Two more Water Chlorine Dosing Control Systems have been designed, manufactured and commissioned by Fast Automation. Both projects completed for government facilities in NSW and are up and running at this moment. The system controls a series of valves by monitoring flow transmitters and other field sensors to correctly dosechlorine, ituses the latest Schneider PLC series M580 with communications to an RTU and SCADA system.
Fast Automation has automated many major waste treatment plants for several leading environmental companies. The systems have all been implemented using Citect or Wonderware SCADA software and various PLC types including Allen Bradley, GE Fanuc, OMRON and SIEMENS.
The SCADA application software has evolved to the level where standard genies facilitate the rapid development of any plants requirements.
Features of Waste Treatment SCADA and PLC software:
SCADA:
PLC:
A packaging giant turned to Fast Automation to complete a challenging vision application. The system utilised Balluf cameras with Siemens S7-1200 PLC systems. Norco touch screens and PLC hardware din rail PC’s. A number of issues were overcome on the SCADA with a number of windows scripting host scripts.
A nearby factory requested a control system upgrade on an old German tissue folding machine that had become problematic. The challenge was with the speed and torque synchronisation and delicacy of the product combined with the need to maintain production. Thankfully, Fast Automation’s David Fonseca was up for the challenge. All requirements and deadlines were met and the machine was faithfully restored to its former glory with a few enhancements to bring it up to date and even improve productivity!
A giant Air-conditioning equipment manufacturer engaged Fast Automation to review and upgrade the safety on its machinery after a serious accident.
Fast Automation implemented a number of changes to bring the German machinery up to present standards. Technology primarily involved SICK pressure sensors and light curtains.
A major paper processing plant experienced problems with an old/outdated S5 PLC system. The system was an S5-95U CPU with a large amount of I/O. The existing system was difficult to troubleshoot and not easy to maintain. Fast Automation was contracted to upgrade the system to a new and serviceable system but at a minimum cost.
Existing System:-
Existing Rack Components:-
| Part No. | Description | Qty |
| 6ES5103-8MA12 | SIMATIC S5 CPU 103 | 1 |
| 6ES5470-8MA11 | Analog Output Module – 2AO | 1 |
| 6ES5385-8MA11 | Down counter with 2 Channels up to 500Hz | 1 |
| 6ES5421-8MA12 | Digital Input 8x 24V DC | 11 |
| 6ES5441-8MA11 | Digital Output 8x 24V DC 1A | 8 |
At first glance not an obvious choice but the Siemens ET200s was selected as the platform solution. Fast Automation believes the Siemens ET200S IM151-7 CPU is a hard option to look past, for smaller Siemens S5 upgrades.
Summary of ET200s suitability factors:-
New Rack Components:
| Order number | Designation | Quantity |
| 6ES7131-4BF00-0AA0 | Electronics module, 8DI, 24 V DC, standard (1 unit) |
14 |
| 6ES7132-4BF00-0AA0 | Electronics module, 8DO, 24 V DC/0.5A, standard (1 unit) |
9 |
| 6ES7135-4FB01-0AB0 | Electronic module, 2AO, U |
2 |
| 6ES7138-4DE02-0AB0 | 1 Count 5V/500kHz, connection for RS422 incremental encoders | |
| 6ES7138-4CA01-0AA0 | PM-E DC 24V power module for electronic modules, with diagn. |
1 |
| 6ES7151-7AA20-0AB0 | IM 151 – 7 CPU |
1 |
| 6ES7193-4CA40-0AA0 | Universal terminal module; screw connection (5 pcs.) |
5 |
| 6ES7193-4CD20-0AA0 | Terminal module for AUX1 supply; screw connection |
3 |
Fast Automation was consulted by a major manufacturer to find a cost effective way of improving the delivery of insulation foam into heater assemblies. The result was Fast Automation working closely with the manufacturers own engineering team to provide the control system. The control system was a difficult assignment as it involved the expansion and interfacing to an old system with no documentation.
Fast Automation was contracted to develop a custom interface to allow the automatic selection of the correct test sequence and test parameters from a database, and then execute an automated electrical test on cylinders.
System overview:-
The system utilised the following technologies:-
Fast Automation was contracted to develop a method for querying weight and product information from a Novell server, and update data records inside a S7-400 PLC.
Technologies used:
The query was bespoke as the data from the Mettler Toledo weigh bridge was being served in a custom named and formatted flat file.
This system has now been completed and is fully operational. Click Here for more info.
Fast Automation was awarded the contract for a small control system on a worlds first Process control pilot plant for a slow release agent with wide reaching applications.
CERAMISPHERE is a pioneering company that develops slow release technology which has wide ranging applications. The technology selected for this project is Siemens S7-300 with Wonderware Intouch SCADA and ET200s remote I/O. This new pilot plant is scheduled for commissioning late June 2013.
This System has: