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| Projects Details |
| Projects
> DFC Ceramics Australia –Kiln PLC Replacement |
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| Project Title: |
| DFC Ceramics Australia –Kiln PLC Replacement |
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| Customer: |
Company: |
DFC Ceramics Australia |
Description: |
DFC Ceramics manufactures Fire Assay Crucibles
and Magnesite Cupels which are the first choice of most
major laboratories both within Australia and around the
world. |
Contact: |
Alan Osborn (General Manager) |
Phone No.: |
+61 (08) 9249 4400 |
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| Customer Requirements: |
| DFC Ceramics Australia operates a production
plant in Malaga WA. When the old TI505 PLC control system, which
controlled the operation of the Kiln, was damaged following
a power outage at the plant in August 2006, DFC Ceramics contacted
KAPP Engineering to repair or replace the PLC. With the Kiln
out of operation, the entire plant had to be shut down, which
meant a potential loss of $20,000 in sales per day. Needless
to say, General Manager Alan Osborn was desperate to get the
plant up-and-running in the shortest possible time. |
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| Solution: |
With the required replacement parts for the faulty
TI505 PLC 3-4 weeks away, KAPP Engineering was instructed to
supply, program and commission a new PLC system to perform the
same functions as the TI505. A complete set of Koyo PLC hardware
was ordered the same day, and arrived at the plant before midday
the next working day. The new Koyo DL205 PLC control system
consisted of the following:
• 1 x Main Control PLC Rack (156 I/O points)
• 1 x Expansion I/O Rack (24 I/O
points)
• 1 x Remote I/O Rack at Kiln Entry (88 I/O
points)
• 1 x Remote I/O Rack at Kiln Exit (100 I/O
points)
• ZipLink Terminal Blocks were supplied for all PLC I/O
Modules, providing
for quick and simple re-wiring of the existing input and output
wire connections
• 1 x 10Mbps Ethernet Communications Network, linking
the Main PLC
to all remote and expansion I/O racks
While the new Koyo PLC system was being installed and wired
by Darryn Doble and his team at Electrical Automation, the team
at KAPP Engineering dedicated its resources to converting the
TI505 ladder program (more than 650 rungs of code) into DirectSOFT
to run the program on the new Koyo PLC.
The end result saw the Kiln up-and-running in fully automatic
mode within 5 working days following the breakdown of the old
TI505. |
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