PROJECT: 600 TON SHEAR/BALER
CLIENT: MACAULAY METALS ROTORUA
Custom programmed HMI Panel Master Control Panel Screen
We were asked to electrically install, commission and test a 600 ton hydraulic compression shear/baler that had been purchased as a refurbished machine from Austria, and shipped to Macaulay Metals, in Rotorua, New Zealand. Unfortunately, the supporting documentation was in German, and the machine coding and electrical drawings were in Italian. In addition the wiring modifications made overseas were unfinished and incorrect, the hydraulic and wiring schematic drawings supplied were for a different machine (similar but by no means identical) and the PLC programming contained multiple bugs. A major headache for the client...but not for us.
Always one for a challenge, side by side with our trusted Rotorua based mechanical/hydraulic contractors, we painfully worked through the schematic drawings, the field wiring and the plc logic. By a process of elimination, using a methodical and logical mindset, we forced or bypassed plc inputs, limit switches, sensors and hydraulic valves, and installed additional cabling to work out exactly how the machine should operate best for the client. For timeframe reasons, the client decided that replacing the Master PLC out, with a custom programmed new PLC was not a viable option short term (but likely a future option for upgrades) so we opted instead to take the primary PLC outputs and feed them into Slave PLC controllers with some simple custom end programming to make the necessary minor end changes required to give the desired control, monitoring and feedback via a custom programmed HMI screen.
The customer was extremally grateful for our willingness to assist, and our persistence and prioritization of their project so that we met the deadline and budget.
Existing Schneider Modicon M340 PLC control mounted in distribution panel with retrofitted Schneider Zelio SR3 PLC automation upgrade.
Our custom programmed HMI control panel main user screen for control, trending of machine operational characteristics ,and input/output feedback monitoring for diagnostics.
HMISTU-655 Home Screen
Schneider Modicon PLC Controller
Schneider Zelio SR3B261BD PLC modules with Schneider SR3MBU01BD RTU Modbus Communication
Schneider HMISTU-855 HMI Harmony Panel
IFM Pressure Transducer/Switches for the automation of the machine hydraulic valves
We have the ability to easily implement for networking the custom built HMI program to provide the potential for remote monitoring and even remote operation if required using the Schneider HMISTU-655 HMI screen.