Introduction: The need for modernization

Modern production in the field of industrial automation requires continuous improvement of efficiency and compliance with safety standards. Older safety systems, such as the Heidenhain LC183-340 5.0 safety relays, although functional, do not meet today's requirements. In particular, they do not meet the requirements of EU Ecodesign and regular energy audits. In this regard, the modernization of security systems becomes not only necessary, but also critical to maintain competitiveness and compliance.

Evaluation of old systems before upgrading

Before starting the upgrade, a thorough assessment of the existing security system should be carried out. The main assessment criteria are listed in the table:

Modern alternatives: Programmable safety controllers (SIL 3)

A safety upgrade is possible with programmable safety controllers that meet the requirements of SIL 3. One of the most suitable options is the Heidenhain LC183-340 5.0 controller. This controller provides high reliability, compliance with EN 60068-2, EN 60204-1 standards, as well as compliance with DSTU 3049-2013.

Calculation of return on investment

Security upgrades have a significant economic impact. The return on investment (ROI) calculation includes energy savings, reduced downtime and cost of restoration.

Energy saving: The Heidenhain LC183-340 5.0 controller consumes 30% less energy, which corresponds to savings of UAH 3,000 per year at an energy cost of UAH 1.5/kWh.

Reduced Downtime: The old system required a regular check of once a month, which required 2 hours of work time. The new system reduces this time to 1 hour. At a rate of 20 hryvnias/hour, this gives savings of 2,000 hryvnias per year.

Cost of restoration: The cost of restoring the old system is UAH 5,000, which is higher than the cost of a new controller (UAH 8,000). However, this reduces the risk of failure and recovery costs.

Total savings: UAH 3,000 (energy) + UAH 2,000 (down time) = UAH 5,000 per year. The restoration cost of UAH 8,000 is approximately returned in 1.6 years.

Phased implementation plan

Security updates should be phased to minimize production downtime:

1. Planning: Collect all necessary documents, identify resources, perform risk analysis.
2. Supply: Order new components from UNITEC-D, which manufactures components for security systems.
3. Installation: Install new controllers, disable old systems, configure.
4. Commission: Conduct testing, perform a security audit, receive confirmation of compliance.

Technical challenges and their solutions

The following technical challenges may occur during a security update:

• Compatibility with existing software: Use controllers that support existing protocols such as PROFINET.
• Increased energy consumption: Use energy-efficient components that meet EN 60068-2. standards
• System failure: Minimize the risk of failure by using controllers with a high MTBF (50,000 hours).

Case Stage: Before/After Upgrade

In the production of components in Kharkiv, the security system was updated. Before the upgrade, the system met SIL 2 but did not meet EU Ecodesign requirements. After upgrading to the Heidenhain LC183-340 5.0 controller, the system reached SIL 3, which provided a higher level of safety.

Key indicators:

• Power consumption: reduced by 30% (from 5.0 to 3.5 W).
• MTBF: increased from 10,000 to 50,000 hours.
• Recovery Cost: Reduced by 30%.

Commission and confirmation

After installing the new components, it is necessary to test and obtain confirmation of compliance. Controllers must be tested for compliance with DSTU 3049-2013, EN 60068-2 and EN 60204-1.

Acceptance criteria:

• Compliant with SIL 3.
• Energy efficiency (energy consumption ≤ 3.5 W).
• MTBF ≥ 50000 hours.

Conclusion and purpose

Updating security systems is not just a technical task, but a strategic requirement for industrial enterprises. The use of safety controllers such as the Heidenhain LC183-340 5.0 ensures a high level of safety, energy efficiency and compliance with modern standards.

To obtain components and solve your security system upgrade task, visit UNITEC-D E-Catalog.

List of used literature

• Heidenhain LC183-340 5.0: Technical documentation.
• DSTU 3049-2013: Requirements for security systems.
• EN 60068-2: Standard for environmental resistance.
• EN 60204-1: Hardware requirements.

Introduction

Modern production requires safe, effective and up-to-date management systems. Legacy safety relay systems, although functional, do not meet today's energy efficiency, safety and regulatory requirements. Standards such as DSTU 3013-94, EN 60204-1 and ISO 13849-1 require the use of a high safety level (SIL 3) for critical processes. Updating security systems is not only an improvement, but a necessary part of the production strategy.

Evaluation of the old system

Before upgrading, you need to analyze the current security system. The main criteria include:

Modern alternatives

Programmable safety controllers (SIL 3) provide a high level of reliability, flexibility and compliance with modern standards. For example, the HYDAC VR 2 D.1 / -L24 controller meets the requirements of EN 60204-1 and ISO 13849-1. Below is a comparison table:

Calculating Return on Investment (ROI)

Upgrading your security system can provide significant economic benefits. Below is the ROI calculation taking into account energy consumption, labor costs and downtime.

