The Problem

The existing PLC was an obsolete Modicon Compact controller. Though the PLC still operated and program could be modified, if a PLC component was to fail, a replacement in all likelihood would be hard to find. This could cause long unscheduled down times in the process. The old control system relied on Modbus Plus and serial communication to communicate with the local SCADA system, variable frequency drives, and various equipment in the facility.

The Solution

The existing control panel back pan was replaced with a new back pan with a new Schneider M340 PLC. Ethernet communication was installed. All Modbus Plus communication cards installed in the Yaskawa variable frequency drives were replaced and configured to communicate with the new M340 PLC. With the implementation of the M340 the programming software platform was upgraded from Concept to Unity.