Industrial Control Repair & Retrofit Case Studies
See how Control Concepts helps industrial facilities diagnose equipment failures, restore production, modernize outdated control systems, and avoid unnecessary replacement costs.
DRIVE, PLC, HMI, SERVO, MOTOR CONTROL FIELD SERVICE AND SALES. DRIVES IN STOCK TO AUTHORIZED PREMIER DISTRIBUTOR
Featured Case Study
HIGH-HP DRIVE RETROFIT
300 HP & 800 HP Allen-Bradley Drives Retrofitted to Yaskawa
Control Concepts replaced large-horsepower Allen-Bradley PowerFlex 700S drives with Yaskawa technology while retaining the facility’s existing Allen-Bradley controls
Result: 300 HP retrofit completed in two days, avoiding a five-week OEM lead time and costing less than the quoted replacement drive.
More Case Studies
Explore additional industrial control repairs, retrofits, upgrades, and automation projects completed by Control Concepts.
CONTROL SYSTEM RETROFIT
Failing Cut-to-Length Controller Replaced with Modern PLC, HMI & VFD
Control Concepts replaced a failing cut-to-length controller with an integrated PLC, HMI, encoder and Yaskawa VFD system while recreating the machine’s original operating functions.
Result: Retrofit completed in less than one week at approximately half the OEM-quoted cost, compared with a six-month OEM lead time.
DC-TO-AC RETROFIT
Two High-Horsepower Extruder Systems Converted from DC to AC
Control Concepts converted aging 250 HP and 400 HP DC drive and motor systems to modern AC technology while retaining the facility’s existing Allen-Bradley controls.
Result: Modern AC technology with reduced routine maintenance, retained controls, and reliable operation in temperatures up to 50°C.
EXTRUDER DRIVE RETROFIT
75 HP Extruder Drive Retrofitted to Yaskawa GA800
Control Concepts replaced an existing 75 HP extruder drive with a Yaskawa GA800 and tuned the new drive to resolve a recurring motor-stall condition
Result: Drive retrofit completed in one day with application-specific tuning and a quick return to operation.