid this, Siemens recommends, depending on the converter generation, either replacement with the successor product SINAMICS SL150 or the upgrading the control unit to SINAMICS SL150 technology.

Your benefits at a glance:

  • Retrofit/Upgrade ensures spare parts supply
  • The transformer, motor and power cable can be reused

Offering details

Retrofit

SIMOVERT D 1st generation type 6QC6 (SITOR modules)

For the SIMOVERT D 1st generation with SITOR modules and to be able to continue to use the production units, Siemens offers a complete replacement of your obsolete SIMOVERT D drives by SINAMICS SL150. On request, a control upgrade is possible as well.

Upgrade

SIMOVERT D 2nd generation type 6SD28 (thyristor stacks)

The production units of SIMOVERT D converters 2nd generation 6SD28 consist of very robust modules (thyristors). Experience shows that the life expectancy of the thyristors is higher than that of the control electronics. In order to continue using the drives in your production line, Siemens offers a control unit-upgrade to SINAMICS SL150 technology.

When upgrading to the SINAMICS SL150 control technology, the control unit will be replaced and the power section will remain except minor modifications


 



SINAMICS PERFECT HARMONY GH180

Due to age, spare part supply for the SINAMICS PERFECT HARMONY GH180 (initially known as ROBICON PERFECT HARMONY) converters, is already restricted. . In case of a failure, it is possible that plant downtimes cannot be resolved immediately. To avoid this, Siemens recommends, depending on the converter generation, either replacement with the successor product from the SINAMICS series or upgrading the control unit to the latest NXG control technology.

Your benefits at a glance

  • Higher performance (control performance)
  • Retrofit/Upgrade ensures spare parts supply
  • Reduced maintenance effort
  • Optional: SIDRIVE IQ ready

Offering details

Retrofit

Replacement of all obsolete ROBICON / SINAMICS PERFECT HARMONY drives

All obsolete air- and water-cooled PERFECT HARMONY drives can be replaced with models of the latest SINAMICS PERFECT HARMONY GH180 generations.

Upgrades

The control electronics have been continuously re-engineered for more performance and to be able to respond to the obsolescence of single components. The new NXG control electronic has been built according to the new standards including all necessary features and functions.

When upgrading to the latest NXG control technology, the control unit will be replaced and the power section will remain except minor modifications

Downloads and Resources

NXGpro Digital Control System Upgrade.pdf (279,3 KB)





Retrofit for non-Siemens drives

Siemens is also offering retrofit and upgrade solutions for competitor products, building on a market leading portfolio of medium voltage drives for all applications and power ranges.

Your benefits at a glance

  • Retrofit ensures spare parts supply
  • Upgrade ensures spare parts supply for the replaced parts
  • The transformer, motor and power cable can be reused

Offering details

Retrofit

Depending on the converter type, Siemens is offering a suitable replacement for almost all competitors’ converters with a product from the current SINAMICS development series.

Upgrade

Siemens is offering a conversion of the entire control electronics of competitors’ LCI converters (Load Commutated Inverter) to the current SINAMICS GL150 control technology.
When upgrading to the SINAMICS GL150 control technology, the control unit will be replaced and the power section will remain except minor modifications





  • About
  • Solutions for SINAMICS drives
  • SINAMICS PERFECT HARMONY GH180

Lifecycle Services for Drives

Lifecycle Services is a holistic approach to keep our drives available and reliable along their entire lifetime. It’s not only a matter of preventive maintenance, but considers a broad perspective like spare parts availability, retrofit & upgrades, service agreements and digitalization.​

Your benefits at a glance

  • Higher performance (control performance)
  • Guaranteed spare parts availability
  • Reduced maintenance effort

 

Aging and wear processes affect the availability of your SINAMICS and SINAMICS PERFECT HARMONY drives. To avoid possible consequences like transformer failures, cooling-hose leakages and unexpected downtime, we offer you comprehensive services to keep your drives running reliably.

