Project overview

IDEC PLC & HMI UPGRADE

Upgrading the automation controls on a rotomoulding machine from an obsolete IDEC FC3A PLC to the newer FC6A platform.

Manufacturing · Singleton · Industrial support · Automation & control

IDEC PLC modules in the control panel, with input status lights on and ribbon cables connected

Customer need

An industrial tank manufacturer in the Hunter Valley needed to replace the obsolete IDEC FC3A PLC controlling a rotomoulding machine. The upgrade required the existing PLC and HMI programs to be converted and updated for the FC6A platform, including changes to suit differences in I/O and analogue input handling.

What we did

Converted and updated the existing FC3A PLC program for the FC6A platform.
Converted and updated the HMI program.
Bench tested the updated programs before onsite commissioning.
Installed the new PLC and modified wiring to suit the new I/O modules.
Completed onsite commissioning and functional testing.
Completed further PLC and HMI improvements, including alarms, heat/cool air controls, trend and data logging, web interface changes and updated electrical drawings.

How it helped

The upgrade replaced an unsupported PLC while retaining and updating the existing rotomoulding machine controls. The completed system provided an updated PLC and HMI platform, along with improved controls, data logging and documentation to support ongoing operation and maintenance.

The HMI touchscreen showing time remaining and oven temperature, above the reset and emergency stop buttons

Close view of IDEC input modules, with their status lights on and ribbon cables plugged in below

The HMI trolley process screen, with oven rocking, rotation, oven setpoint and heat and cool air timer settings

Automation & control

Practical onsite automation support, backed by engineering and trade experience.

New facilities & expansions

Electrical delivery for a complete new facility or the next stage of an existing site.

Industrial maintenance

Ongoing electrical support for industrial sites.

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The finished VSD control panel on the front of the pump skid, with emergency stop and isolator

Mining & resources · Hunter Valley · Automation & control

Mine site pump VSD & control system

What we didDesigned and built the VSD and control system, including the control panel, programming and electrical documentation.

How it helpedThe equipment passed introduction to site without delay and operated for the duration of the project without issue.

Read the project

Completed pump control systems mounted on mobile skids

Mining & resources · Hunter Valley · Automation & control

Mine site pump control systems

What we didDesigned and built two identical pump control systems.

How it helpedThe mobile skid and plug-in supply simplified transport, setup and connection onsite.