The situation
Sugar Australia’s Remote Control Loader — a silo cleaning machine — was equipped with an ageing Omron PLC controlling radio-operated proportional hydraulics, tilt switches, and proximity sensors. KSG Electrical needed specialist PLC engineering support: first to understand the current state of the existing program, then to quote for a modern replacement controller.
Our approach
Phase 1 — Omron PLC Bench Test:
- Procured Omron programming cable and CX Programmer software to establish connectivity with the PLC.
- Extracted the existing PLC program backup from the unit.
- Created a complete I/O list documenting all inputs and outputs based on the supplied electrical schematics.
- Developed an I/O function test sheet and verified correct operation of each channel by bridging inputs and driving relay outputs to simulate field conditions.
- Recorded all test outcomes in the I/O function test sheet. Phase 2 — Replacement PLC (Quoted):
- PLC with I/O modules as a replacement controller platform.
- Software for PLC development and bench testing.
- A replacement PLC program based on the extracted Omron logic and supplied electrical schematics.
- Bench-testing of the replacement PLC with full I/O verification prior to site installation.
- I/O function test sheet documenting all test outcomes for record keeping.
Outcome
Phase 1 was completed at the KSG workshop, providing KSG Electrical and Sugar Australia with a fully verified, bench-tested PLC ready for site re-installation. Beetle Engineering has quoted to transition from the obsolete Omron platform to modernise the loader’s control system with a supported, maintainable controller — with documented I/O test records to support future commissioning and maintenance.