Your benefits at a glance

  • Maximized drive availability
  • Scheduled downtime for maintenance work
  • Minimization of the risk of unexpected costs due to unplanned downtime of the entire drive
Upgrade servicesUpgrades generalUpgradesRepair services
SINAMICS GM150
6SL3810-2    SINAMICS GM150 IGBT Air Cooled
  • CU320/2 due to obsolescence of CU320
  • PSA4 due to obsolescence of PSA1/2
  • Diodes Powercards
  • IGBT Powercards
  • IGCT Phasemodule
6SL3815-2    SINAMICS GM150 IGBT Water Cooled
  • CU320/2 due to obsolescence of CU320
  • PSA4 due to obsolescence of PSA1/2
  • Differential pressure sensor due to higher reliability
  • Diodes Powercards
  • IGBT Powercards
  • IGCT Phasemodule
6SL3835-2    SINAMICS GM150 IGCT Water Cooled
  • CU320/2 due to obsolescence of CU320
  • PSA4 due to obsolescence of PSA1/2
  • Differential pressure sensor due to higher reliability
  • Diodes Powercards
  • IGBT Powercards
  • IGCT Phasemodule
SINAMICS SM150
6SL3810-7    SINAMICS SM150 IGBT Air CooledNot required actual
  • IGBT Powercards
  • IGCT Phasemodule
6SL3815-7    SINAMICS SM150 IGBT Water CooledNot required actualDifferential pressure sensor due to higher reliability
  • IGBT Powercards
  • IGCT Phasemodule
6SL3845-7    SINAMICS SM150 IGCT Water CooledNot required actualDifferential pressure sensor due to higher reliability
  • IGBT Powercards
  • IGCT Phasemodule
SINAMICS GL150
6SL3850       SINAMICS GL150 Air Cooled
  • CU320/2 due to obsolescence of CU320
  • PSA4 due to obsolescence of PSA1/2
  • TAS21K/L
Thyristorstacks GL150
6SL3855       SINAMICS GL150 Water Cooled
  • CU320/2 due to obsolescence of CU320
  • PSA4 due to obsolescence of PSA1/2
  • TAS21K/L
Thyristorstacks GL150
SINAMICS SL150
6SL3860       SINAMICS SL150 Air CooledNot required actualThyristorstacks SL150
6SL3865       SINAMICS SL150 Water CooledNot required actualThyristorstacks SL150
SINAMICS GH150
6SL3820       SINAMICS PERFECT HARMONY GH150 Air CooledNot required actual
  • Diodes stacks GH150
  • DoubleSubModule DSM GH150
6SL3825       SINAMICS PERFECT HARMONY GH150 Water CooledNot required actual
  • Diodes stacks GH150
  • DoubleSubModule DSM GH150
6SL3822         SINAMICS PERFECT HARMONY GH150 integral air to air HEX – Air CooledNot required actual
  • Diodes stacks GH150
  • DoubleSubModule DSM GH150
6SL3826     SINAMICS PERFECT HARMONY GH150 integral indirect Water CooledNot required actual
  • Diodes stacks GH150
  • DoubleSubModule DSM GH150
SINAMICS GH180
SINAMICS PERFET HARMONY GH180 Air Cooled
  • NXGpro control upgrade
  • Overvoltage protection upgrade
  • Premagnetization upgrade
  • Power cell refurbishment and inspection
  • Spare Transformer solution
SINAMICS PERFET HARMONY GH180 Water Cooled
  • NXGpro control upgrade
  • Overvoltage protection upgrade
  • Premagnetization upgrade
  • Power cell refurbishment and inspection
  • Spare Transformer solution
  • Rehosing of water-cooled drives
SINAMICS SM120 CM
6SL3875       SINAMICS SM120 CM (ALM / BLM) Water CooledNot required actual
  • Diodes stacks SM120
  • DoubleSubModule DSM SM120
6SL3885       SINAMICS SM120 CM (MoM 3L-NPC / MoM 3L-M2C / BRM 3L-NPC) Water CooledNot required actual
  • Diodes stacks SM120
  • DoubleSubModule DSM SM120
6SL3871       SINAMICS SM120 CM(CoM / DCM / RCM) Water CooledNot required actual
  • Diodes stacks SM120
  • DoubleSubModule DSM SM120
SINAMICS SH150
6SL3805     SH150 Water CooledNot required actual
  • Diodenstacks SH150
  • DoubleSubModule SH150

