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Lenze Retrofit

Industrial machines often remain mechanically fully functional, while their electrical drives, control electronics or communication systems become outdated, energy-inefficient or no longer compatible with the requirements of modern production.

In such cases, modernization or retrofitting is an ideal solution — especially with the use of Lenze components, which enable reliable machine upgrades without the need to replace the entire machine.

We provide comprehensive support for replacing older Lenze systems with newer generations, including programming, parameter transfer and communication integration.

What Lenze Retrofitting Includes

Lenze retrofitting can include the replacement, upgrade or modernization of existing drive and control technology, while keeping the mechanical structure of the machine largely unchanged.

Typical retrofit solutions include:

  • replacement of outdated drives, such as Lenze 8200 or 9300 series, with newer systems such as i500, i550, i950, 8400 or ECS,
  • upgrade of older control units and PLC systems with Lenze c300/c520 controllers or motion controllers,
  • refurbishment or replacement of servo motors and encoders while retaining the existing mechanical design,
  • improvement of machine safety and communication by adding STO functions, Profinet or EtherCAT support,
  • transfer of existing programs or development of new software logic according to modern standards.

Our Services

We offer complete technical support throughout the entire retrofit process — from the initial analysis to commissioning and optimization.

Analysis of the Existing System

Before any retrofit project, we carefully inspect the existing machine and its electrical equipment. This includes:

  • technical assessment of drives, controllers, HMI and PLC units,
  • identification of functions that need to be retained, improved or replaced,
  • review of the existing motor, cable and communication topology,
  • preparation of a migration concept that minimizes changes to the existing machine structure.

The goal is to define a technically reliable and economically sensible upgrade path.

Replacement and Integration of New Equipment

Based on the technical analysis, we select and dimension suitable Lenze components for the application.

Our work includes:

  • dimensioning and supply of suitable Lenze drive and control components,
  • electrical and mechanical integration with minimal intervention in the existing machine,
  • connection to existing motors, sensors, actuators and higher-level systems,
  • functional testing in real production conditions,
  • integration with SCADA, MES or other production systems where required.

This approach reduces downtime and ensures a controlled transition from the old system to the new one.

Programming and Parameterization

A successful retrofit does not end with hardware replacement. Correct software configuration, parameterization and testing are crucial for reliable machine operation.

We provide:

  • transfer or reconstruction of existing programs in Lenze Engineer, Easy Starter or PLC Designer,
  • configuration of communication protocols, I/O points and application functions,
  • parameterization of drives, motion functions and safety settings,
  • optimization of machine behavior, energy efficiency and cycle times,
  • testing and commissioning of the upgraded system.

Typical Applications

Lenze retrofit solutions are suitable for a wide range of industrial machines and production systems, especially where the mechanical part of the machine is still in good condition.

Typical applications include:

  • older CNC and machine tools,
  • conveyor lines with uncontrolled asynchronous motors,
  • packaging and labeling machines with outdated frequency inverters,
  • hydraulic machines with analog speed control,
  • automated cells with outdated I/O logic or PLC systems without modern connectivity.

Reliable Modernization with Lenze Technology

A well-planned retrofit can significantly extend the service life of a machine, improve reliability, reduce downtime and adapt existing equipment to the requirements of modern production.

With Lenze drive and automation technology, older machines can be upgraded with modern communication, improved safety functions, better diagnostics and more efficient motion control — while preserving the value of the existing mechanical structure.

Trecon provides professional support in the planning, implementation and commissioning of Lenze retrofit projects, ensuring that the upgraded machine is reliable, efficient and ready for future production requirements.