Modernizing Industrial DC Drives
Power Converter Retrofit for DC Motors
Specialized power conversion technology for the continued operation of existing DC systems
FEST modernizes production-critical DC drives with DC power converters for systems operating at over 1 kV to ensure the reliable continued operation of existing industrial facilities.
The retrofit power converter solutions combine high performance with reliability. They enable modernization without the need to build new equipment and allow for PLC integration into the existing automation system.
Benefit from our experience
Safely Modernize Existing DC Drives
Many industrial plants are designed to use high-performance DC drives. In such cases, building a completely new plant is often neither economically nor technically necessary.
FEST modernizes the central power conversion equipment, configures the systems for grid voltages exceeding 1 kV, and handles commissioning as well.
Common Reasons for a Power Converter Retrofit
Outdated power conversion technology with an increasing risk of failure
Limited availability of replacement parts for existing systems
Lack of interfaces to the PLC, visualization system, or production data collection system
High demands on dynamics, current stability, and availability
Short downtime windows for retrofitting and commissioning
The Need for Modern Protection, Control, and Diagnostic Technology
The Benefit for Your Project
The existing drive technology remains usable. FEST brings the central power conversion technology up to a modern, integrable, and reliable standard.
Product Description
The DC power converter for high industrial power ratings
The FEST Power Converter Retrofit is designed for high-power industrial DC motors. The solution combines robust thyristor technology with modern digital control and can be integrated into existing automation systems.
Key Technical Specifications
- Up to 10 kA output current per unit
- Up to 1,500 V DC output voltage
- scalable to meet higher performance requirements
- B6C Thyristor Bridges
- Digital control with Siemens SINAMICS DCM 6RA80
- PROFINET and IBA-compatible interfaces
Designed to meet standard requirements
The systems are designed on a project-by-project basis in accordance with the relevant requirements for power electronic converter systems, including IEC 62477-2, EN 60204-1/11, EN 61439-1/2, and IEC 61936-1 for high-voltage systems above 1 kV. The relevant components are sized on a project-by-project basis and tested prior to shipment.
The Technology Behind the Retrofit
The brochure contains additional information on system design, power electronics, protection technology, measurement technology, system construction, and commissioning.
For which systems is the FEST power converter suitable?
The FEST power converter is designed for industrial facilities where DC motors continue to play a central role. This solution is particularly relevant for high DC drive power ratings, input voltages above 1,000 V, short downtime windows, or special retrofit requirements.
Steel and Rolling Mills
Winding and Drawing Machines
Crushers and Large Conveyor Belts
Heavy-duty cranes and large pumps
Special-Purpose Drives in Heavy Industry
Generator-Motor Combinations
Production lines with existing DC drive technology
Cross-industry experience
Is a retrofit worth it for your system?
FEST evaluates technical feasibility and cost-effectiveness based on your plant data. Take advantage of our many years of automation expertise!
Success stories
Selected Modernization Projects
These companies have achieved impressive results through process automation and plant modernization.
Alanod, Germany
Modernization of the safety equipment of a slitting line,
Aluminium processing
Novelis, USA
Production of control cabinets and operating stations for a cold and hot rolling mill,
Aluminum processing
Salzgitter AG, Germany
Replacement of the control system of the pre- and finishing line of a hot bath,
Stahlverarbeitung
Nucor / Yamato Steel, USA
Programming and visualization of complete 3D simulation IBN in the test center for the new construction of a tandem roll stand, steel processing
KME, Germany
Modernization of the system control of a cross cutter,
Copper processing
MAHLE, UK
Modernization of a cladding mill incl. new drive technology, motors, assembly, control and visualization, steel and aluminum processing
Novelis, Germany
Retrofit of the electrical and mechanical equipment of the coil high-bay warehouse with mandrel stacking crane and management system, aluminum processing
Power Converter Retrofit: More Than Just Replacing Components
Specialized retrofit and commissioning expertise is crucial, especially when dealing with high-power DC drives, high input voltages, and existing plant structures.
FEST delivers a power converter solution that has been fully tested during cold commissioning and is tailored to the existing plant, the existing control system, and the requirements of ongoing operations.
FEST combines power electronics, control cabinet construction, automation, and commissioning into a coordinated project approach.
Project-specific design based on the machine data sheet
In-house manufacturing of control cabinets and thyristor stacks
Cold Commissioning Before Delivery
Commissioning under actual plant conditions
Integration with existing PLC and visualization systems
Specialized commissioning expertise for high-power DC drives
The Benefit for Your Project
FEST minimizes interfaces, coordinates technical trades, and oversees the modernization process until the system is operating reliably.
Have Your System Evaluated for a Retrofit
Please send us your system specifications or the machine data sheet. You will receive an initial technical assessment of the feasibility and the best course of action.
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Contact for process automation
Dennis Steckhan
Director Sales Process Technology
