A failed, obsolete control board on an asphalt plant's filter replaced with a Mitsubishi FX5UC PLC, now controlling 48 valves across multiple cleaning sequences.
48Valves controlled across multiple cleaning sequences
Bench-testedProgrammed and tested in our office before shipping
The problem
The valve control for an asphalt plant's filter ran on a dedicated circuit board. When that board failed, there was no replacement available: it was obsolete, and a bespoke board is not something a site can repair or reprogram itself.
Before: the obsolete control boards
After: Mitsubishi FX5UC, bench-tested before shipping
What we did
We replaced the board with a Mitsubishi iQ-F FX5UC PLC, with 16 digital inputs and 64 digital outputs on spring clamp terminals for quick, tidy installation.
The new PLC:
Controls 48 valves across the filter's multiple cleaning sequences
Provides real-time running status and alarm indicators
Was fully programmed and bench-tested in our office before it was shipped for installation
The result
The filter now runs on a standard PLC with spares available off the shelf, and a program that can be backed up, read and changed. It is a good example of how a modern PLC can extend the life of industrial equipment while improving reliability and control.
Automation software for a new 2,000 kW refrigeration plant supplying chilled water at +2 °C and glycol at −2 °C, with four 20,000 litre stainless steel storage tanks.
Control and SCADA for two process vessels with mixing, product pumping, load cells, temperature control and CIP, built on Siemens S7-1500 and WinCC Professional with a reusable library.
PLC
Siemens S7-1500
SCADA
WinCC Professional
Drives
Danfoss VSDs on PROFINET
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