The aging and wear processes affect the availability of your SINAMCS PERFECT HARMONY GH180 drive
Operational challenges

  • Faults or changes in the power network such as voltage peaks without using an appropriate overvoltage protection
  • High currents and mechanical/electrical stress can occur when switching electrical equipment
  • Highly stressing operating conditions such as increased temperature
  • Conflict between production requirements and maintenance measures
  • Delayed reactions to alerts and warnings
  • Missing information about the topology of the power supply and thus deviations to the norms

Possible consequences:
Without any maintenance there is a regular aging and wear where you risk and could cause severe damage

  • for the complete drive:
    Increased risk of a total breakdown of the drive and thus unexpected downtimes
  • for transformers:
    Increased risk of failures results in long downtimes in case the transformer needs to be replaced
  • for cooling hoses of a water-cooled drive:
    Increased risk of leakages (especially on hoses which are older than 8-10 years)
  • About
  • High Power Range Motors and Synchronous Motors
  • Modular cooled machines
  • Surfaced cooled machines

Retrofit for Motors and Generators

When the lifecycle of your motor or generator comes to an end, Siemens offers different options to cover your asset. This can either be a replica where the whole existing machine will be reproduced.

If you prefer to choose a retrofit, the latest technology machine from the current portfolio wil be used with interface adaptions to fit into the existing installation.




High Power Range Motors and Synchronous Motors

SIEMENS LDA decided to offer the possibility to produce 1:1 replica machines and care about phased-out designs considering large and special machines (synchronous and asynchronouns).

...With different rotor designs such as:

  • massive salient pole
  • massive cylindrical (2-pole) and
  • laminated cylindrical,

Why?

  • these machines are made for 25 years of operation and beyond
  • driving the core of production
  • existing sites continue operation and get lifetime extensions
  • “one of models” with unique design fitting into sites, grid- and processes requirements

Benefits of replica machines:

  • same electrical and mechanical interfaces which provide quick exchange w/o site modifications
  • no additional engineering e.g. torsional recalculation of machine train
  • keeping of drive-, excitation- and protection-settings for quick plant re-commissioning
  • swap-back option
  • no additional spare part stocking for new and existing machine
  • lower project risk

 
 

Modular cooled machines

For our Siemens modular cooled machines, we offer the option of Retrofit as a fully technical adequate, economical option to get an existing machine to state-of-the-art.

Also for some designs, on request, we still offer the option for a 1:1 replica.

With a retrofit, machines from the current Siemens portfolio (H- compact+ (1R.4) and HV M (1R.6/ 1R.7)) are used. The electrical performance data and mechanical interfaces will be adapted in a way, that it will fit the existing motor as close as possible. That includes frame size, shaft end, foot and overall dimensions as well as the interfaces for main and auxiliary cables, water and oil piping and more. This allows for an easy, quick and smooth replacement on site. With this solution even old machines of other manufacturers can be replaced by new Siemens machines.


 
 
 

Surfaced cooled machines

For our Siemens surfaced cooled machines, we offer the option of Retrofit as a fully technical adequate, economical option to get an existing machine to state-of-the-art.

With a retrofit, machines from the current Siemens portfolio (H- compact (1L.4) and HV C (1N.1)) are used. The electrical performance data and mechanical interfaces will be adapted in a way, that it will fit the existing motor as close as possible. That includes frame size, shaft end, foot and overall dimensions as well as the interfaces for main and auxiliary cables, oil piping and more. This allows for an easy, quick and smooth replacement on site. With this solution even old machines of other manufacturers can be replaced by new Siemens machines.


