The machine had already undergone a safety retrofit in 2002: a new safety control system, an extension of the hydraulics and mechanical guards on the table were added. At that time, I was involved in the retrofit as an employee of Wiechern Engineering.
In 2021, the machine was sold to Spain. I carried out commissioning and operator training on site.
At the end of 2023, the hall in which the Hera was installed collapsed – causing substantial damage to several machines, including this press.
Because the operator had to replace or repair several machines, the focus for the renewed retrofit was on a cost-effective solution.
From my point of view, a more extensive modernisation step would have been preferable, in particular:
- Replacement of the PLC (PSS 3000 – obsolete, no longer available)
- Replacement of axis controllers and drives (currently Baldor plus older Cybelec controllers, both no longer available)
Scope of the retrofit
The actual retrofit of the machine was implemented as follows:
- The existing, defective Cybelec DNC 90 was replaced by a Cybelec Cybtouch 15 PS.
- The new control was installed in a Rittal panel together with the operating devices.
- The support arm system was renewed.
- Defective cables were replaced.
- Adaptations were made in the control cabinet to integrate the new control.
- A defective safety valve (Rexroth) was replaced.
Commissioning & operation
Commissioning took longer than usual, because the signals of the Cybtouch 15 differ from those of the DNC 90 and changes in the PLC were required.
Operator training, on the other hand, was straightforward:
The Cybtouch 15 is comfortable, easy to use and is a clear improvement over the old control for the operators.
Update October 2025
In October 2025, I was on site again at the operator’s premises to replace a defective measuring system – an issue that two Spanish companies had previously not been able to solve.
For the coming year, the plan is to replace the obsolete PSS 3000 with a PNOZmulti.
International perspective
This project is a good example of how German machine safety expertise can be applied in international projects – in this case in Spain, with a press that originally operated in Germany.
You can find more about my view on international markets and why diversifying beyond Germany makes sense in the English article:
“Why international diversification in machine safety is now essential – and Germany alone is no longer enough”