Hale Engineering completed a pre-tipper PLC upgrade after ageing controls and missing plant connectivity prolonged fault recovery. Engineers traced undocumented wiring, built a new CompactLogix control panel and integrated the machine with SCADA. The upgrade improved fault diagnosis and operator visibility, with fewer faults and reduced downtime reported.
Project Overview
The hydraulic bin pre-tipper operated with an outdated Mitsubishi programmable logic controller (PLC). Hale Engineering Consultancy & Services Ltd replaced the control panel and rewrote the operating program, preserving the existing process while connecting it to the wider plant systems.
Operational Challenge and Risks
The existing controller could not communicate with the plant’s Allen-Bradley-based supervisory system. Each fault required a controls engineer to attend site before operation could resume, extending downtime and leaving operators dependent on specialist support.
Undocumented modifications, unlabelled wiring and redundant cables complicated fault finding. A faulty safety relay had caused a previous stoppage, contributing to the decision to replace the panel entirely.
Engineering Assessment
Engineers physically traced all inputs and outputs (I/O) to their connection points. Continuity testing verified the connections, with each result double-checked.
The survey also identified undocumented sensors. An updated I/O list and new 2D and 3D panel drawings in EPLAN established an accurate basis for the replacement design.
Hale Engineering’s Pre-Tipper PLC Upgrade
The work included:
- producing electrical schematics and building a new control panel;
- preparing a Functional Design Specification (FDS) to define the intended operation;
- writing a structured control program;
- creating SCADA graphics and alarms; and
- installing, integrating and commissioning the replacement system.
Equipment and Control Strategy
An Allen-Bradley CompactLogix 5380, model 5069-L306ER, matched the plant’s established platform, simplifying communication and spares sourcing. Ethernet over Cat5 cabling connected the new controller to other plant PLCs and FactoryTalk View SE SCADA—supervisory control and data acquisition—for real-time process visibility.
Previously, a fixed timer governed lifting and return. During a stall or fault, continued hydraulic operation could risk damage. A new home-position interlock stops the hydraulics when the pre-tipper returns home. Additional alarms make faults visible to operators.
Installation, Integration, Testing and Commissioning
Workshop testing checked all I/O against the electrical drawings, followed by a Factory Acceptance Test (FAT) with the project team. Site Acceptance Testing (SAT) and commissioning took place during a planned shutdown.
The main integration challenge was coordinating signals with adjacent systems. The pre-tipper waits for an upstream ready signal before loading, then sends a completion signal to allow the downstream process to proceed. Engineers verified this signal exchange before handover.
Results and Operational Benefits
The client gained online system access and full SCADA communication for the first time. New graphics and alarms enabled quicker fault diagnosis, allowing operators to resolve faults without always waiting for an engineer to arrive.
Project feedback confirmed fewer faults and reduced downtime. Updated drawings also gave maintenance teams a clearer reference for future investigations.
Why This Engineering Approach Matters
For plant managers, replacing ageing hardware is only part of improving reliability. This pre-tipper PLC upgrade combined verified wiring records, structured sequencing and accessible diagnostics, helping maintenance teams understand faults and restore operation more efficiently.
Frequently Asked Questions
Why was CompactLogix selected?
It matched the plant’s Allen-Bradley platform and simplified spares sourcing.
How were undocumented connections verified?
Physical tracing and continuity testing established the updated I/O record.
What changed for operators?
SCADA graphics and alarms made faults easier to identify and resolve.
If ageing controls or limited diagnostics are delaying fault recovery, Hale Engineering can assess your existing system and help define a practical upgrade scope.
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