Press retrofit – 600-ton hydraulic press (DE)

600-t hydraulic press after retrofit—safety control, operating concept and safeguards with ISO 13855 evidence — 600-ton hydraulic press after retrofit—new safety control, revised operating concept and adapted safeguards; ISO 13855 evidence (EN/DE).

Objective

Restore reliable production and bring the press up to today’s safety state of the art with an operator-friendly concept and audit-ready documentation (EN/DE)—at a fraction of the cost of a new machine.

Scope (before/after)

Before: age-ing control, recurring faults/downtime; safeguarding partly outdated.
After (retrofit): new safety control system (PL/SIL path defined), revised operating concept, adapted safeguards, validation & acceptance with documentation.

CControl section after retrofit: new safety control, clear diagnostics and documented release logic.

Old control section with ageing components and inconsistent wiring before retrofit — CControl section after retrofit: new safety control, clear diagnostics and documented release logic.

What we did

Assessment & concept
- Condition check (hydraulics, electrics, safeguarding, operator workflow).
- Safety concept incl. PL/SIL allocation and ISO 13855 distance evidence.
Control system replacement
- New safety control system with clear diagnostics and documented release logic.
- Wiring refresh and tidy cabinet layout; labelled components.
Safeguarding
- Review/adjust light curtain or multi-beam AOPD (as applicable); rear/under-reach checks.
- Guard doors/interlocks per anti-tamper principles; restart prevention.
Operating concept
- Clean modes (set-up / single stroke / automatic), two-hand/enable logic, clear signalling.
Validation & acceptance
- Functional tests and (where needed) stop-time measurements; ISO 13855 distance calculations.
- Acceptance protocol and audit-ready documentation (EN/DE).

New power section with organised feeders and labelled components after retrofit — Power section after retrofit: organised feeders, labelled components and EMC-clean cable routing.

Power section before retrofit: mixed protective devices, unclear feeders, higher failure risk. — Power section after retrofit: organised feeders, labelled components and EMC-clean cable routing.

Results

Fast, stable production with clear diagnostics.
Higher safety (documented PL/SIL pathway; distances per ISO 13855).
Lower total cost vs. new machine; the press frame remains the longest-lasting part.
Audit-ready evidence for internal/external reviews.

Standards & evidence

ISO 13849-1 · IEC 62061 · ISO 13855/13857 · IEC 61496 (AOPD) · IEC 60204-1 · ISO 16092 (presses)

Deliverables

Concept & action list (priorities, owners, timelines)
Cabinet documentation & updated schematics (PDF)
Validation plan, test records, acceptance report (EN/DE)
Label (date & next interval) + short operator/maintenance briefing

Related projects

Hydraulic press – Müller Weingarten 250 t – full retrofit: hydraulics, cabinet, operating concept → equivalent to a new machine.
Eccentric press – robot cell – contactor logic → safety control system, new releases → downtime −18%.