Automotive

One of the “big three” automotive manufacturers began having communication problems with its Modbus Plus network. This particular plant has a unique Modbus Plus system in that it has over six hundred nodes. This is one of the, if not the, largest Modbus Plus networks in the world. Also unique to the system, Bob Culley assisted in its initial design and installation while working for Modicon.

The customer first called their local distributor and asked them to call the factory to dispatch a field service engineer to troubleshoot and repair their network. The distributor contacted Delta Automation Inc. They immediately responded with two experienced field engineers and all of the proper and necessary test equipment to the site. After discussing the network problems with the automotive engineers, Delta Automation, Inc. began its testing and troubleshooting.

The fault was located in an extremely short time, and was determined to be a revision compatibility problem with the Modbus Plus repeaters. The units were updated and the system was online in minutes, after being down for two days. This is just an example of how Delta Automation’s experience and superior knowledge was able to assist. Most certainly no other third party service company would have been as swift to respond and locate the fault.

Pulp and Paper

One of the world’s largest pulp and paper manufacturers began experiencing intermittent remote I/O problems with one of its paper making machines. This problem caused the company to lose production on the order of $15,000 per hour. An emergency call was made to the high tech distributor, who made several calls for help.

Delta Automation, Inc. responded with immediate service, coordinated through the HTAD distributor. A plane was chartered, and an engineer with test equipment was dispatched. Within hours, the system was up and running at full production. Several cable faults were localized and repaired. In addition, all of the company’s J890s needed updates.

Delta Automation, Inc. modified over 20 units at its repair facility and delivered them for installation the following day. The success on this paper machine dictated a company standard and modifications were applied to the remaining machines. This paper manufacturer has advised its high tech distributor to utilize Delta Automation, Inc. for it’s future Modicon field service and repair requirements.

Delta Automation, Inc. provided the expertise and willingness to respond in a timely, economical fashion with highly qualified and knowledgeable personnel. Delta Automation, Inc. creates a win-win situation, both for the customer and distributor, while building a profitable relationship.

Petrol/Chemical

When one of the controllers failed, an oil refinery was utilizing a 584 redundancy system. Because it was a redundancy system, the refinery’s process didn’t go down. However, the plant was concerned about running without a hot standby unit. He called Delta Automation Inc. for support. He was routed to an experienced engineer with a vast knowledge of 584 redundancy systems. He described his problem to the engineer, and a most likely solution was discussed.

The engineer warned the customer about the pitfalls of repairing a 584 redundancy system, which was new information to him. Several different scenarios were discussed. The customer took Delta Automation Inc.‘s advice on which route to pursue. The proper parts were flown to the customer site and installed. The redundancy system immediately came up. The plant lost no production time.

Transportation

A large railroad coal carrier’s train car storage and staging area was the victim of a lightning strike, knocking out all of the yard’s traffic controls, controlled by a Modicon 984 and five remote drops operated by Modicon push button assemblies. Delta Automation, Inc. responded immediately with engineers and the proper test equipment. The lightning damage was severe. The Remote I/O system was tested using Delta Automation, Inc.’s specialized test. All five of the push-button panels were damaged by the strike.

Delta Automation, Inc. rushed all five to its facility, where the failures were diagnosed, and the necessary components were specially ordered. The parts arrived the following day. All units were repaired and returned to service at once. Delta Automation, Inc. proved it had the resources, willingness, capability, and experience to locate and repair the customer’s system.