 
 
 
  • About
  • Level 1 – Basic Inspection
  • Level 2 – Preventive Inspection
  • Level 3 – Preventive Overhaul
  • Level 4 – End of Lifecycle

Lifecycle Services for Motors

Lifecycle Services offer you a holistic approach to optimize availability and reliability of your motors over their entire lifetime. Our offering includes preventive maintenance and considers crucial factors like spare parts availability, retrofit & upgrades, service agreements and digitalization. It’s a multi-level concept for motor services. Age, operation hours and machine condition indicates which service applies.


 

Exemplary maintenance plan for an aged motor


 
 
 

The aging and wear processes affect the availability of a motor. This can lead to severe operational challenges like motor contamination, faults or changes in the power network, external mechanical faults, highly stressing operating conditions or insufficient compatibility between production requirements and maintenance measures.

With our Lifecycle Services for SIMOTICS HV motors, you can quickly reduce operational challenges in your production line and boost asset availability.

Your benefits at a glance

  • In-depth analysis of the motor condition by experts gives transparency
  • Services from a single source matched to the actual condition of an individual motor
  • Minimization of downtimes during the analysis and implementation phases
  • Ideally, financing only via OPEX

 
 
 

Level 1 – Basic Inspection

Level 1 inspections take place annually and take approximately one day with one field service engineer on-site. The motor will be at standstill and the inspection covers will be opened.

The Level 1 inspection includes:

  • Data analysis e.g. vibrations, temperatures, partial discharges.
  • Visual inspection of the motor exterior e.g.: foundation cracks, motor anchoring, oil and water leakages, lose parts and other abnormalities
  • Visual Inspection of the accessible motor interior through the inspection covers for e.g.: dirt, debris, water, oil.

Your benefits at a glance

  • Inspection of motor interior and motor housing gives an early indication of dirt and dust migration
  • Loose parts are identified before they cause harm
  • Checking cooling efficiency and condition of housing and sealings ensures smooth operation


 
 
 

Level 2 – Preventive Inspection

Level 2 preventive inspection are scheduled after approximately 35.000 operating hours or after 4 years. The motor will be at standstill for about 3 to 5 days with a field service engineer and a test engineer on-site.

The Level 2 inspection includes all level 1 measures plus:

  • Repair or replacement according to the conclusions of earlier inspections.
  • Winding diagnosis of rotor and stator (Insulation resistance [PI], winding resistance, PD measurement)
  • Endoscopic inspection of airgap
  • Bearing: open, shells and seals inspection, resealing
  • Heat exchanger inspection and pressure test according to manufacturer’s manual

Your benefits at a glance

  • Winding overhang is checked for position and foreign particles
  • Bearings are checked for optimum functionality
  • Cleaning and functional test of heat exchanger


 
 
 

Level 3 – Preventive Overhaul

Level 3 preventive maintenance is scheduled after approximately 113.000 operating hours or 12 years. The motor will be at standstill for about 8 to 10 days with 2 to 3 field service engineers on-site.

The Level 3 inspection includes all level 2 measures plus:

  • Extraction of rotor and stator
  • Prepare components for inspection
  • Deep inspection of stator and rotor
  • Exciter and rotating parts (sync. Motor)
  • Repairs if necessary
  • Thorough cleaning of components (dry ice, electric cleaner or wet clean and baking)

Your benefits at a glance

  • The complete stator is checked, cleaned and reconditioned
  • The complete rotor is checked, cleaned and reconditioned

 
 
 

Level 4 – End of Lifecycle

Level 4 end of lifecycle services will be performed based on motor condition and considers economical and technical aspects to decide how to best proceed with one of the following options:

  • Repair (rewind)
  • Rebuilt or upgrades with new components
  • Replacement of machine (Retrofit or replica)

Your benefits at a glance

  • Expert evaluation of asset status
  • Recommendation of the most cost-efficient option for your requirements

 
 
 

Your contact for personal support

Discover how our retrofit and upgrade services generate added value for your company