Why you should maintain your compensation system

Start the New Year Safely: Why You Should Maintain Your Compensation System

First and foremost, we wish you a healthy and successful new year and hope you started 2025 on the right foot. To ensure that 2025 remains a year free of unpleasant surprises for your systems and employees, today we want to provide you with key information about the maintenance and care of compensation systems.

Wartungsarbeiten an einer Kompensationsanlage
Figure1: How electrical systems must be maintained is regulated by many standards. Source: Adobe Stock

Few countries are as renowned  — or infamous — for their regulations as Germany. These rules may sometimes seem complex, but they offer crucial advantages: safety and reliability in all areas. 

Compensation systems are no exception. As a central component of a stable power supply and energy-efficient production, regular maintenance is essential. This not only ensures optimal operation but also prevents costly failures and dangerous situations. One thing is certain: taking operational safety seriously not only saves money but also protects smooth operations and human lives.

Legal Requirements: Why Maintenance is Mandatory

The safety of people and systems is paramount. Laws such as the Occupational Safety Regulation (BetrSichV), the German Statutory Accident Insurance (DGUV) regulations, and international standards like IEC 60364-6 require operators of electrical systems to conduct regular inspections. The goal is to identify and address hazards early, which also provides a financial advantage. But what do these regulations entail in detail?

Before use, a risk assessment must be conducted per BetrSichV § 3, identifying all relevant risks and deriving appropriate protective measures. This assessment forms the basis for establishing individual inspection intervals. Furthermore, § 14 of BetrSichV mandates regular inspections of work equipment, with frequency depending on usage and environmental conditions. Specific guidelines for inspection steps, such as visual checks, measurement of electrical parameters, and testing of protective mechanisms, are found in DIN VDE 0105-100. This standard addresses the operation and maintenance of electrical systems and includes general requirements for working with electrical systems of all voltage levels. It also specifies that inspections must be conducted by qualified electricians with knowledge of comparable systems.

Each inspection must be documented in detail according to DGUV Regulation 3 § 5, including technical results, equipment used, and the qualifications of the inspector. This documentation serves as proof for authorities and insurers, protecting you in case of disturbances or accidents. Failure to comply with these regulations can have severe consequences, ranging from fines to criminal liability if lives are endangered.

Mitarbeiter im Service
Figure 2: The framework conditions for maintenance are prescribed in numerous standards – but they are not always easy to keep track of.

Detailed Insights into Legal Foundations

The legal requirements include key provisions specifically relevant to electrical systems. For example, § 10 of BetrSichV highlights the obligation for maintenance and specifies the qualifications of inspectors: only qualified electricians or individuals under their supervision may conduct inspections. This ensures that the system can operate safely and reliably throughout its lifecycle.

14 of BetrSichV explicitly states that work equipment exposed to harmful influences must be regularly inspected by a competent person. These inspections cover all aspects required to ensure safe operation, and the results must be thoroughly documented. DGUV Regulation 3 reinforces these requirements, emphasizing the need for regular inspections, especially before initial commissioning and after changes or repairs. Recurring inspections must take place at appropriate intervals based on the risk assessment.

Additionally, DIN VDE 0100-600 governs the initial inspection of electrical systems, outlining steps such as visual checks, measurement of insulation resistance, and testing of protective devices to ensure operational safety. It complements the requirements of DIN VDE 0105-100 but focuses on low-voltage systems. For portable electrical devices, DIN VDE 0701-0702 provides clear testing guidelines to identify hazards such as insulation faults and ensure electrical safety.

Maintenance: Benefits for Safety and Performance

In summary, regular maintenance is crucial to ensure the longevity and safety of compensation systems. Timely replacement of wear parts like capacitors and contactors can effectively minimize potential hazards, especially in detuned systems. In systems with frequent switching operations, wear and tear is a critical factor that can be controlled through maintenance.