The investment cost is €220, and the annual savings is €5,084. That is, the return of the investment is achieved in 0.5 years.

Implementation route

Security updates should be phased to minimize the impact on production.

1. Planning: analysis of the current state of the system, determination of needs and selection of components.
2. Order: manufacture of components and production of necessary documents.
3. Installation: dismantling of old components, installation of new ones and configuration.
4. Confirmation: testing the system, performing security tests and obtaining documentation.

Technical challenges

Updating the security system can be accompanied by a number of technical problems. Here's how to solve them:

• Compatibility with other systems: The use of programmable controllers provides flexibility and compatibility with other systems.
• Redesign required: if necessary, performing additional work based on technical specifications.
• Delivery of documentation: obtaining documentation and certifications from the supplier.

Use case

The security system was updated in the production of one of the Ukrainian factories. Results:

• 45% reduction in energy consumption
• MTBF increase from 15,000 hours to 50,000 hours
• Downtime reduction by 20%
• Investment return in 6 months

Validation and implementation

After installing the new components, the following procedures are performed:

• Testing the system for compliance with standards.
• Execution of rejection tests.
• Obtaining documentation and certifications.
• Confirmation of compliance with DSTU, EN and ISO requirements.

Conclusion

Updating security systems is not just an improvement, but a necessary part of the production strategy. The use of SIL 3 programmable controllers provides a high level of safety, energy efficiency and flexibility. To replace old components and obtain modern solutions, visit UNITEC-D E-Catalog.

Sources

• EN 60204-1:2011 - Equipment safety.
• ISO 13849-1:2015 - Safety of industrial automated systems.
• Manufacturer's help HYDAC.
• Energy efficiency notice (EU Ecodesign).

Introduction

Modernizing legacy safety systems in industrial facilities is critical to ensuring compliance with current regulations, increasing efficiency and reducing risk. Old safety relay systems, although functional, often turn out to be insufficiently reliable, energy-efficient and incompatible with modern technologies. In Ukraine, where production is subject to strict energy and environmental regulations, such modernization becomes necessary to meet eco-design standards, carry out energy audits and ensure the safety of workers.

Evaluation of the old system

Before retrofitting, a detailed assessment of the existing security system must be carried out. The main criteria include:

Modern alternatives

Modern programmable safety controllers such as the Parker TF0195 MS010AAAA offer high reliability, energy efficiency and SIL 3 compatibility. Here is a comparison chart:

Calculating ROI

The return on investment (ROI) calculation includes energy savings, reduced downtime and maintenance costs. Example:

Energy saving: 3.5 W * 24 h * 365 days * 2000 h/year = 61.2 MWh

Energy cost: €0.12/kWh

Energy savings per year: 61.2 MWh * €0.12 = €7344

Installation cost: €600 - €250 = €350

Maintenance fee: €500/year

Amount of saved resources: €7344 - €500 = €6844

Investment return period: €350 / €6844 ≈ 0.051 year (≈ 20 days)

Implementation route

Modernization should be carried out in phases to minimize the impact on production:

1. Planning: Definition of needs, evaluation of the system, selection of components.
2. Supply: Obtaining components from UNITEC-D, which ensures CE, UkrSEPRO certification, as well as compliance with DSTU, EN, ISO standards.
3. Installation: Replacing old relays with new ones, making appropriate connections.
4. Commission: System testing, setting parameters, execution of documentation.

Technical challenges

Problems may occur during implementation, such as:

• Compatibility with other systems.
• Lack of qualified personnel for setup.
• High cost of old components.

Solution:

• Use of relevant standards and certifications.
• Staff training or cooperation with certified suppliers.
• The use of components that ensure a long service life.

Use case

The Parker TF0195 MS010AAAA system was implemented in one of the Ukrainian metal production factories. Results:

• Energy saving: €7344 per year.
• Downtime reduction: 15%.
• Installation cost: €350.
• Total savings: €6,844 per year.
• Investment return period: 20 days.

After the implementation of the safety system, a high level of safety, energy efficiency and compliance with regulatory requirements was achieved.

Commission and validation

After installing the new system, the following procedures are performed:

• System performance testing.
• Setting security parameters.
• Implementation of documentation and reports.
• Confirmation of compliance with standards (DSTU, EN, ISO).

Acceptance criteria:

• System functioning without errors.
• Compliant with SIL 3.
• Energy efficiency.
• Compliance with environmental standards.

Conclusion

The implementation of SIL 3 programmable safety controllers is critical for modern industrial installations. They provide high reliability, energy efficiency and compliance with regulatory requirements. If necessary, UNITEC-D GmbH provides components that ensure high quality, certification and support. Learn more about our security retrofit solutions in the UNITEC-D E-Catalog.

Sources

• Manual for replacing old security systems with programmable controllers.
• Energy efficiency and safety standards: DSTU, EN, ISO.
• Regulatory requirements: Ecodesign, energy audits.