Optimally maintained systems operate at maximum efficiency, which not only increases productivity but also reduces energy consumption. Early intervention also prevents costly repairs and unplanned downtime. Studies show that well-maintained systems can result in up to 30% lower total costs over the long term. According to the “Value of Reliability” study, unplanned downtime costs German companies an average of €147,000 per hour.

Why KBR Systems Are Among the Safest

At KBR, safety and quality are our top priorities. Our products combine innovative technology with the highest manufacturing standards to meet the demands of modern industries. Every detail of our systems is designed to ensure maximum operational safety. We use only high-quality materials produced in our German factory.

Brand eines Kondensators im Schaltschrank
Figure 3: Regular maintenance is essential to minimize fire risks.

Our capacitors boast high temperature resistance and durability, with a lifespan of up to 250,000 operating hours—equivalent to almost 29 years of continuous operation! Modern safety mechanisms, such as three-phase overpressure disconnection, ensure that in case of overloads or faults, the capacitor safely shuts down without endangering the system or its surroundings.

With our safety and maintenance module, we offer innovative control technology that activates automatic shutdown mechanisms in emergencies. For applications with frequent switching, our thyroswitch series is specially designed to handle high switching frequencies while minimizing wear.

Thanks to our visual energy software, operational data can be monitored in real time, enabling proactive maintenance and ensuring maximum efficiency and safety. Our Power Quality Maintenance Service allows real-time monitoring of voltage quality—alerting you immediately in the event of voltage dips.

Our systems also set benchmarks in sustainability. The use of energy-efficient technologies helps protect the environment while reducing operating costs in the long term. Regular innovation cycles integrate the latest developments into our products, ensuring our customers always have access to the best available technology.

However, despite these features, regular maintenance is essential to ensure maximum availability, efficiency, and safety. This is where our highly trained factory service team comes in. Let our experts handle the maintenance while you focus on your business. Save time and costs while ensuring maximum system availability.

Kondensatoren in der Fertigung
Figure 4: With products from KBR, you choose quality and durability.

Introducing KBR’s Maintenance Service

Aufkleber nächste Wartung
Figure 5: With our maintenance contracts, you not only keep track of your costs but also your next maintenance appointment – ensuring greater planning and operational reliability.

Our maintenance service offers comprehensive and flexible support for your systems, regardless of the manufacturer. Our services include checking the torque of screw connections and inspecting your system’s operating conditions, such as ventilation, dust levels, and emissions. Our technicians measure capacitor currents and perform visual inspections to evaluate the overall condition of the system. Special attention is paid to the discharge resistors, controller parameters, fan functionality, and filter mats.

If necessary, we perform routine maintenance and minor repairs immediately. For major issues, we provide a detailed proposal. Finally, you receive a comprehensive system report documenting all actions taken. We also provide suggestions on how to update your system to ensure maximum safety and efficiency.

With our maintenance service, you benefit from a nationwide fixed price in Germany – regardless of your location. We recommend an annual system check. Choose between on-demand maintenance or one of our maintenance contracts, which include price stabilization and automatic reminders for the next service. Our contracts are available nationwide and can be cancelled at any time with written notice. For international customers, we offer a network of experienced service partners in your region. Our technicians are available on-site from Monday to Thursday, and you can reach us via our service hotline during regular business hours.

Aufkleber Service-Hotline
Figure 6: Our service technicians are available to assist you – either by phone or directly on-site.

In addition to maintenance, we offer training programs to empower your employees to handle minor maintenance tasks independently. Our consulting services help you modernize your systems and meet regulatory requirements effectively.

Rely on safety and efficiency in 2025. With KBR, you have a partner who not only knows the regulations but also implements them practically—with decades of experience and specially trained service technicians. 

Contact us today to schedule a maintenance appointment. We are happy to assist!

Jonas Klaus | Technischer Redakteur

Yours, Jonas Klaus

Technical writer

KBR GmbH